Inverter Fusion 315A User manual

Instruction Manual
USER MANUAL * MIGSTAR -1-
MIGSTAR SERIES
Instruction Manual
315A
250A

Instruction Manual
USER MANUAL * MIGSTAR -2-
________________________________________________________________
CONTENTS
GUARANTEE……………………………………………………………………………3
INTRODUCTION………………………………………………………………………..3
Equipment Identification………………………………………………………..3
WARNING……………………………………………………………………………….3
SAFETY REGULATIONS……………………………………………………………...4
HAZARDS……………………………………………………………………………….4
Fire Prevention………………………………………………………………….4
Metal Fume Hazard…………………………………………………………….5
Positioning Power Source……………………………………………………..5
Electromagnetic Field………………………………………………………….6
INSTALLATION…………………………………………………………………………6
User’s Liability and Protection…………………………………………………6
TECHNICAL DATA…………………………………………………………………….7
MODE OF OPERATION……………………………………………………………….8
Shielding Gas Connection………………………………………………..……8
Welding Wire Connection………………………………………………………8
Fitting the Welding Wire………………………………………………………..8
WELDING TECHNIQUE……………………………………………………………….9
Influence of the Welding Position………………………………………….…10
WORKING ENVIRONMENT…………………………………………………………11
MAINTENANCE……………………………………………………………………12-13
TROUBLESHOOTING………………………………………………………………..13
WARRANTY………………………………………………………………………..14-15

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GUARANTEE
We give our unreserved guarantee that the Inverter Welding and Cutting Power
Source series comply with IEC60974 international safety standard.
Maintenance for one year since the date of purchase.
INTRODUCTION
This manual has been written for professional welders and should be read
carefully before using your MIGSTAR welder.
The welding machines, type MIG STAR SERIES have been developed for thin
plate welding and car body repair.
The MIG STAR SERIES are designed to normal single—phase 220-240V 35A or
three-phase 380V 20A mains supply. The welding transformer has been
dimensioned to obtain optimum welding capacities, and for a working temperature
of 150°C.
Equipment Identification
The unit's identification number (specification or part number), model, and serial
number usually appear on a nameplate attached to the control panel. Make a
record of these numbers for future reference.
WARNING
These powerful machines provide exceptional performance for welding of mild
steel and stainless steel with high reliability and easy maintenance. Do not
attempt to set up, operate or service equipment if not qualified to do so.
Contact Inverter Fusion Ltd direct for technical assistance.
Welding is a source of radiation, noise, heat and fumes, therefore the protection
of the operator and any third persons must be guaranteed with suitable safety
precautions.
Never approach the arc or hot metal; failure to adhere to these regulations could
lead to serious health risks.

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SAFETY REGULATIONS
1. Operate the welding power source only on power supply with a reliable
well-protected connection point.
2. Use the welder away from flammable material.
3. Use appropriate protective clothing for your hands, eyes and body.
4. Always wear safety glasses with side shield: be aware of others in your
work area.
5. Make sure the welding cables and the main power supply are in good
condition before carrying out your work.
6. Use the welding power source only in a dry indoor location. If outdoors, use
in a place of limited exposure to sunlight and rain. Never use welding
equipment near water. Ensure that the surrounding area, including any
objects therein and the equipment, is dry
7. Make sure objects do not obstruct the fan cooling system of the welding
power source. Always keep the welder well ventilated
HAZARDS
Fire prevention
1. Keep fire extinguishers, water and sand, within easy reach.
2. Never weld or cut closed containers or pipes.
3. Never weld or cut containers or pipes (even open) containing or which
have contained substances that could give rise to explosions, humidity or
heat sources.
Metal fume hazards
Welding fumes and gases may be hazardous if inhaled for long periods of time.
1. Install a natural or forced-air ventilation system in the work area.
2. Use forced-air ventilation system when welding lead, beryllium, cadmium,
zinc, zinc-coated or painted materials and wear a protective mask.

