AWT MIG-140 User manual

MIG-140
Inverter Welding Machine（FLUX-CORED MIG, STICK）
READ AND UNDERSTAND ALL INSTRUCTIONS AND PRECAUTIONS BEFORE
PROCEEDING.
OPERATOR’S MANUAL

CONTENTS
1.PACKING 2
7.TROULBESHOOTING 22
6.MAINTENCE 20
3.PRODUCT DESCRIPTION 6
4 INSTALLATION 8
3.5 TECHNICAL SPECIFICATIONS 7
2.1 Symbol Usage 3
2.2 Arc Welding Hazards 3
3.1 How To Use This Manual 6
3.2 Receipt of Equipment 6
3.3 Description 6
3.4 Duty Cycle 6
4.1 Installation and Setup For MIG with Gas less 9
5 OPERATION 15
2.SAFETY PRECAUTIONS - READ BEFORE USING 3
8.CIRCUIT DIAGRAM 23

1.MIG Welder
2.MIG Torch With 6.6ft （2m）cable
3.Ground clamp with 10ft (3m) cable
4.Electrode holder with 10ft (3m) cable
5..030"/2lbs Flux Cored Wire
6.Brush/hammer
7.Knurl Groove Drive Roller: .030”/.035”(on the machine)
8.Contact tip: .030” & .035”
9.Nozzle
10.Glove
11.Mask
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P3P4
P6
P9
P8
P5
P1
P2
1.PACKING
P10
P11

DANGER! Indicates a hazardous situation which, if not avoided, will result in death
or serious injury. The possible hazards are shown in the adjoining symbols or
explained in the text.
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury. The possible hazards are shown in the adjoining symbols or
explained in the text.
NOTICE − Indicates statements not related to personal injury.
Protect yourself and others from injury — read, follow, and save these important
safety precautions and operating instructions.
2.SAFETY PRECAUTIONS - READ BEFORE USING
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2.1 Symbol Usage
2.2 Arc Welding Hazards
Welding can be dangerous to you and other persons in the work area. Read and
understand this instruction manual before using your AWT welding machine. Injury
or death can occur if safe welding practices are not followed.The symbols shown
below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to
avoid the hazard.
Safety information is set forth below and throughout this manual.
The following explanations are displayed in this manual, on the labeling, and on all
other information provided with this product.
The electrode and work (or ground) circuits are electrically “hot” when the welder
is on. Do not touch these “hot” parts with your bare skin or wet clothing.
Always wear dry, protective clothing and leather welding gloves and insulated
footwear. Use suitable clothing made from durable flame-resistant material to protect
your skin.
Always operate the Welder in a clean, dry, well ventilated area. Do not operate the
Welder in humid, wet, rainy or poorly ventilated areas.
Do not touch live electrical parts.
Disconnect Welder from power supply before assembly, disassembly or
maintenance of the torch, contact tip and when installing or removing nozzles.
Frequently inspect input power cord and ground conductor for damage or bare
wiring – replace immediately if damaged – bare wiring can kill.
Be sure that the work piece is properly supported and grounded prior to beginning
an electric welding operation.
Always attach the Ground Clamp to the piece to be welded and as close to the
weld area as possible. This will give the least resistance and best weld.
ELECTRIC SHOCK CAN KILL

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Welding produces fumes and gases. Breathing these fumes and gases can be
hazardous to your health. Keep your head out of the fumes. Do not breathe the
fumes.
Work in a confined space only if it is well ventilated, or while wearing an
air-supplied respirator.
Do not weld in locations near degreasing, cleaning, or spraying operations. The
heat and rays of the arc can react with vapors to form highly toxic and irritating
gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel.
Fumes And Gases Can Be Hazardous
Arc rays from the welding process produce intense visible and invisible (ultraviolet
and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
Wear an approved welding helmet fitted with a proper shade of filter lenses to
protect your face and eyes from arc rays and sparks when welding or watching (see
ANSI Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash, glare and sparks;
warn others not to watch the arc.
Wear body protection made from durable, flame−resistant material (leather, heavy
cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Arc Rays Can Burn Eyes And Skin
Electric welding produces sparks which can be discharged considerable distances
at high velocity igniting flammable or exploding vapors and materials.
DO NOT operate electric arc Welder in areas where flammable or explosive
vapors are present.
DO NOT use near combustible surfaces. Remove all flammable items from the
work area where welding sparks can reach (min. of 35 feet).
Always keep a fire extinguisher nearby while welding.
Use welding blankets to protect painted and or flammable surfaces; rubber
weatherstripping, dash boards, engines, etc.
Ensure power supply has properly rated wiring to handle power usage.
Welding And Cutting Sparks Can Cause Fire Or Explosion
ELECTROMAGNETIC FIELDS CAN BE A HEALTH HAZARD!
The electromagnetic field that is generated during arc welding may interfere with
various electrical and electronic devices such as cardiac pacemakers. Anyone using
such devices should consult with their physician prior to performing any electric
welding operations.
Exposure to electromagnetic fields while welding may have other health effects
which are not known.

