Duralloy MIG 200 User manual

MIG 200
OWNER’S MANUAL
www.duralloy.net.au | 1300 369 456

Congratulations on your new DURALLOY®product!
The DURALLOY range uses latest technology design and engineering to produce welding products
that combine market leading value and features with durability. Designed for discerning operators who
seek professional results and product quality without the price tag of a full professional setup. Design
emphasis is placed on simple, functional design and operation. DURALLOY product is subject to
stringent quality control and designed and manufactured to EN60974-1.2012 standards.
Common use of DURALLOY products include:
• Light Engineering
• Automotive
• Home / Hobby Engineering
• Farming
• Industrial Maintenance & Repairs
For industrial welding solutions, check out the DURALLOY at www.duralloy.net.au
DURALLOY is a market leading provider of innovative power equipment solutions to a wide range of
industries across Australia. Key product categories are; welding equipment, engineering supplies and
abrasives.
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MIG 200
OWNER’S MANUAL

www.duralloy.net.au | 1300 369 456
CONTENTS
Know Your Machine
Quick Start Guide
Wiring Diagram
Care & Maintenance
Welding Settings
Basic MIG Welding Guide
Safety
Warranty
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MIG 200
OWNER’S MANUAL

www.duralloy.net.au | 1300 369 456
MIG 200
240V MIG Inverter
Welding Machine
PART NO: DA200MIG
4
MIG
Gas & Gasless Operation
ARC STABILITY
Waveform control for added stability of the arc,
even at low current.
DIGITAL DISPLAY
Variable amperage control with digital meters for a
simultaneous welding current and voltage display.
PROTECTION
Equipped with temperature, voltage and current
sensors for greater protection.
FEATURES
• 2 Roll Drive feed System
• Generator Friendly (8.5Kva)
• Industrial Cable Connectors (35-50)
• Industrial Binzel Style MIG Torch MB24
• 240V 15A
• Protective Front Fascia cover
• IP23 Rating
MIG
EN60974-1.2012
APPLICATIONS
• Maintenance
• General Fabrication
• Rural Applications
• On-site Fabrication
MATERIALS
• Mild Steel
• Aluminium
• Stainless Steel
PACKAGE INCLUDES
• Power Source
• 3M MB 24 Style MIG Torch
• 3M Earth Lead
• 1.5M Gas Hose
• Argon Regulator
• Owner’s Manual
• 0.9-1.2 FC Roller for
Gasless Wires
3 YEAR
WARRANTY
MIG 200
OWNER’S MANUAL
SPECIFICATIONS
Power Supply 1-220/230/240 ± 10%
Frequency 50/60Hz
Input Power 5.6 kW
Input Current 40 A
Duty Cycle
40oC 10min
200A 30%
145A 60%
110A 100%
No Load Voltage 46 V
Welding Current 40A - 200A
Welding Voltage 12V - 24V
Eciency 85%
Power Factor 0.65
Wire Diameter Fe, Ss, Flux-Cored: 0.6 / 0.8 / 0.9 / 1.0
Net Weight 12kg
Dimensions 471mm x 213mm x 400mm
Insulation Class H
Protection Class IP23
Cooling Auto Fan

KNOW YOUR MACHINE
More detailed explanations of function on following pages.
1. MIG Wire Feed Speed
2. MIG Voltage
3. Wire Feed Speed/ Current Display Meter*
4. Power Indicator. Lights when input power connected and
machine switched On
5. Error/ Overload Indicator*
6. Display Value Indicator- Wire Feeding Speed
7. Display Value Indicator- Current
8. Trigger Switch Selector 2T/4T
9. Mig Wave Control/ Inductance Knob*
10. Display Value Indicator- Voltage
11. Negative (-) Welding Power Output Connection Socket
12. MIG Torch Euro Connection Socket
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MIG Wire Feed Speed
This knob sets the wire feeding speed.
MIG Voltage
This knob sets the welding voltage.
Wire Feed Speed/ Current Display Meter
Displays wire feeding speed in m/minute prior to welding, during
welding displays welding current output.
Display Meter
Displays welding voltage.
Overload/ Error Indicator
Lights when over voltage, over current or electrical overheating
(due to exceeding duty cycle) is detected and protection is
activated. When protection is activated, welding output will be
disabled until the safety system senses the overload has reduced
suciently and indicator lamp goes out. May also trigger if
machine experiences an internal power circuit failure.
When protection is activated, welding output will be disabled until
the safety system senses the overload has reduced suciently
and indicator lamp goes out. May also trigger if machine
experiences an internal power circuit failure.
FURTHER CONTROLS EXPLAINED
12
36 10
9
8
11
12
MIG 200
OWNER’S MANUAL
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4
5

