Hong Kong Easyweld EasyMig 250i User manual

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EasyMig EasyMig
MIG Welding System
Instruction Manual EasyMig 250i
EFFECTIVE October 2009
IMPORTANT
Safety and Operating
Instructions
For Your Safety...
PLEASE READ
AREFULLY!
Hong Kong EasyWeld Limited

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CONTENTS
- Instruction 3
- General Welding Safety Instruction 3
- Main Parameter 8
- Installation 8
- Operation 13
- Speed-Read Ta le 15
- Maintenance 17
- Daily Check 18
- Trou leshooting 20

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INTRODU TION
This User’s Guide provides specific information a out your EasyMig Welding System. This
guide provides pertinent information needed to safely and effectively use your Welding
System. The information in this manual applies to specific EasyMig Welding System
models. It gives instructions on set-up, installation and actual use of your EasyMig
Welding System.
SAFETY PROFILE
Tradesmen respect the tools and equipment with which they work. They are also aware
that tools and equipment are dangerous if used improperly or a used.
Read this guide prior to using your welding system. It ena les you to do a etter and
safer jo . You will also learn the machine’s application, limitations and the specific
potential hazards related to welding.
SAFETY INFORMATION
The following safety information is provided to you as a guideline. Use it to operate your
new Easyweld Welding System under the safest possi le conditions. Any equipment that
uses electrical power is potentially dangerous to use when the safety or safe handling
instructions are not known and/or are not followed. This safety information gives you the
necessary information for safe use and operation.
Items in this manual that significantly affect safety are identified with the following
headings. Please read and understand this manual. Pay special attention to items
identified with these headings.
WARNING- Means there is a possi ility of injury or death to yourself or others if the
proper safety precautions are not followed
AUTION-Means there is the possi ility of damage to the Easyweld Welding System
or other property.
NOTI E- Indicates points of interest for more efficient and convenient installation or
operation. It may e used efore or after a procedure to highlight or etter explain the
step.
READ ALL SAFETY AND WARNING INSTRUCTIONS CAREFULLY efore attempting
to install, operate or service this welding unit. Your failure to comply with the
instructions could result in personal injury and/or property damage.
IMPORTANT RETAIN THESE INSTRU TIONS FOR YOUR FUTURE REFEREN E.
GENERAL WELDING SAFETY INSTRU TIONS
LO ATION
Welding processes of any kind can e dangerous not only to the operator ut to any
person situated near the equipment, if safety and operating rules are not strictly
o served.

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PERSONAL PROTE TION
1. WEAR closed, non-flamma le protective clothing, without pockets or turned up
trousers.
2. WEAR a non-flamma le welding helmet to shield the neck, face and sides of the head.
Keep the protective lens clean. Replace the protective lens if roken or cracked.
Position a transparent glass etween the lens and the welding area. Weld in a closed
area that does not open into other working areas.
3. NEVER look at the arc without proper protection to the eyes.
4. Thoroughly clean metal of rust or paint to avoid producing harmful flumes. Parts
degreased with a solvent must dry efore welding.
5. NEVER weld on metals or coated metals containing zinc, mercury, chromium,
graphite, lead, cadmium or eryllium unless the operator and the people standing in
the same area use an air-supplied respirator.
SAFETY INSTRU TIONS
For your safety, BEFORE connecting the power source to the line, follow these
instructions:
1. Insert an adequate two-pole switch, equipped with time-delay fuses, efore the main
outlet.
2. Make the single-phase connection with a two-pole plug compati le with the a ove
mentioned outlet.
3. The two wires of the two-pole input ca le are used for the connection with the
single-phase line. The yellow/green wire is for the compulsory connection to the
ground in the welding area.
4. When working in a confined space, keep the power source outside the welding area
and fix the ground ca le to the work piece. NEVER work in a damp or wet area.
5. DO NOT use damaged input or welding ca les.
6. NEVER operate the power source without its panels in place. This could cause serious
injury to the operator and could damage the equipment.
FIRE PREVENTION
Welding operations use fire or com ustion as a asic tool.
1. The work area MUST have a fireproof floor.
2. Work enches or ta les used during welding operations MUST have fireproof tops. DO
NOT weld on wooden work enches.
3. Use heat-resistant shields or other approved material to protect near y walls or
unprotected flooring from sparks and hot metal.
4. Keep an approved fire extinguisher of the proper size and type in the work area.
Inspect it regularly to ensure that it is in proper working order. Know how to use the
fire extinguisher.
5. Remove all com usti le materials from the work site. If you can not remove them,
protect them with fireproof covers.
WARNING NEVER perform welding operations on a container that has held toxic, com-
usti le or flamma le liquids or vapors. NEVER perform welding operations in an area
containing com usti le vapors, flamma le liquids or explosive dust.