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Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As
welds cool, they can throw off slag.
Wear approved safety glasses with side shields even under your welding helmet.
FLYING METAL or DIRT can injure eyes.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves
and clothing to prevent burns.
Hot Parts Can Burn
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Buildup Of Gas Can Injure Or Kill.
Verify that the facility power source has properly rated wiring to handle power requirements
of this Welder.
CAUTION INADEQUATE WIRING CAN CAUSE FIRE AND INJURY!
The electromagnetic field that is generated during arc welding may interfere with
various electrical and electronic devices such as cardiac pacemakers. Anyone using
such devices should consult with their physician prior to performing any electric
welding operations.
Exposure to electromagnetic fields while welding may have other health effects
which are not known.

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3.PRODUCT DESCRIPTION
3.1 How To Use This Manual
To ensure safe operation, read the entire manual, including the chapter on safety instructions and
warnings.
3.2 Receipt of Equipment
When you receive the equipment,check it against the invoice to make sure it is complete and
inspect the equipment for possible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Move the equipment to the installation site before un-crating the
unit. Use care to avoid damaging the equipment when suing bars , hammers, etc., to nu-crate the
unit.
3.3 Description
This MIG140 takes the guess work out of welding with an impressive SYNERGIC SET function
that allows the user to weld like a Pro with no previous welding experience necessary.
3.4 Duty Cycle
The rated Duty cycle refers to the amount of welding that can be done within an amount of time.
The AWT MIG-140 has a duty cycle of 25% at 120 Amps for 110 Volts. It is easiest to look at your
welding time in blocks of 10 Minutes and the Duty Cycle being a percentage of that 10 Minutes. If
welding at 120 Amps with a 25% Duty Cycle, within a 10 Minute block of time you can weld for 2.5
Minutes with 7.5 Minutes of cooling for the Welder.
If the Duty Cycle is exceeded, the Welder will automatically shut off, however the fan will continue
running to cool the components. When a safe temperature has been reached, the Welder will
automatically switch the Welder output back on. To increase the duty cycle you can turn down the
Voltage Output control.

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3.5 TECHNICAL SPECIFICATIONS
TECHNICAL PARAMETER
Model
MIG-140
AC 110V+15% 50/60Hz
36.5A
4.1KVA
20A~115A
20A~120A
60V
25%
IP21S
2.5-11
0.73
F
Wind Cooling
370*195*260mm
-
Rated Input Voltage
Rated Input Power
Rated Input Current
MMA Welding Current
MIG Welding Current
No-Load Voltage
Rated Duty Cycle
Enclosure Protection
Wire Feed Speed Range
Power Factor
Insulation Class
Cooling Type
Dimension
Units
V
KVA
A
A
A
V
%
IP
m/min
cosφ

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4 INSTALLATION
MIG-140
MIG-140
MIG-140
MIG-140

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[1] Ensure that the power switch is “OFF".
[2] Connect the weld power cable and tighten it.
[3] Connect the earth clamp into the Positive socket(+)and tighten it.
IMPORTANT:Loose welding terminal connections can cause overheating and result in the male
plug being fused in the terminal. Remove any packaging material prior to use. Do not block the air
vents at the front or rear of the Welding Power Source
[4]Select a suitable wire according to process being used(W knurled drive roller for gas less flux
cored welding). The wire diameter must be matched to the drive roller and contact tip.
[5] Place the Wire Spool onto the Spool Holder -Note:the spool retaining nut is top thread. Snip
the wire from the spool being sure to hold the wire to prevent rapid uncoiling.Feed the wire into the
wire feeder inlet guide tube through to the drive roller.
[6] Carefully feed the wire over the drive roller into the outlet guide tube,feed through about
150mm into.
[7] Align the wire into the groove of the drive roller and close down the top roller making sure the
wire is in the groove of the bottom drive roller, lock the pressure arm into place.
[8] Apply a light amount of pressure to the drive roller. Too much pressure will crush the cored
wire.
[9] Remove the gas nozzle and contact tip from the torch neck.
[10] Switch the power source to “ON”.
[11] Press and hold the MIG Torch switch to feed the wire through to the torch neck.
[12] Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip
holder of the torch head and nip it up tightly. Screw the nozzle to the torch head.
[13]Screw the nozzle to the torch head. Use pliers to cut the wire to about 10mm.
4.1Installation and Setup For MIG with Gas less
MIG-140

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1
3
2
1.Power switch
2.Connect power cable
3.connect earth clamp
4.Install the correct knurled drive roller for gas
less flux core wire. Wire diameter must be
matched to the drive roller and contact tip.
5-6. Place wire onto spool holder(spool retaining
nut is top thread). Feed the wire through the inlet
guide tube on to the drive roller.

