Digital Equipment AMIG280PM User manual

1
Dear Customer
This instruction manual will help you get to know your
new machine. Read the manual carefully and you will
soon be familiar with all the many great features of your
new product. Meanwhile, please remember well safety
rules and operate as instruction.
If you treat your product carefully, this definitely helps to
prolong its enduring quality and reliability–things which
are both essential prerequisites for getting outstanding
results.
Production specification may change without advance
notice.
The model you purchase is for:
AMIG280PM
Please find corresponding models from the "Contents".
Important:
Please take special note of safety rules and operate as
instruction in case of damage and serious injury.

2
Safety Rules
“Danger” indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
“Warning!” indicates a possible hazardous situation which, if not
avoided, could result in death or serious injury. The possible hazards are
explained in the text.
“Caution” indicates a possible hazardous situation which, if not avoided,
may result in slight or moderate injury.
“Note!” indicates a situation which implies a risk of impaired welding
result and damage to the equipment.
Utilization for intended purpose only
•The machine may only be used for jobs as defined by the “Intended
purpose”.
•Utilization for any other purpose, or in any other manner, shall be
deemed to be “not in
accordance with the intended purpose”. The manufacturer shall not be
liable for any
damage resulting from such improper use.
Safety signs
•All the safety instructions and danger warnings on the machine must
be kept in legible condition, not removed, not be covered, pasted or
painted cover.
Safety inspection
•The owner/operator is obliged to perform safety inspection at regular
intervals.
•The manufacturer also recommends every 3-6 months for regular
maintenance of power sources.
Electric shock can kill
•Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the output is
on. The input power circuit and machine internal circuits are also live
when power is on. In MIG/MAG welding, the wire, drive rollers, wire
feed housing and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment
is a hazard.
•Do not touch live electrical parts of the welding circuit, electrodes and
wires with your bare skin or wet clothing.
•The operator must wear dry hole-free insulating welding gloves and

3
body protection while performs the welding.
•Insulate yourself from work and ground using dry insulating protection
which is large enough to prevent you full area of physical contact with
the work or ground.
•Connect the primary input cable according to rules. Disconnect input
power or stop machine before installing or maintenance.
•If welding must be performed under electrically hazardous conditions
as follow: in damp locations or wearing wet clothing; on metal
structures such as floors, gratings, or scaffolds; when in cramped
positions such as sitting, kneeling, or lying; or in occasion when there is
a high risk of unavoidable or accidental contact with the work piece or
ground. Must use additional safety precautions: semiautomatic DC
constant voltage (wire) welder, DC manual (MMA) welder and AC
welder with reduced open-load voltage.
•Maintain the electrode holder, ground clamp, welding cable and
welding machine in good, safe operating condition. Replace damaged
part immediately.
Electric and magnetic fields (EMF)may be dangerous
•If electromagnetic interference is found to be occurring, the operator is
obliged to examine any possible electromagnetic problems that may
occur on equipment as follow:
-mains, signal and data-transmission leads
-IT and telecoms equipment
-measurement and calibration devices
-Wearers of pacemakers
•Measures for minimizing or preventing EMC problems:
-Mains supply
If electromagnetic interference still occurs, despite the fact that the mains
connection in accordance with the regulations, take additional measures
-Welding cables
Keep these as short as possible
Connect the work cable to the work piece as close as possible to the area
being welded.
Lay term well away from other cables.
Do not place your body between your electrode and work cables.
-Equipotential bonding
-Work piece grounding (earthing)
-Shielding
Shield the entire welding equipment and other equipment nearby.