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3. Beware of gas leaks. Shield gases such as argon are denser than air, and
when used in confined spaces will replace it.
4. Store gas cylinders in a well-ventilated area.
5. Close the main valve when gas cylinder is not in use.
6. Irritation of the eyes, nose and throat are symptoms of inadequate
ventilation. Take immediate steps to improve ventilation. Do not continue
welding if symptoms persist.
Positioning & transporting the power source
1. The operator must have unobstructed access to controls and equipment
connections.
2. Do not position equipment in confined, closed spaces. Ventilation of the
power sources is extremely important. Avoid dusty or dirty locations, where
dust or other debris could be aspirated by the system.
3. Equipment (including connecting leads) must not obstruct corridors or work
activities of other personnel.
4. Position the power source securely to avoid falling or overturning
5. Bear in mind the risk of falling of equipment situated in overhead positions.
6. The power source handle or suitable sized nylon webbing may carry the
machine.
7. Always disconnect the power source and accessories from main supply
before lifting or handling operations.
8. Do not drag, pull or lift equipment by the cable
Electromagnetic Field
Before installing welding equipment the user should make an assessment of
potential electromagnetic problems in the surrounding area. The following shall be
taken into account:
1. Other supply cables, control cables, signalling and telephone cables;
above, below and adjacent to the welding equipment, radio and television
transmitters and receivers, computer and other control equipment.
2. The health of the people around, e.g. the use of pacemakers and hearing
aids.

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3. The time of day that welding or other activities are to be carried out.
4. The size of the surrounding area to be considered will depend on the
structure of the building.
INSTALLATION
•Connect the ground lead as near as possible to the operating area. Earth
connections to structural parts of the building or to other places distant
from the operating area will reduce their effectiveness and increase the
danger of electric shock.
•Avoid all the direct contact between the skin or wet garments with live
metal parts. Check that gloves and protections are dry!
•Always wear gloves and rubber soled shoes when working in wet areas or
standing on metal surfaces.
•Always turn off equipment when not being used or in the event of power
failure. Accidental earth discharge may cause overheating and tire
hazards. Do not leave the machine unattended when it is turn on.
User's Liability and Protection
1. No modifications of the parts of this machine should be carried out.
2. Wear ear protectors; welding operations are often noisy and may disturb
other persons in the work area.
3. Position a fire-resistant screen or curtain around the welding area to
protect persons in the vicinity from rays, sparks and slag.
4. Compressed gas cylinders are potentially dangerous; consult the supplier
for correct handling procedures. Always protect cylinders from direct
sunlight flames, sudden temperature changes and low temperatures
TECHNICAL DATA

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DATA WELDING MACHINE
250 315
Mains Supply Single Phase 50Hz / 60Hz 3 - Phase 50Hz / 60Hz
Voltage 230V AC 380V AC
Maximum Input Current 35 Amps 20 Amps
Fuse 35 Amp (Slow) 25 Amp (Slow)
Cable Cross Section 4 ~ 10mm
2
Permissible Loading
Duty Cycle Loading
20% 250A / 25V --
30% 189A / 23.5V --
60% 140A / 21V 315A / 29.8V
100% 100A / 19V 244A / 26.2V
Output Control
Voltage Adjustment 6 Steps 30 Steps
Open Circuit Voltage 24 ~ 45V DC 18 ~ 38 V DC
Maximum Welding
Output 250A / 25V 315A / 29.8V
Minimum Welding
Output 50A / 16.5V 70A / 17.5V
Filler Wire Dimensions 0.6 ~ 1.0 Ø mm 0.8 ~ 1.2 Ø mm
Wire Feed Speed 1 ~ 18m / min
Timer
(Spot or Stitch Welding) 0 ~ 5 sec
Static Characteristics Flat (Constant Voltage)
Physical Properties
Dimensions
(L X W X H) mm 870 X 310 X 650 950 X 380 X 730
Weight 75kg 100kg
Temperature Class F 150°C
Degree Of Protection IP21S
MODE OF OPERATION