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Note:
Flux core / Gas less wire don’t use for a long time(more than 3days) need to
store sealed.
The recommended electrode for the flux-cord, self-shielded process are 0.8 or
0.9mm diameter spools.
Flux-cord wire is excellent for single-pass lap,fillet and butt welding of thin
gauged galvanised and mild steels.
7-8. Close down the top roller bracket and clip
the pressure arm into place. Apply a medium
amount of pressure to the drive roller
13.Screw the nozzle to the torch head. Use pliers
to cut the wire to about 10mm.
9-11.Remove the nozzle and contact tip from the
front end of the MIG torch.Press and hold the
MIG Torch switch to feed the wire through to the
torch neck.
12.Fit the correct sized contact tip and feed the
wire through it, screw the contact tip into the tip
holder of the torch head and nip it up tightly.

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Spindle
Spool
Spool spacer
Spring
Spool lock
Turn machine power switch to the OFF
position before working inside the wire
feed enclosure.
Make sure that the wire feed drive roll and
the contact tip of the gun match the diam-
eter and type of wire used.
Wire Loading and Threading
1) Push the spool onto the spindle so that
the wire deeds off the bottom of the spool,
toward the drive roll.
2) Push the spool spacer onto the spindle,
against the spool.
3) Slide the spring onto the spool, them
press on the spool lock, turning it clock-
wise to lock the
spool assembly onto the spindle.
Installation of Wire Spool
1) Release the spring loaded thumb
screw and rotate the idle roll arm away
from the wire deed drive roll. Ensure that
Wire Threading Details
Wire Feed Drive Roll
Idle Arm
Access Guide Tube
Spring Loaded Thumb Screw
the visible, stenciled size on the drive roll side facing you matches the wire size being used.
2) Carefully detach the end of the wire from the spool. Maintain tension on the wire to prevent
the spool from unwinding and do not release the wire until after step 8.
3) Cut the bent portion of wire off and straighten the first 4”(100 mm).
4) Thread the wire through the incoming guide tube, over the drive roll, and into the gun liner.
5) Close the idle roll arm and turn down the thumbscrew until the idle roller presses down firmly
on the wire. (Now you may release the welding wire ). Make sure the wire is positioned in the
groove of the lower drive roll.
6) The spring loaded thumbscrew on the idle roll arm adjusts the pressure on the wire. Adjust
pressure by turning the thumbscrew to prevent spool overrun, but still allow smooth and easy
wire deeding. Start with the pressure set to an intermediate value. Readjust, if necessary.If the
drive roll slips while feeding wire , the pressure should be increased until the wire feeds proper-
ly.

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Warning
When feeding the welding wire through the gun, the drive roll, the gun connector block
and the gun contact tip are always energized relative to work and ground.
Wire Stick Out
7) Remove the contact tip and nozzle from the gun.
8) Turn the machine ON .
9) Straighten the gun cable assembly.
10) Depress the gun trigger switch and feed welding wire through the gun and cable. (Point the gun
away from yourself and others while feeding wire). Release the gun trigger after wire appears at the
end of the gun.
11)Turn off the machine.
12) Install the nozzle and contact tip. Cut the wire off so the 3/8” to 5/8”(10-15mm) protrudes from
the end of the tip.
13) Turn on the machine . The machine is now ready to weld.

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STICK WELDING (MMA)
1)Ensure that the power switch is “OFF".
2)A primary power supply cable is available for this welding machine. Connect the power supply
cable to the rated input power.
3)The primary cable should be tightly connected to the correct socket to avoid oxidization.
4)Check whether the voltage value varies in acceptable range with a multi-meter.
5)Insert the cable plug with electrode holder into the “+” socket on the front panel of the welding
machine, and tighten it clockwise.
6)Insert the cable plug with earth clamp into the “-” socket on the front panel of the welding
machine, and tighten it clockwise.
7)Insert the electrode to be used into the electrode holder
8)Connect the ground clamp to a clean bare metal surface of the part to be welder
9)Turn on the power switch at the back panel of the welder
10)The welder is now ready to use
Earth clamp
Electrode holder
Work piece
-MMA