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VENTILATION
WARNING Ventilate welding work areas adequately. Maintain sufficient air flow to
prevent accumulation of explosive or toxic concentrations of gases. Welding operations
using certain com inations of metals, coatings and gases generate toxic fumes. Use
respiratory protection equipment in these circumstances. BEFORE welding, read and
understand the Material Safety Data Sheet for the welding alloy.
ELE TROMAGNETI OMPATIBILITY
BEFORE installing a MIG power source, inspect the surrounding area checking the
following points:
1. Make sure there are no other power supply ca les, control lines, telephone ca les or
other devices close to the power source.
2. Make sure those telephones, televisions, computers or other control systems are not
in the working area.
3. People with pace-makers or hearing aides should keep far from the power source. In
particular cases, special protection measures may e required.
Reduce interference y following these suggestions:
1. If there is interference in the power source line, mount an E.M.T. filter etween the
power supply and the power source.
2. Shorten the output ca les of the power source, keep them together and connected to
ground.
3. Securely fasten the panels of the power source in place after performing maintenance.
SAFETY WARNINGS
Please familiarize yourself with the warning message listed on this manual. Please e
alert e alert to the possi ility of personal injury and carefully read the message that
follows.
●ELE TRI SHO K AN KILL! Reduce the risk of death or serious injury from shock.
Read, understand and follow the following safety instructions. Additionally, make certain
that anyone else who uses this welding equipment, or who is a ystander in the welding
area, understands and follows these safety instructions as well.
●FIRE OR EXPLSION AN XAUSE DEATH, INJURY AND PROPERTY DAMAGE!
Reduce the risk of death, injury or property damage from fire or explosion. Read,
understand and follow the following safety instructions. Additionally, make certain that
anyone else who uses this welding equipment, or who is ystander in the welding area,
understands and follows these safety instructions as well. Remem er, welding y nature
produces sparks, hot spatter, molten metal drops, hot slag and hot metal parts that can
start fires, urn skin and damage eyes.
●AR RAYS AN INJURE EYES AND BURN SKIN! Reduce the risk of injury from arc
rays Read, understand and follow the following safety instructions. Additionally, make
certain that anyone else who uses this welding equipment, or who is a ystander in the
welding area, understands and follows these safety instructions as well.

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●FUMES, GASSES AND VAPORS AN AUSE DIS OMFORT, ILLNESS AND DEATH!
Reduce the risk of discomfort, illness or death Read, understand and follow the following
safety instructions. Additionally, make certain that anyone else who uses this welding
equipment, or who is a ystander in the welding area, understands and follows these
safety instructions as well.
●IMPROPER HANDLING AND MAINTENAN E OF OMPRESSED GAS YLINDERS
AND REGULATORS AN RESULT IN SERIOUS INJURY OR DEATH! Reduce the risk
of injury or death from compressed gasses and equipment hazards. Read, understand
and follow the following safety instructions. Additionally, make certain that anyone else
who uses this welding equipment, or who is a ystander in the welding area,
understands and follows these safety instructions as well.
PROTE TIVE WELDING GASSES
1. These welders use only inert or non-flamma le gases for welding arc protection. It is
important to choose the appropriate gas for the type of welding eing performed.
2. DO NOT use gas from unidentified cylinders.
3. DO NOT connect the cylinder directly to the welder. Use a pressure regulator.
4. Make sure the pressure regulator and the gauges function properly.
5. DO NOT lu ricate the regulator with oil or grease.
6. Each regulator is designed for use with a specific gas. Make sure the regulator is
designed for the protective gas eing used.
7. DO NOT use damaged cylinders.
8. Make sure that the cylinder is safely secured tightly to the welder with the chain
provided.
9. DO NOT carry the cylinder y holding it y the valve.
10. NEVER expose cylinders to excessive heat, sparks, slag or flame.
11. Make sure that the gas hose is ALWAYS in good condition.
12. Keep the gas hose away from the working area.
HEALTH HAZARDS
The welding process can e hazardous to your health. Therefore, follow these
precautions:
1. ALWAYS wear protective clothing without pockets and cuffs. Wear a helmet, gloves
and shoes with an insulating sole.
2. ALWAYS use a welding mask or helmet with the properly tinted protective glass in the
shade adequate to the welding operation eing performed and to the current intensity.
3. Make certain that ystanders in the welding area are also following these precautions.
4. ALWAYS keep the welding mask glass clean. Replace it if it is cracked or chipped.
5. NEVER weld in a damp area or come in contact with a moist or wet surface when
welding.
6. If the welding area lacks proper ventilation, use flume extractors.
7. Be sure the welding pieces are free of solvents or alogenous grease which develops
toxic gases when exposed to heat.
ELE TRI SHO K
WARNING ELE TRI SHO K AN KILL! Reduce the risk of death or serious injury
from shock. Read, understand and follow ALL safety instructions. Be sure that
everyone who uses this welding equipment or who is a ystander in the welding area
understands and follows ALL safety instructions as well.
WARNING ELE TRI SHO K AN BE FATAL. A person qualified in First Aid

