Duralloy 171 MULTIMIG User manual

171 & 191 MULTIMIG
OWNER’S MANUAL
www.duralloy.net.au | 1300 369 456

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171 & 191 MULTIMIG OWNER’S MANUAL
SAFETY
Welding and cutting is dangerous to the operator, people in or
near the working area, and the surrounding, if the machine is not
correctly operated. Therefore, the performance of welding/cutting
must only be under the strict and comprehensive observance of
all relevant safety regulations. Please read and understand this
instruction manual carefully before the installation and operation.
• The switching of function modes is possibly damaging to the
machine, while the welding operation is performed.
• Do disconnect the electrode-holder cable with the machine,
before the performance of welding.
• A safety switch is necessary to prevent the machine from
electric-leakage.
• Welding tools should be of high quality.
• Operators should be qualified.
Electric shock: It could be fatal!
• Connect the earth cable according to standard regulation.
• Avoid all contact with live electrical parts of the welding
circuit, electrodes and wires with bare hands. It is necessary
for the operator to wear dry welding gloves while he
performs the welding task.
• The operator should keep the working piece insulating from
himself/herself.
Smoke and gas generated while welding or cutting: harmful to
people’s health.
• Avoid breathing the smoke and gas generated while welding
or cutting.
• Keep the working area well ventilated.
Arc rays: harmful to people’s eyes and skin.
• Wear welding helmet, anti-radiation glass and work clothes
while the welding operation is performed.
• Measures also should be taken to protect people in or near
the working area.
Fire hazard
• The welding splash may cause fire, thus remove flammable
material away from the working place.
• Have a fire extinguisher nearby, and have a trained person
ready to use it.
Noise: possibly harmful to peoples’ hearing.
• Noise is generated while welding/cutting, wear approved ear
protection if noise level is high
Machine fault:
• Consult this instruction manual.
• Contact your local dealer or supplier for further advice.

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This welding machine is composed of the inverter MIG welder
power supply with variable voltage output external characteristics
manufactured with advanced IGBT inverter technology designed
by our company.
With high-power component IGBT, the inverter converts the DC
voltage, which is rectified from input 50Hz/60Hz AC voltage,
to high-frequency 20 KHz AC voltage; as a consequence, the
voltage is transformed and rectified. The features of this machine
are as follows:
• IGBT inverter technology, current control, high quality with
stable performance
• Closed feedback circuit, variable voltage output, great ability
of balance voltage up to ±15%;
• Electron reactor control, stable welding, low spatter, deep
penetration, excellent weld bead shape.
• Welding voltage can be preset, and the voltmeter displays
the preset voltage value when not welding.
• Both welding current and welding voltage can be observed
at the same time.
• Burn back time is adjustable.
• Slow wire feeding during arc starting, removes the melted
ball after welding oering reliable arc starting;
• Wire feeding part is separated from the welding machine
with wide welding operation range.
• Small-sized, light-weight, easy to operate, economical,
practical.
Unpacking your machine:
When unpacking, inspect carefully for any damage that may have
occurred during transit. Check carefully to ensure all the contents
on the list below have teen received in good condition
Included items:
Operating environment:
Adequate ventilation is required to provide proper cooling for
the machine. Ensure that the machine is placed on a stable level
surface where clean cool air can easily flow through the unit. The
machine has electrical components and control circuit boards
which will be damaged by excessive dust and dirt, so a clean
operating environment is essential.
LIFT TIG
Needed items: inverter welder with LIFT TIG function 2 Piece TIG
Torch with one output power cable and one Gas Hose.
The operation of LIFT TIG is shown as below:
The output power cable connects with the negative output
terminal, and the Gas hose connects with the gas regulator on
the gas bottle. There is a nut on the gas hose, which can connect
with the gas regulator. Then open the valve of the gas bottle and
open the valve of the gas regulator, you can control the gas flow
by adjusting the gas regulating valve on the TIG Torch. Make the
tungsten electrode touch the workpiece, lift the TIG Torch up, this
will produce the arc.
GENERAL DESCRIPTION
• 171 & 191 MULTIMIG
welder
• Owner’s Manual
MMA lead and holder Earth lead and clamp 3m MIG torch Gas Hose FC roller V roller Regulator

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MAIN PARAMETER
Note: The welding duty cycle is the percentage of actual continuous welding time that can occur in a ten minute cycle. For example:
15% at 200amps- this means the welder can weld continuously at 200 amps for 1.5 minutes and then the unit will need to be rested for
8.5 minutes.
The duty cycle can be aected by the environment in which the welder is used. In areas with temperatures exceeding 40oC, the duty
cycle will be less than stated. In areas less than 40oC, higher duty cycles have been obtained
All tests on duty cycles have been carried out at 40oC with a 50%. So in practical working conditions the duty cycles will be much
greater than those stated above.