4
ARC rays can burn.
•Visible and invisible rays can burn eyes and skin.
•Wear an approved welding helmet or suitable clothing made from
durable flame-resistant material (leather, heavy cotton, or wool) to
protect your eyes and skin from arc rays and sparks when welding or
watching.
•Use protective screens or barriers to protect other nearby personnel
with suitable, non-flammable screening and/or warn them not to watch
the arc nor expose themselves to the arc rays or to hot spatter or
material.
Fumes and gases can be dangerous
•Welding may produce fumes and gases, breathing these fumes and
gases can be hazardous to your health.
•When welding, keep your head out of the fume. If inside, ventilate the
area at the arc to keep fumes and gases away from the breathing zone.
If ventilation is not good, wear an approved air-supplied respirator.
•Work in a confined space only if it is well ventilated, or while wearing an
air-supplied respirator.
•Welding fumes and gases can displace air and lower the oxygen level
causing injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
Welding and cutting sparks can cause fire or explosion.
•When not welding, make sure the electrode circuit is not touching the
work or ground. Accidental contact can cause sparks, explosion,
overheating, or fire. Make sure the area is safe before doing any
welding.
•Welding and cutting on closed containers, such as tanks, drums, or
containers, can cause them to blow up. Make sure proper steps have
been taken.
•When pressure gas is used at the work site, special precautions are
required to prevent hazardous situations.
•Connect work cable to the work as close to the welding zone as
practical to prevent welding current from passing too long and creating
fire hazards or overheat.
•Wear oil-free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes, and a cap. Wear ear plugs when welding
out of position or in confined places. Always wear safety glasses with
side shields when in a welding area.
•Be attention that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas and
start a fire. Remove fire hazardous from the welding area, if not
possible, cover them thoroughly. Do not weld where flying sparks can

5
strike flammable material and where the atmosphere may contain
flammable dust, gas, or liquid vapors (such as gasoline).
•Protect yourself and others from flying sparks and hot metal. Remove
any combustibles from operator before perform any welding.
•Keep a fire extinguisher readily available.
•Empty containers, tanks, drums, or pipes which have combustibles
before perform welding.
•Remove stick electrode from electrode holder or cut off welding wire at
contact tip when not in use.
Apply correct fuses or circuit breakers. Do not oversize or bypass them.
Cylinder can explode if damaged.
•Pressure gas cylinders contain gas under high pressure. If damaged, a
cylinder can explode. Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
•Cylinders should be located away from areas where they may be
struck or subjected to physical damage. Use proper equipment,
procedures, and sufficient number of persons to lift and move
cylinders.
•Always install cylinders in an upright position by securing to a
stationary support or cylinder rack to prevent falling over or tipping.
•Keep a safe distance from arc welding or cutting operations and any
other source of heat, sparks, or flame.
•No touching cylinder by welding electrode, electrode holder or any
other electrically “hot” parts. Do not drape welding cables or welding
torches over a gas cylinder.
•Use only correct compressed gas cylinders, regulators, hoses, and
fittings designed for the process used; maintain them and associated
parts in good condition.
•Use only compressed gas cylinders containing the correct shielding
gas for the and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the
application and maintained in good condition.
•Open the cylinder valve slowly and keep your head and face away from
the cylinder valve outlet.
Valve protection caps should be kept in place over valve expect when the
cylinder is in use or connected for use.
Hot parts can burn
•Do not touch hot parts with bare hand or skin.
•Ensure equipment is cooled down before perform any work.
•If touching hot parts is needed, use proper tools and/or wear heavy,
insulated welding gloves and clothing to prevent burns.

6
Flying metal or dirt can injure eyes
•When welding, chipping, wire brushing, and grinding can cause sparks
and flying metal. It can hurt your eyes.
•Remember wear appropriate safety glasses with side shields when in
welding zone, even under your welding helmet.
Noise can damage hearing
•Noise from some processes or equipment can damage hearing.
Remember wear approved ear protection to protect ears if noise level is
high.
Moving parts can injure
•Stay away from moving parts such as fans.
•Stay away from pinch points such as drive rolls.
•Keep all doors, panels, covers, and guards closed and securely in
place.
•Have only qualified persons remove doors, panels, covers, or guards
for servicing and maintenance.
•Reinstall doors, panels, covers, or guards when servicing and
maintenance is finished and before reconnecting input power.
Overuse can cause overheating
•Use machine follow duty cycle. Reduce current or reduce duty cycle
before starting to weld again.
•Allow cooling period.
Do not block or filter airflow to unit.
Safety markings
Equipment with CE-markings meets the basic requirements of the
Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant
product standards according to EN 60974).
Safety markings
Equipment with CCC markings meets the requirements of
implementations rules for China compulsory certification （e.g. relevant
product standards according to GB/T 15579）.
Safety markings
CSA marked equipment meets the requirements of the North American
market safety certification implementation rules (e.g. relevant product
standards according to CAN/CSA-E60974,ANSI/IEC 60974)