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•When the trigger at the welding handle is activated, the contactor will
couple voltage to the welding transformer, which will give a secondary
voltage decided by the position of the voltage switch.
•In the rectifier this AC voltage transformed into a DC voltage, which is
applied between welding, torch and return cable.
•At the same time the flow of protection gas and the wire feed motor are
started.
•The number of revolutions is decided by the adjustment button.
•When you lift your finger from the trigger the motor will stop and after a
short delay the contactor and the welding current are interrupted. This
delay has the effect that the welding wire will burn back a little from the
molten pool and thus does not stick to the pool.
•The electronic control can be set to the functions “continuous”, “spot” and
"stitch”.
Spot - the welding will stop after a delay that can be set by the button welding
time. Using this function you are sure of a uniform stitch welding.
Stitch - the wire feed motor will stop with stitch that can be set by the button
welding time and pause time. When you put pauses into the welding, the average
heat volume added is reduced to prevent a burning through on difficult welding
tasks.
Shielding Gas Connection
The shielding gas bottle is mounted on the machine and the regulator on the
bottle. lf the regulator is equipped with a flow meter, the flow rate is adjusted on 5-
15 litres / min.
Welding Hose Connection
The welding hose is put through the hole in the front plate and into switch on the
wire feed console. Keep the inlet nozzle as close to the wire feed roller as
possible without letting them touch each other.
Fitting the Welding Wire
Turn the tension spring aside and tip it up. Check that the wire feed roller, the wire
guide liner and the contact tip correspond to the wire diameter; the wire feed roller
is designed for one dimension. The following guide shows the recommended wire:
WIRE DIAMETER (FE.WIRE) WIRE GUIDE LINER INT. DIAMETER
Dia 0.6MM
Dia 1.0MM
Dia 1.0 –(–1.5)MM
WIRE DIAMETER (AL.WIRE)
Dia 0.8MM
Dia 1.0MM
Dia 1.5MM
Dia 1.5MM
Aluminium Wire
When using aluminium wire use a special guide liner where the internal liner goes
the way through the inlet nozzle. This prevents the aluminium wire from being

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damaged. The reel of wire is put on the hub, and the wire is put through the wire
feed unit and some into the hose. As the wire guide liner is prone to burrs at the
point of the wire, it is important to straighten out the first 10-15cm. Unscrew
contact nozzle. Tip up the level. Set the wire speed at 6, press the start button,
the wire runs through the hose. When the wire is through the hose, stop the
machine and mount the contact nozzle. The pressure of the lever is adjusted to
allow the wire feed roller just to slide on the wire when this is stopped at the
contact nozzle.
WELDING TECHNIQUE
The setting up of a MIGSTAR SERIES welding machine demands some practice
from the welder, the machine having two control points that have to meet; the wire
feed speed and the welding voltage. The welding current is determined by the
wire feed speed, and it should correspond to the work piece. The current will
increase by wire speed, resulting in a shorter arc. Less wire speed will reduce the
current and lengthen the arc. Increasing the welding voltage hardly alters the
current intensity, but lengthens the arc. By decreasing the voltage a shorten arc is
obtained with little change in current intensity. When using CO2 as shielding gas,
increase the voltage by about 5 volts per 100 Amp. When changing the wire
diameters, different control settings are required. A thinner wire needs more
speed to acquire the same strength. A satisfactory weld cannot be obtained if
extreme values are exceeded. If the feed speed is too high for the welding
voltage, blockage will occur in the torch as the wire dips into the molten pool and
does not melt. Welding in these conditions normally gives faults due to lack of
fusion. If however, the welding voltage is too high, large drops will form on the end
of the wire, causing spatter. The correct setting of Voltage and speed can be seen
in an even and calm arc.
Influence of the welding position
The position of the torch and the work piece is important for quality and
appearance of the seam.

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The diagrams below show some of the many possibilities and indicate
schematically the importance of these positions. In practice it is best to use all
combinations of welding positions, torch directions and positions of the work
piece.
Together with the figures, the diagram below may help when an estimation of
separate factors for welding quality.
The terms drawing weld and thrusting weld mean:
Drawing weld: torch sloped in direction of weld.
Thrusting weld: torch sloped away from direction of weld.
Thrusting weld Drawing Weld
Width of seam Wider Narrower
Upper bead Smaller Larger
Penetration Decrease Increase
Tendency to lack of fusion Greater Lesser
Push Weld Pulling Weld
WORKING ENVIRONMENT
1. Shielding
Measures should be taken to shield the supply cable of permanently
installed welding equipment, in metallic conduct or equivalent. Shielding
Push Weld
Sloping Downwards
Pull Weld
Sloping Downwards
Pull Weld
Sloping Upwards