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STRUCTURE OF WELDER
1. Gas selection
2. VRD/2T/4T Selection function
3. welding mode selection button: MMA/LIFT TIG/MIG
4. Voltage/voltage refine/error digital display
5. Current/inductance/wire feed speed digital display
6. Wire diameter (Synergy)selection/manual mode
7. Gas check
8. Wire check
9. welding parameter adjustment knob
10. Function button: adjust the inductance in MIG mode;
adjust the hot start and arc force in MMA mode.
11. MIG Torch ‘Euro Style’ Connection Socket
12. Positive (+) Welding Output Terminal
13. Negative (-) Welding Output Terminal
14. Polarity conversion line
15. welding gas inlet
16. power switch
17. power cable
18. Wire tension adjustment
19. Wire tension arm &
support roller
20. Wire input guide
21. Wire drive roller
22. Drive roller retainer
23. Wire spool retainer
24. Spool brake adjustment
24
23
22
21
20
19
18
15
16
17
25
26
27
28 29
30
31
32
25. Torch trigger switch
26. Torch “Euro” connector
27. Workpiece earth clamp
28. Earth lead quick connector
29. Conical gas nozzle/shroud
30. Welding MIG
31. Shroud spring
32. MIG adapter
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INSTALLATION
5.1. MIG WELDING SET UP & OPERATION
5.1.1 Fitting the spool
5.1.1.1 Open the cover door for the wire feed compartment.
Remove the wire spool retainer (23) by threading o anti
clockwise.
5.1.1.2 Fit the 200mm diameter wire spool to the spool holder,
ensuring the end of the wires exits towards the wire feeder
from the bottom of the spool. Refit the wire spool retainer (23)
and tighten finger tight.
5.1.1.3 Set the spool brake tension by rotating the adjustment
screw (24) using an Allen wrench. Clockwise to increase brake
tension, anti-clockwise to decrease brake tension. The spool
brake tension should be set so that the spool can rotate freely,
but does not continue to rotate once the wire feed stops. This
may need to be adjusted as the wire is used up and the spool
weight decreases.
5.1.2 Loading wire feeder
5.1.2.1 Release the wire
feeder tension arm (19)
by pivoting the wire feed
tension adjuster (18) as
pictured below
5.1.2.2 Check the wire
drive roller (21) groove
matches the selected MIG
wire type and size. The
drive roller will have two
dierent sized grooves,
the size of the groove in use is stamped on the side of the
drive roller. For flux cored ‘soft’ wire, such as that used in
gasless MIG welding, the drive roller groove has a serrated
profit. For solid ‘hard’ MIG wire, the roller groove has a ‘v’
shaped profile
5.1.2.3 The drive roller (21) is removed by threading the drive
roller retainer (22) o in the anti-clockwise direction. Once the
correct drive roller profile is selected, re-fit the drive roller.
5.1.2.4 Thread the MIG wire from the spool through the input
guide tube (20), through the roller groove and into the outlet
guide tube
5.1.2.5 Replace the tension arm (19) and the tension adjustment
(18). Double check the wire has located correctly in the drive
roller groove.
5.1.2.6 Adjusting wire feed tension: this is accomplished by
winding the knob on the wire tension adjustment arm (18).
Clockwise will increase tension, anti-clockwise will decrease
tension. There is a numbered scale on the tensioner to
indicate the position. Ideal tension should be as little as
possible, while maintaining a consistent wire feed with no
drive roller slippage. Check all other possible causes of
slippage, such as; incorrect/ worn drive roller, worn/ damaged
torch consumables, blocked/ damaged torch feed liner, before
increasing feed tension.
Warning! - Before changing the feed roller or wire spool,
ensure that the mains power is switched o
Warning! - The use of excessive feed tension will cause
rapid and premature wear of the drive roller, the support
bearing and the drive motor.
5.1.3 Setup for gasless MIG welding operation
5.1.3.1 Connect the MIG Torch Euro Connector (26) to the
torch socket on the front of the welder (11). Secure by firmly
hand tightening the threaded collar on the MIG Torch Euro
Connector clockwise.
5.1.3.2 Check that the correct flux cored, gasless wire,
matching drive roller (21) and welding tip (30) are fitted
5.1.3.3 Connect Torch
Connection Power Lead
(14) to the negative (-)
welding output terminal
(13).
5.1.3.4 Connect Earth Lead
Quick Connector (28) to
the positive (+) output
welding terminal (12). See
picture below.
5.1.3.5 Connect Earth Clamp (27) to the work piece. Contact
with workpiece must be strong contact with clean, bare metal,
with no corrosion, paint or scale at the contact point.
5.1.4 Setup for gas shielded MIG welding operation
Note - Gas shielded MIG welding requires a shielding gas
supply, gas regulator and gas shielded MIG wire.
5.1.4.1 Connect the MIG Torch Euro Connector (26) to the
torch socket on the front
of the welder (11). Secure
by firmly hand tightening
the threaded collar on the
MIG Torch Euro Connector
clockwise.
5.1.4.2 Check that the
correct gas shielded wire,
matching drive roller (21)
and welding tip (30) are
fitted
MIG
TORCH
EARTH
LEAD
MIG
TORCH
EARTH
LEAD