7
Contents
1- GENERAL REMARKS...................................................................................................8
1-1 Power source features....................................................................................... 8
1-2 Functional principle.............................................................................................8
1-3 Output characteristics.........................................................................................9
1-4 Duty cycle.............................................................................................................9
1-5 Applications....................................................................................................... 10
1-6 Warning label.....................................................................................................11
2-VERSIONS BRIEFS..................................................................................................... 11
3- BEFORE COMMISSIONING......................................................................................12
3-1 Utilization for intended purpose only............................................................. 12
3-2 Machine installation rules................................................................................ 12
3-3 Power source connection................................................................................ 12
3-4 Welding cables instruction...............................................................................13
4 – AMIG280PM................................................................................................................14
4-1 System components.........................................................................................14
4-2 Basic equipments for welding......................................................................... 14
4-3 Control panel..................................................................................................... 15
4-4 Sub-menu...........................................................................................................21
4-5 JOB mode-call&store function........................................................................ 25
4-6 Interface............................................................................................................. 28
4-7 Installation.......................................................................................................... 29
4-8 welding process installation............................................................................ 33
4-9 Technical data................................................................................................... 34
4-10 Dimension........................................................................................................ 35
4-11 Disassembly and reassembly.......................................................................36
5-WIREFEEDER............................................................................................................... 38
5-1 Roller...................................................................................................................38
5-2 Disassembly and reassembly......................................................................... 40
6-TROUBLE SHOOTING................................................................................................ 41
7 –CARE AND MAINTENANCE.....................................................................................44

8
1- GENERAL REMARKS
This series of power sources apply IGBT soft switch inverter technology. Its internal control
system applies digital signal processor which ensures quick response to any change during
the welding process so as to achieve precise control of welding process and ensure optimal
welding results.
1-1 Power source features
This series of power sources are microprocessor controlled and apply MCU + DSP control
technology to improve the control precision. The strong ability of arc self-adjustment ensures
a highly stable welding current against grid fluctuation and arc length change to get optimal
results.
Highlights as follows:
- Thin plate welding expert, especially suitable for 0.7-4mm aluminum alloy thin plate
welding.
- Embedded welding expert database, automatic intelligent combination of parameters.
- To achieve beautiful ripple pattern of welding seam with the function of double pulse MIG.
- Store 100 sets of user-defined parameters, save the operator’s time.
- Perfect functions of starting arc and reducing melting ball while stopping arc.
- Special 4-step mode is suitable for welding metal with good thermal conductivity, with
perfect welding quality when starting arc and stopping arc.
- Multiple protection functions.
- Fully digital wire feeding control system to ensure stable and precise wire feeding.
- The wire feeder is built-in, which has the advantages of small size, light weight and easy
movement
- Fan-on demand cooling system operates when needed to extend the service life of fan.
- Advanced digital communication interfaces for robotic system and automation system.
1-2 Functional principle
This series of power sources adopt IGBT soft switch inverter technology to improve the
dynamic response rate and make the machines with small size and light weight. The control

9
circuit's closed-loop control makes the power source enjoy strong ability against power grid
fluctuation and perfect welding performance.
Fig. 1-2-1: Schematic diagram
1-3 Output characteristics
Fig.1-3-1: Output characteristics
1-4 Duty cycle
Duty cycle is percentage of 10 minutes that a machine can weld at rated load without
overheating. If overheats, thermostat(s) will open, output stops. Wait for fifteen minutes for
the machine to cool down. Reduce amperage or duty cycle before welding.
Note! Exceeding duty cycle can damage the machine and greatly reduce its
lifespan