TIPS & TRICKS
Duty Cycle Rating
welding arc that sets the heat. The wire speed feed simply
controls the rate at which the welding wire is fed into the weld
pool. For any voltage position setting, there will be a specific
corresponding ‘sweet spot’ in the wire feeding speed that will
give the smoothest and most stable welding arc. The correct wire
feeding speed for a given voltage setting is aected by welding
wire type and size, shielding gas, welding material and joint type.
It is recommended to set the welding voltage as desired and
then slowly adjust the wire speed until the arc is smooth and
stable. When reaching this point, if the penetration/ heat input
is too much/ not enough, adjust the voltage setting and repeat
the process.If the operator is not able to achieve a smooth and
stable arc with the desired heat input for the weld, it is likely
that a change in wire size and/or shielding gas type is required
(assuming all other factors are correct).
Wave Control
This setting changes the MIG waveform to simulate changing
the inductance of the welding circuit. Inductance controls the
rate of the current rise and fall as the welding wire contacts the
workpiece (known as a short circuit). More inductance increases
the short circuit time and decreases the short circuit frequency
rate. This causes a wider and more penetrating arc, useful for
thicker weld joints. Less inductance will create a narrow more
focused arc. This eect can also be used to fine tune the arc to
produce less splatter. Wire speed, wire size and type, shielding
gas will all change the eect that the inductance setting has
on the welding arc. Inductance change will have no practical
eect on MIG spray transfer process (as opposed to short circuit
process), MMA or TIG welding process.
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MIG 200
OWNER’S MANUAL

Electrical Connection
The DURALLOY MIG 200 is designed to operate on a 15A 240V
AC power supply. If an extension cord must be used, it should be
a heavy duty version with a minimum cable core size of 2.5mm2.
Operating Environment
Adequate ventilation is required to provide proper cooling.
Ensure that the machine is placed on a stable level surface where
clean cool air can easily flow through the unit. The DURALLOY
MIG 200 has electrical components and control circuit boards
which may be damaged by excessive dust and dirt, so a clean
operating environment is important for reliable product life.
BASIC OPERATION
1. Fitting Wire Spool & Loading Wire Feeder
1.1 Open the wire compartment cover. Unthread the wire spool
retainer. Fit the wire spool to spool holder shaft, ensuring that
the wire exits the spool towards the bottom the spool.
1.2 Set the spool brake tension by adjusting the spool tension
adjustment screw before replacing the wire spool retainer.
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.
WARNING! Excessive spool brake tension will
cause wire feeding issues and aect welding performance
as well as premature failure/ wear of
wire feed components.
1.3 Feed the wire from the spool through the wire drive inlet
guide into the wire feeder.
1.4 Release the wire feed tension arms by pivoting the wire feed
tension adjustment lever from the vertical to the horizontal
position.
1.5 Check the wire drive roller grooves match 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 profile (known as knurled). For solid core ‘hard’ MIG
wire, the drive roller groove used has a ‘V’ shaped profile. For
Aluminium solid core ‘soft’ MIG wire, the drive roller required
has a ‘u’ shaped groove. If necessary, remove and change the
drive roller by unthreading the drive roller retainer.
1.6 Once the correct drive rollers are selected and fitted, manually
feed the wire through the wire drive inlet guide through the
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drive roller grooves and into the brass outlet wire guide tube.
Ensuring that the wire is correctly seated in the drive roller
grooves, replace the wire feed tension arms and lock them
into place by rotating the wire feed tension adjustment lever
back to the vertical position.
Adjusting wire feed tension: this is accomplished by winding the
knob on the tension adjustment lever. Clockwise will increase
tension, anti-clockwise will decrease drive tension. Ideal tension
is as little as possible, while maintaining a consistent wire feed
with no drive roller slippage.
Check all other causes of excess wire feeding friction causing
slippage first, such as; incorrect/ worn drive roller, worn/ damaged
torch consumables, blocked/damaged torch wire guide liner,
before increasing wire feed tension. There is a number scale on
the tension adjustment lever to indicate the adjustment position.
The higher the number indicated, the higher the tension that is
set.
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/ gearbox.
1.7 Connect the MIG Torch Euro Connector to the MIG torch Euro
connection socket (12) on the front of the machine. Secure by
firmly hand tightening the threaded collar on the MIG Torch
connector clockwise.
1.8 Check that the correct matching MIG wire, drive rollers and
MIG torch tip are fitted.
1.9 Connect the machine to suitable mains power using the
mains input power lead. Switch the mains power switch to ‘on’
to power up the machine. Adjust the wire feed speed control
(1) to maximum.
1.10 You are now ready to feed the wire through the torch. With
the wire feeder cover open, pull the trigger of the MIG torch
to check that the wire is feeding smoothly through the feeder
and into the torch.
1.11 With the tip removed from the torch and the torch laid out as
straight as possible, activate the torch trigger until the wire
feeds out through the end of the MIG torch. Replace the tip on
the MIG torch and trim o any excess wire.
QUICK START GUIDE - WELDER INSTALLATION
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MIG 200
OWNER’S MANUAL