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INSTALLATION continued
5.1.4.3 Connect Torch Connection Power Lead (14) to the
positive (+) welding output terminal (12)
5.1.4.4 Connect Earth Lead Quick Connector (28) to the
negative (-) output welding terminal (13). See picture below
5.1.4.5 Connect Earth Clamp (27) to the work piece.
Contact with workpiece must be strong contact with
clean, bare metal, with no corrosion, paint or scale at the
contact point.
5.1.4.6 Connect the gas regulator and gas line to the inlet
on the rear panel (15). If the regulator is equipped with
a flow gauge, the flow should be set between 8 – 15 L/
minute depending on application. If gas regulator is not
equipped with a flow gauge, adjust pressure so gas can
just be heard coming out of the torch conical nozzle (29).
It is recommended that gas flow is checked again, just
prior to starting weld this can be done by triggering the
MIG torch with the unit powered up.
Connection of Shield Gas
Connect the CO2 hose, which come from the wire feeder
to the copper nozzle of gas bottle. The gas supply system
includes the gas bottle, the air regulator and the gas hose, the
heater cable should be inserted into the socket of machine’s
back, and use the hose clamp to tighten it to prevent leaking
or air-in, so that the welding spot is protected.
Please note:
1. Leakage of shielding gas affects the performance of arc
welding.
2. Avoid the sun shine on the gas cylinder to eliminate the
possible explosion of gas cylinder due to the increasing
pressure of gas resulted from the heat.
3. It is extremely forbidden to hit gas cylinder and lay the
cylinder horizontally.
4. Ensure no person is up against the regulator, before the
gas release or shut the gas output.
5. The gas output volume meter should be installed
vertically to ensure the precisely measuring.
6. Before the installation of gas regulator, release and shut
the gas for several time in order to remove the possible
dust on the sieve to avail the gas output.
Note: Since the arc of MIG welding is much stronger than
that of MMA welding, please wear welding helmet and
protective clothing.