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techniques should ALWAYS e present in the working area. If a person is
unconscious and electric shock is suspected, DO NOT touches the person if he or she
is in contact with ca les or electric wires. Disconnect power from the machine, and
then use First Aid. Use dry wood or other insulating materials to move ca les, if
necessary, away from the person.
1. Never touch or come in physical contact with any part of the input current circuit and
welding current circuit.
2. Frequently, check that the input ca le and plug are in good condition.
3. Make sure that the welder is disconnected from the mains BEFORE attempting any
repairs, opening the side panels of the machine or repairing the input ca le.
4. Fit the main line, BEFORE the distri ution outlet, with a three-pole switch with
adequate delayed fuses (check the welder data plate for fuse values).
5. DO NOT weld with ca les, torch or ground clamp in poor shape.
6. DO NOT coil the torch or the ground ca les around your ody.
7. DO NOT point the welding torch at yourself or at ystanders.
8. Should you feel the slightest electrical shock, STOP welding IMMEDIATELY. DO NOT
use the welder until the fault is found and resolved.
WELDER OPERATING HARA TERISTI S
The duty rating defines how long the user can weld and how long the welder must rest
and cool down. Duty Cycle ratings are expressed as a percentage of a ten-minute period.
It represents the maximum welding time allowed at the specified amperage setting. The
remaining alance of a ten-minute period is required for cooling off the unit.
All EasyMig Welding Systems are rated at the required input amperage for proper
operation. Please refer to the data plate located on the front of the unit for the specific
rating that applies to your unit.
INTERNAL THERMAL OVERLOAD PROTE TION
CAUTION DO NOT constantly exceed the duty cycle or damage could result to your
welder. If you do exceed the duty cycle of your welder, the internal thermal overload
protection shuts off all welder functions. If this happens, DO NOT SHUT OFF THE
WELDER. Leave the welder turned on and the fan running. After the welder is
properly cooled, the thermal protector automatically resets and your welder will
function properly.
If you find that your welder does not weld for a 1-5 minute time period without stopping,
reduce the wire speed slightly. Welding with the wire speed set too high not only causes
poor visi le welds ut also increases amperage thaw and shortens the duty cycle.

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MAIN PARAMETER
Model EasyMig 250i
Input Voltage(V) 220 Single
Phase
Frequency(Hz) 50/60Hz
Rated Input Capacity(KVA) 8.3
Rated Input Current(A) 37.7
Output Current Range(A) 50~250
Output Voltage Range(V) 16.5~26.5
Outlet Voltage for
Regulator(V) 220
Adjusta le Steps 7/10
Wire Diameter(mm) 0.6~1.0
Duty Cycle(%) 60
Efficiency(%) 85
Power Factor 0.93
Insulation Class F
Wire Feeder Type Compact
Wire Feeding Speed(m/min) 2~15
Diameter of Spool(mm) 270
Dimension(mm) 490 x 265 x 420
Weight(Kg) 25
ASSEMBLING THE WELDER
The following steps descri e the assem ly, installation, maintenance and operations of your
new welder.
1. Unpack the welder.
2. Install handle.
CAUTION Avoid contacts with wires or parts. DO NOT work with the side panels partially
opened or removed completely from the power source.
3. Place the power source in a well ventilated area. DO NOT o struct the air intake and output
vents. A reduced air flow can cause a reduced duty cycle and damage internal components.
4. Insure at least 6 feet of open space on each side of the welder.