2. Gasless Welding Operation
2.1 Connect the earth cable quick connector to the negative
welding power output socket (11). Connect the earth clamp
to the work piece. Contact with the work piece must be firm
contact with clean, bare metal, with no corrosion, paint or
scale at the contact point.
2.2 Change Polarity link which is situated above Wire feed
system.
2.3 Set the welding voltage adjustment knob (2), wire speed
control knob (1) and wave control knob (9) to the desired
positions. You are now ready to weld!
3. Gas Shielded Welding Operation
3.1 Connect the earth cable quick connector to the negative
welding power output socket (11) Connect the earth clamp
to the work piece. Contact with the work piece must be firm
contact with clean, bare metal, with no corrosion, paint or
scale at the contact point.
3.2 Change polarity Link which is situated above the wire feed
system.
3.3 Assemble the female gas quick connector to the gas line
and to the regulator outlet fitting. Connect the gas regulator
to a gas cylinder (not included with machine) and connect
the female quick connector to the male gas inlet on the rear
of the machine. Ensure all connections are tight. Open gas
cylinder valve and adjust regulator, flow should be between
10-25 l/min depending on application.
3.4 Set the welding voltage adjustment knob (2), wire speed
control knob (1) and wave control knob (9) to the desired
positions. You are now ready to weld!
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Note: MIG welding with aluminium provides a unique challenge, due to
the low column strength of the wire. This causes the wire to deform more
as it is pushed through the feed mechanism and the torch wire delivery
liner, greatly increasing friction. Because good MIG welding results are
dependent on a smooth wire feed, certain changes must be made to the
wire feed system to minimise friction caused issues.
For a standard ‘push’ fed torch, a length of no longer than
3m cable may be used, as well as the torch feed liner must
be changed to a special Teflon/ PVC liner, rather than the
conventional steel liner. Also the correct style drive roller must
be used and specific Aluminium rated torch contact tip (or a
standard tip in one size oversize, e.g. 0.8mm aluminium wire, use
standard 1.0mm contact tip). For this reason, it is quite common
for operators to have an extra MIG torch specifically set up for
aluminium use, if the machine is used for welding steel as well.
MIG 200
OWNER’S MANUAL

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WIRING DIAGRAM
9
MIG 200
OWNER’S MANUAL

Keep your welding machine in top condition
The DURALLOY MIG 200 does not require any special
maintenance, however the user should take care of the machine
as follows:
• Regularly clean the ventilation slots.
• Keep the casing clean.
• Check all cables before use.
• Check electrode holders, work lead/clamps and welding
torches before use.
• Replace worn electrode holders and earth clamps, which do
not provide a good connection.
• Replace worn consumable parts in a timely manner.
• Use a soft cloth or brush to clean electrical components.
• Do not use liquid cleaning products, water or especially
solvents.
• Do not use compressed air to clean electrical components as
this can force dirt and dust further into components, causing
electrical short circuits.
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CARE & MAINTENANCE
10
• Check for damaged parts. Do not use the welderwith
damaged parts.
• A damaged welder must be carefully checked by a qualified
person to determine that it will operate properly. Check for
breakage of parts, mountings and other conditions that may
aect its operation. An authorised service centre should
properly repair a damaged part. Have your welder repaired
by an expert.
This appliance is manufactured in accordance with relevant safety
standards. Only experts must carry out repairing of electrical
appliances, otherwise considerable danger for the user may
result. Use only genuine replacement parts. Do not use modified
or non-genuine parts.
Storing the Welder
When not in use the welder should be stored in the dry and frost-
free environment.
WARNING!
Before performing cleaning/maintenance, replacing
cables / connections , make sure the welding machine is
switched o and disconnected from the power supply.
WELDING SETTINGS
Use a chart as guide only, as optimal settings will vary with weld joint type and operator technique. Cells left blank not recommended combination for
eective welding results.
*Inductance adjustment controls the rate of the welding current rise and fall as the welding wire contacts the workpiece (known as short circuit). More
inductance increases the short circuit time and decreases the short circuit frequency rate. This causes a wider and more penetrating arc, useful for
thicker weld joints. Less inductance will create a narrow, more focused arc. This eect can also be used to fine tune the arc to produce less splatter.
Wire speed, wire size and type, shielding gas will all change the eect that the inductance has on the welding arc. Inductance setting will have no
eect on MIG spray transfer process (as opposed to short circuit process), MMA or TIG welding process.
MIG 200
OWNER’S MANUAL