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5.1.5 Controls for MIG welding
5.1.5.1 Gas selection: CO2--ordinary CO2 gas; MIX--20% CO2
80% argon; FLUX-- flux cored
5.1.5.2 Function selection: 2T in MIG mode/4T in MIG mode;
VRD in MMA mode
5.1.5.3 Welding mode selection: MIG welding mode; TIG
welding mode; MMA welding mode
5.1.5.4 Voltage meter: in MIG mode it shows setting voltage
and welding voltage; in other modes no voltage will be
showed.
Warning! - Disconnect the power supply when the Alarm light
flash.
5.1.5.5 Current meter: in MIG mode it shows wire feed speed,
welding current, inductance; in MMA mode it shows current,
hot start current, arc force current.
5.1.5.6 Wire diameter selection: in Synergy mode, select the
wire diameter, press the 9 adjustment knob, the voltage can
be adjusted by ±1V; in Separate mode, welding current and
welding voltage can be adjusted separately--press the button
one time to select voltage or current separate adjustment;
This button cannot work in MMA or TIG mode.
5.1.5.7 Gas check: gas check function, the button cannot work
in MMA or TIG mode.
5.1.5.8 Wire check: wire fast feed button--short press this
button and
5.1.5.9 Adjustment knob: In MIG mode-- voltage adjustment,
inductance adjustment, wire feed speed adjustment, current
adjustment; In MMA mode -- inductance adjustment, hot start
current adjustment; In TIG mode--current adjustment.
5.1.5.10 Mode selection: Hot start function, Arc force function,
Inductance selection (Hot start function, the voltage meter
shows HOL; Arc force, the voltage meter shows FOГ)
Note: this MIG welding machine MIG welding can be both
synergic and separate, select the wire feed speed the voltage
parameter will be matched automatically.Please select the
wire diameter according to the wire you use. Voltage refine
initialization value is 0, refine the voltage by ±1V according to
dierent kinds of gas. In synergy mode, the base gas is CO2, to
lower the voltage by 2-3V for mix gas. Inductance initialization
value is 0, adjust range ±10.
Note: for flux cored wire, connect the Polarity conversion line to
Negative (-) Welding Output Terminal, connect the earth clamp to
Positive (+) Welding Output Terminal; For ordinary wire, connect
the Polarity conversion line to Positive (+) Welding Output Terminal,
connect the earth clamp to Negative (-) Welding Output Terminal
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WELDING SETTINGS QUICK REFERENCE CHART
BASIC WELDING GUIDE
MIG (GMAW/FCAW) Basic Welding Technique
Two dierent welding processes are covered in this section (GMAW and FCAW), with the intention providing the very basic concepts in
using the MIG mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the
arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
GAS METAL ARC WELDING (GMAW)
This process, also known as MIG welding, CO2 welding, Micro
Wire Welding, short arc welding, dip transfer welding, wire
welding etc., is an electric arc welding process which fuses
together the parts to be welded by heating them with an arc
between a solid continuous, consumable electrode and the
work. Shielding is obtained from an externally supplied welding
grade shielding gas or welding grade shielding gas mixture. The
process is normally applied semi automatically; however
the and fairly thick steels, and some non-ferrous metals in all
positions.
FLUX CORED ARC WELDING (FCAW)
This is an electric arc welding process which fuses together the
parts to be welded by heating them with wan arc between a
continuous flux filled electrode wire and the work. Shielding is
obtained through decomposition of the flux within the tubular
wire. Additional shielding may or may not be obtained from an
externally supplied gas or gas mixture. The process is normally
applied semi automatically; however the process may be
applied automatically or by machine. It is commonly used to
weld large diameter electrodes in the flat and horizontal position
and small electrode diameters in all positions. The process is
used to a lesser degree for welding stainless steel and for
overlay work.

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POSITION OF MIG TORCH
The angle of MIG torch to the weld has an eect on the width of the weld
The welding gun should be held at an angle to the weld joint. (See Secondary Adjustment Variables below) Hold the gun so that the
welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses and use the proper safety equipment.
CAUTION
Do not pull the welding gun back when the arc is established. This will create excessive wire extension (stick-out) and make a very poor
weld.
The electrode wire is not energized until the gun trigger switch is depressed. The wire may therefore be placed on the seam or joint
prior to lowering the helmet.