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Two Gear
Drive Wire
Feed Unit
Cover
Wire Feed
Motor
Torch Socket
Handle
Wire Spool
Holder
Torch Connection
Welding Current
Knob
Ground Cable
Power Switch
Digital
Ampere
Metre
Gas Hose Inlet
220 Voltage
Outlet
Overheat Lamp
Power Cable
Inlet
Power Lamp
Wire Inching
Button
Welding
Inductance
Knob
Digital
Voltage
Metre
Handle
Welding
Voltage
Knob

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POWER SOUR E ONNE TION
Power Requirements
This welder is designed to operate on a properly grounded 220 volt, 50/60 HZ,
single-phase alternating current (AC) power source fused with a 50 amp time-delayed
fuse or circuit reaker. (Please consult local codes for proper plug and receptacle
applications.) A qualified electrician should verify the A TUAL VOLTAGE at the
receptacle into which the welder will e plugged and confirm that the receptacle is
properly grounded. The use of the proper circuit size can eliminate the nuisance of circuit
reaker tripping when welding.
Connection to Power Source
WARNING High voltage danger from power source! Consult a qualified electrician for
proper installation of receptacle at the power source.
This welder must e grounded while in use to protect the operators from electrical shock.
If you are not sure if your outlet is properly grounded, have it checked y a qualified
electrician. DO NOT cut off the grounding prong or alters the plug in any way. DO NOT
use any adapters etween the welder’s power cord and the power source receptacle.
CAUTION Make sure the POWER switch is OFF. Connect the welder’s power cord to a
properly grounded 220 VAC, 50/60 Hz, single-phase, 50 amp power source. DO NOT
operate this welder if the source voltage is less than 200 Volts AC or greater than 240
Volts AC. Contact a qualified electrician if this pro lem exists. Improper performance
and/or damage to the welder will result if operated on inadequate or excessive power.
INSTALLATION OF THE WELDING WIRE
Install the wire into the feeding system y following the instructions elow and referring
to following steps.
WARNING Remove the contact tip and gun nozzle from the MIG gun efore starting this
procedure.
1. Loosen the nut of the spool holder ( rake drum). Remove the spring and the external
ring.
2. Remove the plastic wrapper from the spool. Place the spool on the spool holder. Mount
the external ring, the spring and the plastic spool holder nut. These parts form the
raking system for the wire spool. Tighten nut to appropriate tightness. Excessive
pressure strains the wire feeding motor. Too little pressure does not immediately stop
the wire spool welding is stopped.
3. Loosen and lower the tension adjustment. Release the upper roll of the feeder. Extract
any remaining wire from the torch line.
4. Release the end of the wire from the spool. When it is disconnected grasp it with pliers
so that it cannot exit from the spool. If necessary, straighten it efore inserting it in
the wire input guide. Insert the wire on the lower roll and in the torch liner.
WARNING Keep the torch straight. When feeding a new wire through the liner, make
sure the wire is cut cleanly (no urrs or angles) and that at least 2” from the end is
straight (no curves). Failure to follow these instructions could cause damage to the
liner.
5. Lower the upper roll and lift the tension adjustment kno . Tighten slightly. If tightened
too much, the wire gets locked and could cause motor damage. If not tightened
enough, the rolls will not feed the wire.
NOTICE When changing the wire diameter eing used, or replacing the wire feed roll,
e sure that the correct groove for the wire diameter selected is inside, closest to the

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machine. The wire is driven y the inside groove. Feed rolls are marked on the side
identifying the nearest groove. Feed rolls installed on the machine are marked “0.6”
on one side. When this side is inside, closest to the machine, the groove is suita le for
use with 0.023” (0.6mm) hard wire. The other side is marked “0.8”. When this side is
inside, closest to the machine, the groove is suita le for use with 0.030” (0.8mm)
hard wire and 0.035” (0.9mm) flux core wire.
6. Connect the power supply ca le to the power output line. Turn on the switch. Press the
wire inching utton. The wire fed y the wire feeding motor must slide through the
liner. When it exits from the torch neck, release the utton. Turn off the machine.
Mount the contact tip and the nozzle.
WARNING DO NOT place fingers in the wire feed mechanism. The rolls, when moving,
may crush the fingers. Periodically, check the rolls. Replace them when they are worn
and compromise the regular feeding of the wire.
FOR MIG (GMAW) WELDING WITH A SHIELDING GAS
CAUTION When changing the polarity, make sure the connectors are hand tight.
1. Connect the welding machine to the 220V, 50/60 Hz line.
2. Make sure that the polarity of the MIG gun and work ca le is correctly set.
For MIG (GMAW) welding, the ground ca le must e connected to the
negative terminal, while the MIG gun must e connected to the positive
terminal (Default setting).
3. Connect the work ca le and clamp to the work piece. Make sure there is a
good contact.
4. Make sure the wire-feeding roll is correctly positioned (groove matching
the wire diameter). Note that each roll has two grooves, one is marked
“.030/0.8mm” and the other is marked “.040/1.0mm”.
5. This unit comes with a genuine EASYWELD(Optional) regulator and
requires adjustment of the flow of shielding gas.
Advantages of MIG (GMAW) Welding
1. Clean, strong welding.
2. Better visual welds.
3. A ility to weld thinner materials.
4. Broadens the range of materials, aluminum, stainless and cast
iron.
Gas ylinder onnection
1. Assem le the pressure regulator to the cylinder. Tighten the
regulator nut, ut DO NOT over-tighten. Over-tightening can
damage the cylinder valve.
2. Connect the gas hose to the regulator.
3. Open the cylinder valve. Release the tension adjustment device
on the wire feeder and push the torch trigger to ensure that
the gas is flowing through the torch. The welding machine
must e turned on to check for gas flow.
WARNING Cylinders are highly pressurized. Handle with care.
Serious accidents can result from improper handling or misuse of
compressed gas cylinders. DO NOT drop the cylinder, knock it over, expose

