Duralloy MULTIMIG 200 PFC MV User manual

MULTIMIG 200
PFC MV
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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MULTIMIG 200 PFC MV
OWNER’S MANUAL

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CONTENTS
Know Your Machine
Quick Start Guide
Wiring Diagram
Care & Maintenance
Welding Settings
Basic MIG Welding Guide
Eects of MMA Welding Various Metals
Basic MMA Welding Guide
MMA Welding Techniques
MMA Troubleshooting
Safety
Warranty
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MULTIMIG 200 PFC MV
OWNER’S MANUAL

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MULTIMIG 200 PFC MV
OWNER’S MANUAL
MULTIMIG 200
PFC MV
240V Multiprocess Inverter
Welding Machine
PART NO: DA200MMIG
4
PFC TECHNOLOGY
Most DURALLOY® Welding Machines feature PFC
Technology for maximum electrical eciency and
consistent weld output.
MULTIPURPOSE
MIG, TIG and MMA modes.
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
• Generator friendly (8.5Kva)
• Spool gun function (optional)
• Suits 1kg & 5kg Spools
• Voltage Reduction Device (VRD)
• 2 roll wire feeder
• Industrial cable connectors (35-50)
• Industrial Binzel style MIG torch MB24
• Switched 4 M TIG torch (optional)
• Wide input voltage - 90VAC - 275VAC
• Gas/Gasless MIG Operation
• Wire Inch Switch
• Gas Purge switch
• Quick connect gas fittings
• Protective front fascia cover
• IP23 rating
• Extension lead friendly up to 100m
TIG STICKMIG
EN60974-1.2012
SPECIFICATIONS
Power Supply 90VAC - 275VAC
Supply Plug 15 Amp
Frequency 50/60Hz
1-110/120/130V ± 10% 1-220/230/240V ± 10%
MIG MMA TIG MIG MMA TIG
Input Power 4kW 3.5kW 3.2kW 6.2kW 6.2kW 4.2kW
Input Current 37.8A 32A 29A 29A 30A 20A
Duty Cycle
40oC 10min
140A 35%
110A 60%
85A 100%
110A 30%
80A 60%
65A 100%
150A 40%
125A 60%
95A 100%
200A 30%
145A 60%
110A 100%
200A 25%
130A 60%
100A 100%
200A 35%
155A 60%
120A 100%
No Load Voltage 65V
Welding Current 40A - 200A
Welding Voltage 14V - 24V
Eciency 80%
Power Factor 0.99
Wire Diameter Fe: 0.6 - 0.9 Ss: 0.8/0.9
Flux-Cored: 0.8 - 1.2 AL: 0.9/1.0
Net Weight 15kg
Dimensions 511mm x 213mm x 400mm
Insulation Class H
Protection Class IP23
Cooling Auto Fan
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
• 3M MMA Arc Lead
• 1.5M Gas Hose
• Argon Regulator
• Owner’s Manual
3 YEAR
WARRANTY

KNOW YOUR MACHINE
More detailed explanations of function on following pages.
1. MIG Wire Feed Speed/ MMA/TIG Current Control*
2. MIG Voltage/MMA Arc Force/Downslope Adjustment Knob*
3. MIG Mode Indicator
4. MMA Mode Indicator
5. TIG Mode Indicator
6. Wire Feed Speed/ Current Display Meter*
7. Display Value Indicator- Wire Feeding Speed
8. Display Value Indicator- Current
9. Voltage/ Arc Force / TIG Display Meter*
10. Display Value Indicator- Voltage (when in MIG mode)
11. Display Value Indicator- Arc Force (when in MMA mode)
12. Display Value Downslope when in TIG Mode
13. Power Indicator. Lights when input power connected and
machine switched On (When in TIG Mode).
14. Error/ Overload Indicator*
15. Mig Wave Control/ Inductance Knob*
16. Trigger Switch Selector 2T/4T
17. Negative (-) Welding Power Output Connection Socket
18. Gas hose connector for optional TIG torch
19. Aero Socket For Optional TIG Torch connection
20. MIG Torch Euro Connect Socket
21. Positive(+) Output Welding Connection
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MULTIMIG 200 PFC MV
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MIG Wire Feed Speed/MMA/TIG Current Control Knob
In MIG mode this knob sets the wire feeding speed in MMA/TIG
mode, sets MMA/TIG welding current
MIG Voltage/ MMA Arc Force Adjustment Knob
In MIG mode this knob sets the welding voltage. In MMA mode,
sets arc force. In TIG mode, sets downslope time.
Wire Feed Speed/ Current Display Meter
In MIG mode, displays wire feeding speed in m/minute prior to
welding, during welding displays welding current output. In MMA/
TIG mode, displays welding current. The display meter mode is
shown by the indicator (6/7) that is lit.
Voltage/ Arc Force Display Meter
In MIG mode, displays welding voltage. In MMA mode, displays
arc force adjustment. In TIG mode, displays downslope time. The
display meter mode is shown by the indicator (9/10/12) that is lit.
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
1
3
5
2
67
8
9
10 11
12
413
14
15
16
17
18
19
20
21