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2. Wire Feed Speed. Increase in wire feed speed increases
weld current, Decrease in wire feed speed decreases weld
current
3. Nozzle Angle. This refers to the position of the welding gun
in relation to the joint. The transverse angle is usually one
half the included angle between plates forming the joint. The
longitudinal angle is the angle between the Centre line of the
welding gun and a line perpendicular to the axis of the weld.
The longitudinal angle is generally called the Nozzle
Angle and can be either trailing (pulling) or leading
(Pushing). Whether the operator is left handed or right
handed has to be considered to realize the eects of each
angle in relation to the direction of travel.
The electrode wire stick out from the MIG Torch nozzle should be
between 10mm to 20.0mm. This distance may vary depending on
the type of joint that is being welded
Travel Speed
• The speed at which the molten pool travels influences the
width of the weld and penetration of the welding run
MIG Welding (GMAW) Variables
• Most of the welding done by all processes is on
carbon steel. The items below describe the welding.
• Variables in short-arc welding of 24gauge (0.024”, 0.6mm) to
¼” (6.4mm) mild sheet or plate. The applied techniques and
end results in the GMAW process are controlled by these
variables.
Preselected Variables
• Preselected variables depend upon the type of material
being welded, the thickness of the material, the welding
position, the deposition rate and the mechanical properties.
These variables are:
• Type of electrode wire
• Size of electrode wire
• Type of gas (not applicable to self-shielding wires FCAW)
• Gas flow rate (not applicable to self-shielding wires FCAW)
Primary Adjustable Variables
• These control the process after preselected variables have
been found. They control the penetration, bead width, bead
height, arc stability, deposition rate and weld soundness.
They are:
• Arc Voltage
• Welding current (wire feed speed)
• Travel speed
Secondary Adjustable Variables
These variables cause changes in primary adjustable variables
which in turn cause the desired change in the bead formation.
They are:
1. Stick-out (distance between the end of the contact tube (tip)
and the end of the electrode wire). Maintain at about 10mm
stick-out
DISTANCE FROM THE MIG TORCH NOZZLE TO THE WORK PIECE
ESTABLISHING THE ARC AND MAKING WELD BEADS
Before attempting to weld on a finished piece of work, it is
recommended that practice welds be made on a sample metal of
the same material as that of the finished piece
The easiest welding procedure for the beginner to experiment
with MIG welding is the flat position. The equipment is capable of
flat, vertical and overhead positions.
For practicing MIG welding, secure some pieces of 16 or 18
gauge (0.06” 1.5mm or 0.08” 2.0mm) mild steel plate 6” x 6” (150
x 150mm). Use 0.030” (0.8mm) flux cored gasless wire or a solid
wire with shielding gas

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SETTING OF THE POWER SOURCE
Power source and Wire feeder setting requires some practice
by the operator, as the welding plant has two control settings
that have to balance. These are the Wire speed control and the
welding Voltage Control. The welding current is determined
by the Wire speed control, the current will increase with increase
Wire speed, resulting in a shorter arc. Less wire speed will
reduce the current and lengthen the Increasing the welding
voltage hardly alters the current level, but lengthens the
arc. By decreasing voltage, a shorter arc is obtained with a little
change in current level.
When changing to a dierent electrode wire diameter,
dierent control settings are required. A thinner electrode wire
needs more Wire speed to achieve the same current level
A satisfactory weld cannot be obtained if the Wire speed and
Voltage settings are not adjusted to suit the electrode wire
diameter and the dimensions of the work piece.
If the Wire speed is too high for the welding voltage, “stubbing”
will occur as the wire dips into the molten pool and does not
melt. Welding in these conditions normally produces a poor weld
due to lack of fusion. If, however, the welding voltage is too high,
large drops will form on the end of the wire, causing spatter. The
correct setting of voltage and
Wire speed can be seen in the shape of the weld deposit and
heard by a smooth regular arc sound. Refer to the Weld Guide
located on the inside of the wire feed compartment door for
setup information.
Electrode Wire Size Selection
• The choice of Electrode wire size and shielding gas used
depends on the following
• Thickness of the metal to be welded
• Capacity of the wire feed unit and Power Source
• The amount of penetration required
• The deposition rate required
• The bead profile desired
• The position of welding
• Cost of the wire