Two dierent welding processes are covered in this section
(GMAW and FCAW), with the intention of providing the very basic
concepts in MIG 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 a gas (GMAW) or flux cored wire (FCAW).
Gas Metal ARC Welding (GMAW)
This process, also known as MIG welding, CO2welding, 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. The process is normally applied semi automatically;
however the process may be operated automatically and can be
machine operated. The process can be used to weld thin and
fairly thick steels, and some non-ferrous metals in all positions.
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BASIC MIG WELDING GUIDE
11
Flux Cored Arc Welding (FCAW)
This is an electric arc welding process which fuses together
the parts to be welded by heating them with an 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.
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.
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.
MIG 200
OWNER’S MANUAL

Distance from the MIG torch nozzle to the work piece
The electrode wire stick out from the MIG torch nozzle should be
between 10mm to 20mm. This distance may vary depending on
the type of joint that is being welded.
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
• Gas flow rate
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
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MIG 200
OWNER’S MANUAL

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
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.
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
(1.5mm or 2.0mm) mild steel plate (150 x 150mm). Use (0.8mm) flux
cored gasless wire or a solid wire with shielding gas.
Setting of the Power Source
Power source and Current (Wire Speed) setting requires some
practice by the operator, as the welding plant has two control
settings that have to balance. These are the Current (Wire Speed)
control and the welding Voltage Control.
The welding current is determined by the Current (Wire Speed)
control, the current will increase with increased Current (Wire
Speed), resulting in a shorter arc. Less Current (Wire Speed) will
reduce the current and lengthen the arc. Increasing the welding
voltage hardly alters the current level, but lengthens the arc.
By decreasing the voltage, a shorter arc is obtained with a little
change in current level.
When changing to a dierent electrode wire dia eter, dierent
control settings are required. A thinner electrode wire needs
more Current (Wire Speed) to achieve the same current level.
A satisfactory weld cannot be obtained if the Current (Wire
Speed) and Voltage settings are not adjusted to suit the electrode
wire diameter and the dimensions of the work piece.
If the Current (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
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voltage is too high, large drops will form on the end of the wire,
causing spatter. The correct setting of voltage and Current (Wire
Speed) can be seen in the shape of the weld deposit and heard
by a smooth regular arc sound.
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
• Type of joint
• 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
MIG 200
OWNER’S MANUAL

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14
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch.
There are two main areas where problems occur with GMAW, Porosity and Inconsistent wire feed.
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within
the molten weld pool which is in the process of escaping during solidification of the molten metal.
Contaminants range from no gas around the welding arc to dirt on the workpiece surface. Porosity can be reduced by checking the
following points.
MIG WELDING TROUBLESHOOTING
WARNING! Disengage the feed roll when testing for gas flow by ear.
Wire feeding problems can be reduced by checking the following points.
MIG 200
OWNER’S MANUAL

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Other weld problems can be reduced by checking the following points.
MIG 200
OWNER’S MANUAL