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.
Arc Force Control
An MMA welding power source is designed to produce constant
output current (CC). This means with dierent types of electrode
and arc length; the welding voltage varies to keep the current
constant. This can cause instability in some welding conditions as
MMA welding electrodes will have a minimum voltage they can
operate with and still have a stable arc. Arc Force control boosts
the welding power if its senses the welding voltage is getting too
low. The higher the arc force adjustment, the higher the minimum
voltage that the power source will allow. This eect will also
cause the welding current to increase. 0 is Arc Force o, 10 is
maximum Arc Force. This is practically useful for electrode types
that have a higher operating voltage requirement or joint types
that require a short arc length such as out of position welds.
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MULTIMIG 200 PFC MV
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Electrical Connection
The DURALLOY MULTIMIG 200 PFC MV 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
MULTIMIG 200 PFC MV 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.
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1.6 Once the correct drive rollers are selected and fitted, manually
feed the wire through the wire drive inlet guide through the
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 (20) 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. Select the welding mode button
so MIG mode indicator (3) is lit. 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. This can also be performed by using the
wire feed toggle switch situated above wire feed assembly.
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. This can also
be performed by using the wire feed toggle switch located
above wire feed assembly.
QUICK START GUIDE - WELDER INSTALLATION
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MULTIMIG 200 PFC MV
OWNER’S MANUAL

2. Gasless Welding Operation
2.1 Connect the earth cable quick connector to the positive
welding power output socket (21). 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
to the Horizontal plane.
2.3 Set the welding voltage adjustment knob (2), wire speed
control knob (1) and wave control knob (15) 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 (17) 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 to the Vertical plane.
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. This can be done
by using gas purge toggle switch situated above wire feed
assembly.
3.4 Set the welding voltage adjustment knob (2), wire speed
control knob (1) and wave control knob (15) to the desired
positions. You are now ready to weld!
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.
Another option to overcome the friction issues is using a spool
gun, which will give better results than a 3m push torch when
welding aluminium.
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MULTIMIG 200 PFC MV
OWNER’S MANUAL
4. ARC/ MMA Welding Operation
4.1 Connect the earth cable quick connector to the negative
welding power output socket (17) 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.
4.2 Insert an electrode into the electrode holder and connect the
electrode holder and work lead to the positive welding power
output socket (21).
Note: This polarity connection configuration is valid for most GP (General
Purpose) MMA electrodes. There are variances to this. If in doubt, check
the electrode specifications or consult the electrode manufacturer.
4.3 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. Set the welding mode to MMA (4).
4.4 Select the required output current (1) and arc force (2). You are
now ready to weld!
5. Lift TIG Operation
Note: Lift TIG operation requires an optional DURALLOY TIG TORCH 174TTM , and
argon gas cylinder.
2.1 Connect the earth cable quick connector to the positive
welding power output socket (21). 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 Insert TIG torch power connection into the negative welding
power output socket (17). Insert Aero Plug from TIG torch
into (19). This plug can only fit in 1 way, please line up prior to
fitting. Fit Gas Hose Connector on TIG torch into (18) quick
connect fitting
2.3 Open gas cylinder valve and adjust regulator, flow should
be between 5-10 l/min depending on application. Re-check
regulator flow pressure with TIG Torch Switch as static gas
flow setting may drop once gas is flowing.
2.4 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. Select Lift TIG welding mode (5) using
the button.
2.5 Select the required output current using the current control
knob (1). Depress Button on TIG Torch ensuring 2T setting
is selected on machine. Arc will start once tungsten IS lifted
FROM THE BASE MATEREIAL.

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WIRING DIAGRAM
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MULTIMIG 200 PFC MV
OWNER’S MANUAL

Keep your welding machine in top condition
The DURALLOY MULTIMIG 200 PFC MV 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
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MULTIMIG 200 PFC MV
OWNER’S MANUAL
• 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.

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
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MULTIMIG 200 PFC MV
OWNER’S MANUAL
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.

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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MULTIMIG 200 PFC MV
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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MULTIMIG 200 PFC MV
OWNER’S MANUAL
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

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MULTIMIG 200 PFC MV
OWNER’S MANUAL
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.