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RANGE OF WELDING CURRENT AND VOLTAGE IN CO2WELDING
The option of the welding speed
The welding quality and productivity should be taken into consideration for the option of welding speed. In case that the welding speed
increases, it weakens the protection eciency and speeds up the cooling process. As a consequence, it is not optimal for the seaming.
In the event that the speed is too slow, the work piece will be easily damaged, and the seaming is not ideal. In practical operation, the
welding speed should not exceed 1m/min.
The length of wire sticking out
The length of wire sticking out the nozzle should be appropriate. The increase of the length of wire sticking out of the nozzle can
improve the productivity, but if it is too long, excessive spatter will occur in the welding process. Generally, the length of wire sticking
out the nozzle should be 10 times as the welding wire diameter.
The setting of the C02flow volume
The protection eciency is the primary consideration. Besides, inner-angle welding has better protection eciency than external-angel
welding. For the main parameter, refer to the following figure.
Option of C02flow volume

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WELDING PARAMETERS TABLE
The option of the welding current and welding voltage directly influences the welding stability, welding quality and productivity. In order
to obtain the good welding quality, the welding current and welding voltage should be set optimally. Generally, the setting of weld
condition should be according to the welding diameter and the melting form as well as the production requirement.
The following parameter is available for reference.
Parameter for butt-welding
Parameter for flat fillet welding
Parameter for fillet welding in the vertical position
Parameter for Lap Welding

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CAUTION
1. Working environment
1. Welding should be carried out in a relatively dry environment with its humidity of 90% or less.
2. The temperature of the working environment should be within -10oC to 40oC.
3. Avoid welding in the open air unless sheltered from sunlight and rain, and never let rain or water infiltrate the machine.
4. Avoid welding in dusty area or environment with corrosive chemical gas.
5. Avoid gas shielded arc welding in environment with strong airflow.
2. Safety tips
Over-current/overheating protection circuit is installed in this welding machine. If the output current is too high or overheating
generated inside this welding machine, this welding machine will stop automatically. However, inappropriate use will still lead to
machine damage, so please note:
1. Ventilation
High current passes when welding is carried out, thus natural ventilation cannot satisfy the welding machine’s cooling requirement.
Maintain good ventilation of the louvers of this welding machine. The minimum distance between this welding machine and any other
objects in or near the working area should be 30cm. Good ventilation is of critical importance for the normal performance and service
life of this welding machine.
2. No over-current.
Remember to observe the max load current at any moment (refer to the optioned duty cycle). Make sure that the welding current should
not exceed the max load current.
If welding is carried out under a current which is higher than the max current, over-current protection will occur; the output voltage of
the welding machine will be not stable; arc interruption will occur. In this case, please lower the current.
3. No over-load.
Over-load current could obviously shorten the welding equipment’s life, or even damage the machine.
A sudden halt may occur while the welding operation is carried out while this welding machine is of over-load status. Under this
circumstance, it is unnecessary to restart this welding machine. Keep the built-in fan working to bring down the temperature inside the
welding machine.
4. Avoid electric shock.
An earth terminal is available for this welding equipment. Connect it with the earth cable to avoid the static and electric shock.

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MAINTENANCE
1. Disconnect input plug or power before maintenance or repair on machine.
2. Be sure input ground wire is properly connect to a ground terminal.
3. Check whether the inner gas-electricity connection is well (esp. the plugs), and tighten the loose connection; if there is oxidization,
remove it with sand paper and then re-connect.
4. Keep hands, hair, loose clothing, and tools away from electrical parts such as fans, wires when the machine is switched on.
5. Clear the dust at regular intervals with clean and dry compressed air; if the working condition is with heavy smoke and air pollution,
the welding machine should be cleaned daily.
6. The compressed air should be reduced to the required pressure so that small components inside the machine will not be
damaged.
7. To avoid water and rain, if there is, dry it in time, and check the insulation with mega-meter (including that between the connection
and that between the case and the connection). Only when there is no abnormal phenomenon should the welding continue.
8. If the machine is not used for a long time, put it into the original packing in dry condition.

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DAILY CHECKS
To make best use of the machine, daily checking is very important. During the daily checking, please check in the order of torch, wire-
feeding vehicle, all kinds of PCB, the gas hole, and so on. Remove the dust or replace some parts if necessary. To maintain the purity of
the machine, please use original welding parts.
CAUTIONS: Only the qualified technicians are authorized to undertake the repair and check task of this welding equipment in case of
machine fault.
11.1. Power supply
11.2. Welding torch

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11.3. Wire feeder
11.4. Cables

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CONNECTION DIAGRAM OF THE MACHINE

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EXPLODED DRAWING