Store and Retain this Manual
Retain this manual for the safety warnings and precautions,
assembly, operating, inspection, maintenance and cleaning
procedures. Write the product serial number at the rear of this
manual and keep this manual and the receipt in a safe and dry
place for future reference.
Important Safety Information
Failure to follow the warnings and instructions may result in
electric shock, fire, serious injury and/or death. Save all warnings
and instructions for future reference.
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SAFETY
This is the safety alert symbol to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
DANGER!
Indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING!
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or
moderate injury.
NOTE: used to address practices not related to personal injury.
General Safety Warnings
1. Maintain labels and nameplates on the welder. These carry
important information. If unreadable or missing, contact
DURALLOY for a replacement.
2. Avoid unintentional starting. Make sure the welder is setup
correctly and you are prepared to begin work before turning
on the welder.
3. Unplug before performing maintenance. Always unplug
the welder from its electrical outlet before performing any
inspection, maintenance, or cleaning procedures.
4. Never leave the welder unattended while energised. Turn
power o before leaving the welder unattended.
5. Do not touch live electrical parts. Wear dry, insulating gloves.
Do not touch the electrode or the conductor tong with bare
hands. Do not wear wet or damaged gloves.
6. Protect yourself from electric shock. Do not use the welder
outdoors. Insulate yourself from the work piece and the
ground. Use non-flammable, dry insulating material if possible,
or use dry rubber mats, dry wood or plywood, or other dry
insulating material large enough to cover the area of contact
with the work or the ground.
7. Avoid inhaling dust. Some dust created by power sanding,
sawing, grinding, drilling, cutting, welding and other
construction activities, contain chemicals known to cause
cancer, birth defects or other harm. Your risk from these
exposures varies, depending on how often you do this type
of work. To reduce your exposure to these chemicals, work
in a well-ventilated area, and work with approved safety
equipment, such as dust masks that are specially designed to
filter out microscopic particles.
8. People with pacemakers should consult their physician(s)
before using this machine.
WARNING!
Electromagnetic fields in close proximity to a heart
pacemaker could cause interference, or failure of the
pacemaker. The use of a Welder is NOT RECOMMENDED
for pacemaker wearers. Consult your doctor.
9. Ensure that the unit is placed on a stable location before
use.
WARNING!
If this unit falls while plugged in, severe injury, electric
shock, or fire may result.
10. Transportation Methods Lift unit with the handles provided, or
use a handcart or similar device of adequate capacity. If using
a fork lift vehicle, secure the unit to a skid before transporting.
CAUTION
Disconnect input power conductors from deenergized
supply line before moving the welding power source.
11. Exercise good work practices.The warnings, precautions,
and instructions discussed in this instruction manual cannot
cover all possible conditions and situations that may occur. It
must be understood by the operator that common sense and
caution are factors which cannot be built into this product, but
must be considered by the operator.
16
MIG 200
OWNER’S MANUAL