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5.OPERATION

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MMA
FLUX
888
1 52
8 9
7 6
3
4
10 11
12
Note:
The 'protection indicator light' will come on if the duty cycle is exceeded. It shows that the
inner temperature is over the permitted level,the machine should be stopped being used to
allow it cool down. Welding can continue after the 'protection indicator light' is off.
The power source should be switched off when not in use.
Welders should wear protective clothing and welding helmet to prevent injury form arc and
thermal radiation.
To prevent others from being affected by the welding arc, it is recommended to use shielding
Do not weld near Inflammable or explosive materials.
CONTROLS AND OPERATIONAL
FEATURES
1.Current Display
2.Voltage Adjustment
3.Amp/Wire Feed Knob
4.Welding Mode Selection
5.Power Light
6.Over Heating Protection Indication
7.MIG Gun Socket
8.Positive Output Terminal
9.Negative Output Terminal
10.Input Power Cable
11.Power Switch
12.Cooling Fan
13.Rating Plate
5.OPERATION
INPUT 110V ONOFF
UL60974
MODEL
MIG-140
S
25
60
100
115
75
60
24.6
23
22.4
№:
20A/20.8V~115A/24.6V
X(%)
I
2
(A)
U
2
(V)
U
0
=60V
1~60 Hz
I
1max
=43A
I
1eff
=21.5A
S
25
60
100
120
75
60
20
17.8
17
20A/15V~120A/20V
X(%)
I
2
(A)
U
2
(V)
U
0
=60V
1~60 Hz
U
1
=110V
U
1
=110V
I
1max
=36.5A
I
1eff
=18A

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(.030") (.035")
Press and hold the
“CHOOSE” button for 3s
1 2
7
3
4 5
6
The Power indicator will not illuminate on when the power source is on. It will be on when trigger
the torch switch.
1.Power Light
.030"Flux-core Wire /.035"Flux-core Wire /Stick Welding
3.Mode switch For switching welding mode:
Use this dial to adjust the arc voltage or "heat" of your welder(low to high). Different materials
and material thickness will require different voltage settings. You will need to adjust your voltage
accordingly for different welding conditions. By properly adjusting your voltage settings and wire
feed speed, you will produce clean welds. NOTE: this is a scale, not actual voltage.
4.Voltage Knob
MMA: for welding amperage adjustment.
Flux-core mode: use this dial to adjust the output current to control speed at which the welder
feeds wire to the gun. The welder comes with synergic MIG control setting. The wire feeding
speed will automatically be changed when we adjust the amperage.
5.Amp/WFS knob
This indicator will turn on when the machine is overheated or over-current. When the indicator
turns off, normal operation is again.
2.Protection Indicator
FRONT PANEL CONTROLS
5.OPERATION

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Display of MMA and Flux-core Amp
6.Amp Display
Synergic mode. The light will turn on when you press and hold button 3 for 3 seconds.
Synergic MIG welding, the wire feed speed and Voltage will be auto fitted by adjusting wire
diameter.
7.SYN light
5.OPERATION
MMA Welding
Electrode Diameter(mm) Welding Current(A) Plant Thickness(mm)
1.0mm 30-50A 1-2mm
1.6mm
40-70A
1.5-2.5mm
2.0mm 50-80A 2-3.5mm
2.6mm
60-115A
2.5-4mm
MIG Welding
Plant Thickness(mm) Welding Wire Diameter(mm) Welding Current(A)
0.5-1.0mm 0.8mm 40-70A
1.0-2.0mm 0.8mm 60-90A
2.0.-3.0mm 0.8/0.9mm 120A

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The joint to be welded must be clean,remove existing rust, greasy dirt, water and paint etc.
Flux-core(Gasless) Synergic MIG
Press and hold button”choose” for 3 seconds start to “synergic” function.
Press “choose” button on Flux wire .030”/.035”
The wire feed speed and Voltage will be auto fitted by adjusting wire diameter.
Point the wire into the joint to be weld, press down the gun trigger, the wire feeds automatically.
The arc is started once the wire is touched the work piece.
Flux-core(Gasless) Manual MIG
Press “choose” button on Flux wire .030”/.035”
Adjust the welding current and welding voltage to match the wire being used.
Point the wire into the joint to be weld, press down the gun trigger, the wire feeds automatically.
The arc is started once the wire is touched the work piece.
MMA/Stick Welding
Connect the Electrode lead to the (+) output terminal on the front of the machine.
Connect the work clamp lead to the (-) output terminal on the front of the machine.
Press “choose” button on MMA
Adjust the welding current
Take up the electrode holder, install the electrode-point the electrode into the joint to be welded,
scratch the work piece to start the arc.
5.OPERATION