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it to excessive heat, flames or sparks. DO NOT strike it against other
cylinders. Contact your gas supplier for more information a out the use and
handling of cylinders.
WARNING
DO NOT use the cylinder if you find oil, grease or damaged parts. Inform your gas
supplier of this condition immediately.
Regulator Gas Flow Information
CAUTION Before using regulator, read instructions thoroughly. For general, small
diameter wire MIG welding the regulator setting is from 15-40 CFH. Example: .030”
wire using 75/25 Argon/CO2 mix gas on 15 gauge sheet metal, gas flow from
regulator should e set at 25 CFH.
MIG GUN
We recommend periodically checking the contact tips and the nozzle. These parts
must e clean and not worn. Replace the torch liner when the wire does not run
smoothly.
MIG WELDING
In MIG (GMAW) welding, a continuously fed metal electrode (the welding wire) is
melted into a welding pool at constant and controlled speed. The wire is connected to
a constant voltage pole while the work piece is connected to the other pole. When the
wire is fed and touches the work piece, an electric arc is produced. The arc melts the
wire that is deposited on the work piece.
MIG welding uses a steel coppered wire as an electrode and an inert gas (CO2.
/Argon mix or pure Argon) for protection of the weld pool.
The wire can e one of three types:
1. Solid wire - ALWAYS used with a protective gas.
2. Cored wire - Has a core of mineral powders to enhance its characteristics and is
used with gas.
3. Gasless cored-wire - Has a core of mineral powders that, when urning, release the
protective gas for the arc. ALWAYS used without gas.
The welding unit consists of a DC power source, a torch, a ground and a gas pressure
regulator(Optional). The welding unit has a kno to regulate the welding voltage, a
kno regulating the welding current, a kno to regulate the welding inductance.
Welding current and wire speed are set considering the thickness of the material to
e welded. The thicker the material, the higher the welding current and the higher
the wire speed. The wire speed can e fine tuned during welding for etter results.
IMPORTANT ONLY experienced personnel should use the power sources.

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WELDING TIPS
1. Keep the torch handle at 45° angle with respect to the work piece. Maintain the
nozzle a out 1/4” (6 mm) from the surface.
2. Move the torch handle with a careful and steady movement.
3. Avoid welding in areas with too much air movement. The air lows away the
shielding gas from the weld pool and causes porosity in the weld.
4. Keep the wire and its cover clean. DO NOT use rusted wire.
5. Avoid sharp ends and kinks in the welding hose.
6. If possi le, clean the wire liner with compressed air when replacing the wire spool.
7. Periodically, remove the dust using low pressure (3-4 ar/45-60 PSI) from the
inside of the power source, to assure adequate heat dissipation from power source
during operation.
ADJUSTMENT OF THE POWER SOUR E
Set the voltage. Use the correct “stick out.” The wire “stick out” is the distance
etween the contact tip and the work piece. The wire “stick out” (sometimes
improperly called the arc length) should remain in the 0.2”-O.4” (5mm-l0mm)
range to o tain the est welding (and sound) performance.
1. Position the voltage switch in the desired position. Select lower position for lower
thickness and higher settings for higher thickness.
2. Adjust the welding current (wire speed adjusted simultaneously) . Start using a
trial metal sheet Connection thoroughly cleaned of layers of rust or paint.
Connect the ground ca le to the work piece. Adjust the wire speed at the high
setting. Press the torch switch.
NOTICE Start welding, squeezing the torch switch and decrease the wire speed
gradually. Continue to decrease the wire speed and listen to the sound. The
sound will change from a crackling noise to a regular and strong uzzing (similar
to the sound of frying acon). This uzzing sound indicates the correct wire
speed for the work piece eing welded. When the current regulation is changed,
reset the wire speed. ALWAYS start from a higher wire speed. This operation
prevents damage to the contact tip during welding. During welding, keep the
torch at a 45° angle from the work piece. Keep the nozzle at 1/4”-1/2” from the
work piece.
OPERATION
-Set the welding current, onnect the gas output tube.
-The short-circuit transition stage, which occurs in case of small diameter of rod,
low voltage and low current, also presents the sta le welding, little spatters
generated, eautiful seams and allows the more precise application setting, is
applica le to rod of which the diameter of 0.8mm~1.6mm.