Welding Safety Instructions & Warnings
WARNING!
Protect yourself and others from possible serious injury or
death. Keep children away. Read the operating/Instruction
manual before installing, operating or servicing this
equipment. Have all installation, operation, maintenance,
and repair work performed by qualified people.
If an operator does not strictly observe all safety rules and take
precautionary actions, welding products and welding processes
can cause serious injury or death, or damage to other equipment
or property.
Safe practices have developed from past experience in the use
of welding and cutting. These practices must be learned through
study and training before using this equipment. Some of these
practices apply to equipment connected to power lines; other
practices apply to engine driven equipment. Anyone not having
extensive training in welding and cutting practices should not
attempt to weld.
Safe practices are outlined in the European Standard EN60974-1
entitled: Safety in welding and allied processes.
WARNING!
Only use safety equipment that has been approved by
an appropriate standards agency. Unapproved safety
equipment may not provide adequate protection. Eye and
breathing protection must be AS/NZS compliant for the
specific hazards in the work area.
DANGER!
Always wear AS/NZS compliant safety glasses and full
face shield fitted with appropriate filter shade number.
(Refer Filter Table in this safety section)
CAUTION
Heavy-duty work gloves, non-skid safety shoes and
hearing protection used for appropriate conditions will
reduce personal injuries.
CAUTION
Have the equipment serviced by a qualified repair person
using identical replacement parts. This will ensure that the
safety of the power tool is maintained.
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Personal Safety
CAUTION
Keep the work area well lit. Make sure there is adequate
space surrounding the work area. Always keep the work
area free of obstructions, grease, oil, trash, and other
debris. Do not use equipment in areas near flammable
chemicals, dust, and vapours. Do not use this product in a
damp or wet location.
1. Stay alert, watch what you are doing and use common sense
when operating equipment. Do not use a tool while you are
tired or under the influence of drugs, alcohol or medication. A
moment of distraction when operating equipment may result
in serious personal injury.
2. Do not overreach. Keep proper footing and balance at
all times. This enables better control of the power tool in
unexpected situations.
Arc Rays can Burn Eyes and Skin
DANGER!
Arc rays from the welding process produce intense heat
and strong ultraviolet rays that can burn eyes and skin.
1. Use a Welding Helmet or Welding Face Shield fitted with a
proper shade filter (refer AS 60974-1, AS/NZS 1337.1 and AS/
NZS 1338.1 Safety Standards) to protect your face and eyes
when welding or watching. (See Filter Table later in this
section)
2. Wear approved safety glasses. Side shields are
recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot safety protection.
5. Never wear contact lenses while welding.
Noise Can Damage Hearing
CAUTION
Noise from some processes can damage hearing. Use AS/
NZS compliant ear plugs or ear mus if the noise level is
high.
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Work Environment Safety
CAUTION
Used with the safety alert symbol, indicates a hazardous
situation which, if not avoided, could result in minor or
moderate injury.
1. When possible, move the work to a location well away from
combustible materials. If relocation is not possible, protect the
combustibles with a cover made of fire resistant material.
2. Remove or make safe all combustible materials for a radius of
10 metres around the work area. Use a fire resistant material
to cover or block all doorways, windows, cracks, and other
openings.
3. Enclose the work area with portable fire resistant screens.
Protect combustible walls, ceilings, floors, etc., from sparks
and heat with fire resistant covers.
4. If working on a metal wall, ceiling, etc., prevent ignition of
combustibles on the other side by moving the combustibles
to a safe location. If relocation of combustibles is not possible,
designate someone to serve as a fire watch, equipped with a
fire extinguisher, during the welding process and well after the
welding is completed.
5. Do not weld or cut on materials having a combustible coating
or combustible internal structure, as in walls or ceilings,
without an approved method for eliminating the hazard.
6. After welding, make a thorough examination for evidence of
fire. Be aware that visible smoke or flame may not be present
for some time after the fire has started. Do not weld or cut in
atmospheres containing dangerously reactive or flammable
gases, vapours, liquids, and dust. Provide adequate ventilation
in work areas to prevent accumulation of flammable gases,
vapours, and dust.
7. Do not apply heat to a container that has held an unknown
substance or a combustible material whose contents, when
heated, can produce flammable or explosive vapours. Clean
and purge containers before applying heat. Vent closed
containers, including castings, before preheating, welding, or
cutting.
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Electricity Can Kill
DANGER!
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 semi-automatic or automatic wire welding,
the wire, wire reel, drive roll housing, and all metal parts touching
the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from the work and the ground using dry
insulating mats or covers.
4. Disconnect input power before installing or servicing this
equipment. Lock input power, disconnect switch open, or
remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to
national, state, and local codes.
6. Turn o all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip the holder
in water to cool it or lay it down on the ground or the work
surface. Do not touch holders connected to two welding
machines at the same time or touch other people with the
holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced
cables.
9. Do not wrap cables around your body.
10. Connect work piece to a good electrical ground.
11. Do not touch the electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or replace
damaged parts as soon as practical.
13. In confined spaces or damp locations, do not use a welder
with AC output unless equipped with a voltage reducer.
Arc rays from the welding process produce intense heat and
strong ultraviolet rays that can burn eyes and skin. Use the
following table to select the appropriate shade number for a
Welding Helmet or Welding Face Shield.
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Fumes And Gases
WARNING!
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use an exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Safety Data Sheets (SDS) and the manufacturer’s
instruction for the metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding ga es used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can react
with vapours to form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air- supplied respirator. The coatings and any
metals containing these elements can give of toxic fumes if
welded.
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Fire & Explosive Risks
WARNING!
Sparks and spatter fly o from the welding arc. The flying
sparks and hot metal, weld spatter, work piece, and hot
equipment can cause fires and burns.
Accidental contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable
material.
3. Remove all flammables within 10m of the welding site.
4. Be alert that welding sparks and hot materials from welding
can easily go through small cracks and openings to adjacent
areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect the work lead/clamp to the job as close to the
welding area as practical to prevent welding current from
travelling long, possibly unknown paths and causing electric
shock and fire hazards.
9. Do not use a welder to thaw frozen pipes.
10. Remove the stick electrode from the holder or cut o the
welding wire at the contact tip when not in use.
Sparks & Hot Metal
WARNING!
Chipping and grinding causes flying metal, and as welds
cool they can throw o slag.
1. Wear an AS/NZS approved face shield or safety goggles. Side
shields are recommended.
2. Wear appropriate safety equipment to protect the skin and
body.
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Cylinders
WARNING!
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use appropriate shielding gas, regulators, hoses, and fittings
designed for the specific application; maintain them and their
associated parts in good condition.
6. Turn your face away from the valve outlet when opening the
cylinder valve.
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