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Other weld problems can be reduced by checking the following points.
High Tensile and Alloy Steels
The two most prominent eects of welding these steels are the
formation of a hardened zone in the weld area, and, if suitable
precautions are not taken, the occurrence in this zone of under-
bead cracks. Hardened zone and underbead cracks in the weld
area may be reduced by using the correct electrodes, preheating,
using higher current settings, using larger electrodes sizes, short
runs for larger electrode deposits or tempering in a furnace.
Manganese Steels
The eect on manganese steel of slow cooling from high
temperatures causes embrittlement. For this reason it is
absolutely essential to keep manganese steel cool during
welding by quenching after each weld or skip welding to
distribute the heat.
Cast Iron
Most types of cast iron, except white iron, are weldable. White
iron, because of its extreme brittleness, generally cracks when
EFFECTS OF MMA WELDING VARIOUS MATERIALS
attempts are made to weld it. Trouble may also be experienced
when welding white-heart malleable, due to the porosity caused
by gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat conductivity of
copper, making pre-heating of heavy sections necessary to give
proper fusion of weld and base metal.
Types of Electrodes
ARC Welding electrodes are classified into a number of groups
depending on their applications. There are a great number of
electrodes used for specialised industrial purposes which are not
of particular interest for everyday general work. These include
some low hydrogen types for high tensile steel, cellulose types
for welding large diameter pipes, etc. The range of electrodes
dealt with in this publication will cover the vast majority of
applications likely to be encountered; are all easy to use.

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Joint Preparation
In many cases, it will be possible to weld steel sections
without any special preparation. For heavier sections and
for repair work on castings, etc., it will be necessary to cut or
grind an angle between the pieces being joined to ensure
proper penetration of the weld metal and to produce sound
joints.
In general, surfaces being welded should be clean and free
of rust, scale, dirt, grease, etc. Slag should be removed from
oxy-cut surfaces. Typical joint designs are shown in Figure
1-19.

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A Word for Beginners
For those who have not yet done any welding, the simplest way
to commence is to run beads on a piece of scrap plate. Use mild
steel plate about 6.0mm thick and a 3.2mm electrode.
Clean any paint, loose scale or grease o the plate and set it
firmly on the work bench so that welding can be carried out in
the down hand position. Make sure that the Work Lead/Clamp is
making good electrical contact with the work, either directly or
through the work table. For light gauge material, always clamp the
work lead directly to the job, otherwise a poor circuit will probably
result.
The Welder
Place yourself in a comfortable position before beginning to weld.
Get a seat of suitable height and do as much work as possible
sitting down. Don’t hold your body tense. A taut attitude of mind
and a tensed body will soon make you feel tired. Relax and you
will find that the job becomes much easier. You can add much to
your peace of mind by wearing a leather apron and gauntlets.
You won’t be worrying then about being burnt or sparks setting
alight to your clothes.
Place the work so that the direction of welding is across, rather
than to or from, your body. The electrode holder lead should be
clear of any obstruction so that you can move your arm freely
along as the electrode burns down. If the lead is slung over your
shoulder, it allows greater freedom of movement and takes a lot
of weight o your hand. Be sure the insulation on your cable and
electrode holder is not faulty; otherwise you are risking an electric
shock.

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Striking the Arc
Practice this on a piece of scrap plate before going on to more
exacting work. You may at first experience diculty due to the tip
of the electrode “sticking” to the work piece. This is caused by
making too heavy a contact with the work and failing to withdraw
the electrode quickly enough. A low amperage will accentuate
it. This freezing-on of the tip may be overcome by scratching the
electrode along the plate surface in the same way as a match
is struck. As soon as the arc is established, maintain a 1.6mm to
3.2mm gap between the burning electrode end and the parent
metal. Draw the electrode slowly along as it melts down.
Another diculty you may meet is the tendency, after the arc is
struck, to withdraw the electrode so far that the arc is broken
again. A little practice will soon remedy both of these faults.
Arc Length
The securing of an arc length necessary to produce a neat weld
soon becomes almost automatic. You will find that a long arc
produces more heat.
A very long arc produces a crackling or spluttering noise and the
weld metal comes across in large, irregular blobs. The weld bead
is flattened and spatter increases. A short arc is essential if a high
quality weld is to be obtained although if it is too short there is the
danger of it being blanketed by slag and the electrode tip being
solidified in. If this should happen, give the electrode a quick
twist back over the weld to detach it. Contact or “touch-weld”
electrodes such as E7014 Stick electrodes do not stick in this way,
and make welding much easier.
Rate of Travel
After the arc is struck, your next concern is to maintain it, and this
requires moving the electrode tip towards the molten pool at the
same rate as it is melting away. At the same time, the electrode
has to move along the plate to form a bead.
The electrode is directed at the weld pool at about 20º from
the vertical. The rate of travel has to be adjusted so that a well-
formed bead is produced.
If the travel is too fast, the bead will be narrow and strung out and
may even be broken up into individual globules. If the travel is too
slow, the weld metal piles up and the bead will be too large.
Rate of Travel
Having attained some skill in the handling of an electrode, you
will be ready to go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in Figure
1-21, allowing 1.6mm to 2.4mm gap between them and tack weld
at both ends. This is to prevent contraction stresses from the
cooling weld metal pulling the plates out of alignment.
Plates thicker than 6.0mm should have their mating edges
bevelled to form a 70º to 90º included angle. This allows full
penetration of the weld metal to the root. Using a 3.2mm E7014
Stick electrode at 100 amps, deposit a run of weld metal on the
bottom of the joint.
Do not weave the electrode, but maintain a steady rate of travel
along the joint sucient to produce a well-formed bead. At first
you may notice a tendency for undercut to form, but keeping the
arc length short, the angle of the electrode at about 20º from
vertical, and the rate of travel not too fast, will help eliminate this.