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Range of welding current and voltage in Short Circuit Transition and granular
Transaction
-The Option of the Welding Speed
The welding quality and productive efficiency should e taken into consideration for
the option of welding speed. In case that the weld speed increases, it weakens the
protection efficiency and increases the cooling. As a consequent, it is not optimal
for the seaming. In the event that the speed is too slow, the work piece will e
easily damage, and the seaming is not ideal. In practical operation, the welding
speed exceeds 30m/h.
-The Length of Wire Stretching Out
The length of wire stretching out the nozzle should e appropriate. In the event
that the wire stretching out the nozzle is too long, excessive spatter presents in the
welding process.
-The Setting of the O2 Flow Volume
The protection efficiency is the primary consideration. Besides, inner-angle welding
has etter protection efficiency than external-angel welding. For the main
parameter refer to the following figure.
Choice of CO2flow volume
Welding mode Thin wire CO2
welding
Thick wire CO2
welding
Thick wire, ig
current CO2 welding
CO2 (L/min) 5~15 15~25 25~50
-The Option of the Power Supplies Poles.
Generally DC Negative connection is ideal for CO2 welding. For AC positive
connection please refer the following figure.
Application & characteristic of different pole connection
Power connection Application Characteristic
Negative
connection
(The wire to
“+” )
Common welding of short
circuit transaction, granular
transaction and welding of
the common work piece.
Little splash, unsta le arc,
deep melting, and low
metal-containing crack.
Positive
connection
(The wire to “-” )
High speed CO2 welding, pile
welding and iron-casting
welding.
High wire welding rate, and
low depth, and ig melting
width and high piling up.
-The sta le welding performance can only e accessi le, in case to opt the wire
feed wheel of applica le specifications and the suita le diameters of wire feed tu e
of welding torch and the nozzle specifically according to the diameter of rod.
Short circuit
transaction
Granular Transition
Wire Ø (mm)
Current (A) Voltage (V) Current (A) Voltage (V)
0.6 40-70 17-19 160-400 25-38
0.8 60—100 18-19 200-500 26-40
1.0 80-120 18-21 200-600 2T—40
1.2 100—150 19-23 300—700 28-42
1.6 140—200 20-24 500—800 32-44

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SPEED-READ TABLE
Weld condition setting directly influences the sta ility of the weld course and the
weld. In order to o tain the good weld, the welding current and welding voltage
should e set optimally. Generally, the setting of weld condition should e
according to the welding diameter and the melting form as well as the production
requirement.
The following parameter avails for reference.
Parameter for Butt Welding (Please refer to the following figure.)
Plate
Thickness
(mm)
Gap
g(mm)
Wire
Ø(mm)
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(cm/mm)
Gas
volume
(L/min)
0.8 0 0.8~0.9 60-70 16~16.5 50~60 10
1.0 0 0.8~0.9 75-85 17~17.5 50~60 10~15
1.2 0 1.0 70-80 17~18 45~55 10
1.6 0 1.0 80-100 18~19 45~55 10~15
2.0 0~0.5 1.0 100-110 19~20 40~55 10~15
2.3 0.5~1.0 1.0 or 1.2 110-130 19~20 50~55 10~15
3.2 1.0~1.2 1.0 or 1.2 130—150 19~21 40~50 10~15
4.5 1.2~1.5 1.2 150-170 21~23 40~50 10~15
Parameter for Flat Fillet Welding (Please refer to the following figure.)
Plate
Thickness
t (mm)
Corn size
I (mm)
Wire
Ø (mm)
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(cm/mm)
Gas
volume
(L/min)
1.0 2.5~3.0 0.8~0.9 70~80 17~8 50~60 10~15
1.2 2.5~3.0 1.0 70~100 18~9 50~60 10~I5
1.6 2.5~3.0 1.0~1.2 90~120 18~20 50~60 10~15
2.0 3.0~3.5 1.0~1.2 100~130 19~20 50~60 10~20
2.3 2.5~3.0 1.0~1.2 120~140 19~21 50~60 10~20
3.2 3.0~4.0 1.0~1.2 130~170 19~21 45~55 10~20
4.5 4.0~4.5 1.2 190~230 22~24 45~55 10~20

16
Parameter for Fillet Welding in the Vertical Position (Please refer to the
following figure.)
Plate
Thickness
(mm)
Corn size
I (mm)
Wire
Ø (mm)
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(cm/mm)
Gas
volume
(L/min)
1.2 2.5~3.0 1.0 70~100 18~19 50~60 10~15
1.6 2.5~3.0 1.0~1.2 90~120 18~20 50~60 10~15
2.0 3.0~3.5 1.0~1.2 100~130 19~20 50~60 10~20
2.3 3.0~3.5 1.0~1.2 120~140 19~21 50~60 10~20
3.2 3.0~4.0 1.0~1.2 130~170 22~22 45~55 10~20
4.5 4.0~4.5 1.2 200~250 23~26 45~55 10~20
Parameter for Lap Welding (Please refer to the following
figure.)
Plate
Thickness
t (mm)
Welding
Position
Wire
Ø (mm)
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(cm/mm)
Gas
volume
(L/min)
0.8 A O.8~0.9 60~70 16~17 40~45 10~15
1.2 A 1.0 80~100 18~19 45~55 10~15
1.6 A 1.0~1.2 100~20 18~20 45~55 10~15
2.0 A or B 1.0~1.2 100~130 18~20 45~55 15~20
2.3 B 1.0~1.2 120~140 19~21 45~50 15~20
3.2 B 1.0~1.2 130~160 19~22 45~50 15~20
4.5 B 1.2 150~200 21~24 40~45 15~20

17
ADDITIONAL SAFETY INFORMATION
Make sure you read and understand all of the information and instructions contained in
this manual BEFORE proceeding.
The National Electrical Code, Occupational Safety and Health Act (OSHA) regulations,
local industrial codes and local inspection requirements also provide a asis for
equipment installation, use and service.
For additional information concerning welding safety, refer to the following standards and
comply with them as applica le.
• ANSI Standard Z49. 1 - SAFETY IN WELDING AND CUTTING - o taina le from the
American Welding Society, 2051 N.W. 7th St. Miami, FL 33125 [phone].
• ANSI Standard Z87. 1 - SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE
AND FACE PROTECTION - o taina le from the American National Standards Institute,
1430 Broadway, New York, NY 10018.
• NFPA Standard SIB - CUTTING AND WELDING PROCESSES - o taina le from the
National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.
• CGA Pamphlet P-I - SAFE HANDLING OF COMPRESSED GASSES IN CYLINDERS -
o taina le from the Compressed Gas Association, SOO5th Avenue, New York, NY
10038.
• OSHA Standard 29 CFR, Part 1910, Su part 0.- WELDING, CUTTING AND BRAZING -
o taina le from your state OSHA office.
• CSA Standard Wi 17.2 - CODE FOR SAFETY IN WELDING AND CUTTING - o taina le
from Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario Canada
M9W 1R3.
• American Welding Society Standard A6.0 - WELDING AND CUTTING CONTAINERS
WHICH HAVE HELD COMBUSTIBLES - o taina le from the American Welding Society,
2051 N.W. 7th St., Miami, FL 33125 [phone].
MAINTENAN E
1. Disconnect input plug or power efore maintain 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, hands, hair, loose clothing, and tools away from moving parts such as
fans, wires.
5. Clear the dust at regular intervals with clean and dry compressed air; if the working
condition has heavy smoke and pollution, the welding machine should e cleaned once
a month.
6. The compressed air should e reduced to the required pressure lest the little parts in
the welding machine e damaged.
7. To avoid water and rain, if there is, dry it in time, and check the insulation with
mega-meter (including that etween the connection and that etween the case and
the connection) only when there is no a normal phenomena can the welding continue.
8. If the machine is not used for longtime, put it into the original packing in dry
condition.

18
DAILY CHECKING
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, and the gas hole, and so on
Remove the dust or renew 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.
1.Power Sources
Part heck Remarks
Control Panel 1.Operation, replace and
installation of Switch.
2. Switch on the power, and check
whether the power light indicator
is on.
Fans on Demand Make certain that Fan on demand is
functioning.
In case of malfunction,
check and correct the
malfunction.
Power Sources Switch on the power source, and
check whether that a normal
vi ration, heating of the case of this
equipment, variation of colors of
case and uzz present.
Other Parts Make sure that gas connection is
availa le.
2. Welding Torch
Part heck Remarks
Nozzle 1. Make certain the nozzle is fixed.
2. Check whether there is spatter
sticking on the nozzle.
1. Possi le gas leakage
occurs due to the
unfixed nozzle.
2. Spatter possi ly leads to
the damage of torch.
The anti-spatter agent
eliminated the spatter.
Contact Tip 1. Make certain the contact tip
should e fixed.
2. Make sure that the contact tip is
physically complete.
1. Unfixed contact tip
possi ly leads to the
damage of torch.
2. The physically
incomplete contact tip
possi ly leads to the
unsta le arc and arc
automatically
terminating.
Wire Feeding Tu e 1. Measure length of wire feed tu .
2. Make sure that there is the
agreement of wire and wire feed
tu e.
1. The length of the wire
feed tu e should e long
enough to contact the
contact tip. Replace it