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The electrode needs to be moved along fast enough to prevent
the slag pool from getting ahead of the arc. To complete the joint
in thin plate, turn the job over, clean the slag out of the back and
deposit a similar weld.
Heavy plate will require several runs to complete the joint. After
completing the first run, chip the slag out and clean the weld
with a wire brush. It is important to do this to prevent slag being
trapped by the second run. Subsequent runs are then deposited
using either a weave technique or single beads laid down in the
sequence shown in Figure 1-22. The width of weave should not
be more than three times the core wire diameter of the electrode.
When the joint is completely filled, the back is either machined,
ground or gouged out to remove slag which may be trapped
in the root, and to prepare a suitable joint for depositing the
backing run. If a backing bar is used, it is not usually necessary to
remove this, since it serves a similar purpose to the backing run in
securing proper fusion at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular crosssection made
by depositing metal in the corner of two faces meeting at right
angles. Refer to Figure 1-14, 1-23 and 1-24.
A piece of angle iron is a suitable specimen with which to begin,
or two lengths of strip steel may be tacked together at right
angles. Using a 3.2mm 6012 Stick electrode at 100 amps, position
angle iron with one leg horizontal and the other vertical. This is
known as a horizontal-vertical (HV) fillet.
Strike the arc and immediately bring the electrode to a position
perpendicular to the line of the fillet and about 45º from the
vertical. Some electrodes require being sloped about 20º away
from the perpendicular position to prevent slag from running
ahead of the weld. Refer to Figure 1-23.
Do not attempt to build up much larger than 6.4mm width with a
3.2mm electrode, otherwise the weld metal tends to sag towards
the base, and undercut forms on the vertical leg. Multi-runs can
be made as shown in Figure 1-24. Weaving in HV fillet welds is
undesirable.
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your work bench in
an upright position. Use a 3.2mm E7014 Stick electrode and set
the current at 100 amps. Make yourself comfortable on a seat in
front of the job and strike the arc in the corner of the fillet. The
electrode needs to be about 10º from the horizontal to enable a
good bead to be deposited. Refer Fig. 1-25.
Use a short arc, and do not attempt to weave on the first run.
When the first run has been completed deslag the weld deposit
and begin the second run at the bottom. This time a slight
weaving motion is necessary to cover the first run and obtain
good fusion at the edges.

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At the completion of each side motion, pause for a moment to
allow weld metal to build up at the edges, otherwise undercut
will form and too much metal will accumulate in the centre of
the weld. Figure 1-26 illustrates multi-run technique and Figure
1-27 shows the eects of pausing at the edge of weave and of
weaving too rapidly.
2. Vertical Down
The 6012 Stick electrode makes welding in this position
particularly easy. Use a 3.2mm electrode at 100 amps. The tip of
the electrode is held in light contact with the work and the speed
of downward travel is regulated so that the tip of the electrode
just keeps ahead of the slag. The electrode should point upwards
at an angle of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary, overhead
welding is not much more dicult that down hand welding.
Set up a specimen for overhead welding by first tacking a length
of angle iron at right angles to another piece of angle iron or a
length of waste pipe. Then tack this to the work bench or hold in
a vice so that the specimen is positioned in the overhead position
as shown in the sketch.
The electrode is held at 45º to the horizontal and tilted 10º in
the line of travel (Figure 1-28). The tip of the electrode may be
touched lightly on the metal, which helps to give a steady run. A
weave technique is not advisable for overhead fillet welds.
Use a 3.2mm E6013 Stick electrode at 100 amps, and deposit the
first run by simply drawing the electrode along at a steady rate.
You will notice that the weld deposit is rather convex, due to the
eect of gravity before the metal freezes.