19
3. Make sure that there is no
ending or elongation of wire
feed tu e.
4. Make sure that there is no dust
or spatter accumulated inside
the wire feed tu e, and the wire
fee tu e is locked.
5. Both the wire feed tu e and O
shape seal ring are physically
incomplete.
otherwise unsta le arc
possi ly presents.
2. Disagreement of the
diameters of wire and
wire feed tu e possi ly
leads to the unsta le
arc. Replace it/them if
necessary.
3. Bending and elongation
of wire feed tu e
possi ly leads to the
unsta le wire feed and
arc. Replace it if
necessary.
4. If there is dust or
spatter, remove it.
5. The Physical incomplete
wire feed tu e and O
shape seal ring possi ly
lead to the excessive
spatters. Replace the
wire feed tu e and O
shape seal ring if
necessary.
Diffuser 1. Make sure that the diffuser of
required specification is installed
and is un locked.
1. Defection weld or even
the damage of torch
occurs due to the
non-installation of
diffuser or the
unqualified diffuser.
3. Wire Feed Unit
Part heck Remarks
Pressure adjusting
handle
1. Whether the pressure-adjusting
handle is fixed
The unfixed
pressure-adjusting handle
leads to the unsta le weld
output
Wire-feeding hose 1. Where there is dust or spatter
inside the hose or wire-feeding
wheel.
2. Whether there is a diameter
agreement of rod and wire
guiding grove.
3. Check whether rod and wire
feeding groove are concentric.
1. Remove the dust.
2. Non-agreement of the
diameter of rod and wire
guiding tu e possi ly
leads to the excessive
spatter and unsta le arc.
3. Unsta le arc possi ly
occurs.
Wire-feeding wheel 1. Whether there is an agreement
of wire diameter and wire feed
wheel.
2. Check whether the wire groove
1. Non-agreement of wire
diameter and wire feed
wheel possi ly leads to
the excessive spatter

20
is locked. and unsta le arc.
2. Replace it if necessary.
Pressure Adjusting
Wheel
1. Whether the rotating of the
pressure adjusting wheel is
smooth; the pressure adjusting
wheel is physical complete.
1. Insufficient wire feed
leads to the unsta le
arc.
4. ables
Part heck Remarks
Torch Ca le 1. Whether the ca le of
torch is twisted.
2. The connections of air
plug are not availa le.
1. The twisted torch ca le
leads to insufficient wire
feeding.
2. The twisted torch ca le
leads to unsta le arc.
Output Ca le 1. Whether the ca le is
physically complete.
2. Whether this welding
equipment is well
grounded.
1. Relevant measures
should e taken to
prevent the possi le
electric shock.
Input Ca le 1. The connections of input
ca le should e
sufficient.
2. Whether this welding
equipment is well
grounded.
Earth Ca le 1. Make sure that the earth
ca les are well fixed and
not short-circuited.
1. Relevant measures
should e taken to
prevent the possi le
electricity leakage.
TROUBLESHOOTING INFORMATION
Problem Possible ause Remedy
Dirty, porous or rittle
weld. Plugged welding nozzle. Clean or replace welding nozzle
Arc works ut is not
feeding wire Faulty wire speed control assem ly.
No tension on the drive
roller.
Faulty drive motor (very
rare).
Replace wire speed control
assem ly.
Adjust the drive tension
Replace drive motor.
When trigger pulled, there
is no wire feed, weld output
or gas flow.
Fan does not operate.
Incorrect voltage.
No power.
Circuit reaker in off
position.
Check for correct voltage.
Confirm power switch is on.
Reset circuit reaker.
Wire feeding, ut there is
no arc. Bad ground or loose connection. Check ground and connections. Tighten as
necessary.
Check connection to gun or
replace gun.
Fan operates normally, ut
when gun trigger pulled,
there is no wire feed, weld
Faulty trigger on gun.
Faulty transformer (rare).
Exceeded duty cycle:
Replace trigger.
Replace transformer.
Allow welder to cool at