Inverter Fusion 315A User manual

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

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________________________________________________________________
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

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should be electrically continuous throughout its length. The shielding
should be connected to the welding power source so that good electrical-
contact is maintained.
2. Maintenance
The welding equipment should be routinely maintained. All access and
service doors and covers should be closed and properly fastened when the
welding equipment is in operation. In particular, the spark gaps of arc
striking and stabilizing devices should be adjusted and maintained.
3. Cables
Welding cables should be kept as short as possible and should be
positioned close together, running close to the floor level.
4. Earthing
Where the work-piece is not bonded to earth for electrical safety, not
connected to earth because of its size and position, care should be taken
to prevent the earthing of the work piece increasing the risk of injury to
users or damage to other electrical equipment. Where necessary, the
connection of the work piece to earth should be made by a direct
connection to the work.
5. Screening and shielding
Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference.
.
EQUIPMENT INSTALLATION AND MAINTENANCE MUST BE
PERFORMED IN COMPLIANCE WITH LOCAL SAFETY STANDARDS
Electric shock could be fatal.
Never touch exposed
electrical parts.
Switch off and disconnect
the power source before
Use a protective mask with
suitable glass filter (at least
NRl0) to safeguard eyes.
Wear appropriate eye, ear
and body protection.
Fumes and gases may
present a safety hazard.
Fumes and gases generated
during welding may be
dangerous if inhaled over a
long period of time

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installing or opening.
Only qualified persons may
perform installation.
Installation procedures must
comply with national
electricity standards and all
other relevant regulations
Warn others to keep away
from arc rays and hot metal. Keep clear of fumes.
Ventilate welding area or
wear a breathing mask.
Install a natural or forced air
ventilation system in the
work area.
Welding wire may cause
injury.
Do not point the torch toward
any part of the body, other
persons
Moving parts may cause
injury.
Keep clear of hazardous
areas, such as moving
rollers.
Keeps all doors, panels and
covers closed and in place
Hot areas may cause injury.
Let the power source of
other parts cool before
performing any
maintenance.
A falling power source or other
equipment may cause serious
injury to persons or damage to
objects.
Always make use of the
handle to lift power source
(applies to portable models).
Use eyebolts and adequate
lifting equipment to raise the
power source.
WELDING MAY CAUSE
FIRES OR EXPLOSIONS.
Never weld near flammable
material
Beware of weld flame.
Always keep a fire
extinguisher close at hand.
Never place welding
equipment on flammable
surfaces.
Do not weld in closed areas.
Let welding equipment and
material cool before handling
them
The positioning of welding
equipment on flammable
surfaces could lead to fire
outbreak or explosion.
Never position equipment
near combustible or
flammable surface.
Do not install equipment in
the vicinity of flammable
liquids.
MAINTENANCE - Checking Items
The following items demand special attention:
Wire feed unit
This unit is to be checked regularly at the wire feed roller and the wire nozzles, as
it is of great importance for a satisfactory welding result and a minimum of wear
and tear that the wire passes through the mechanism without any deformations of
the wire feed roller. The wire nozzle should often be checked and changed if the
copper coating of the wire is damaged on its way through the nozzles. Copper
dust may totally hinder free passage through the wire liner.
A weekly check and cleaning of the nozzles as welding hose as well as the wire
feed roller is recommended.
Welding hose
Great care should be taken that the welding hose is not overloaded. lt should not
be pulled over sharp edges, and other heavy machines should not run over it as it
may damage the wire lines. The hose should be dismantle every week and blown
out with dry air.

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Welding torch
There are many parts in the welding torch that have to be cleaned regularly. The
main ones are the contact tip and gas nozzle. During the welding process, these
parts are bombarded with spatters that stick in the nozzles. This may disturb the
shielding gas blocked up with spatters, there is a danger that a short-circuit will
occur between the contact tip and the gas nozzle. The spatter should therefore be
removed regularly and the cleaning process, the gas nozzle be removed.
REMEMBER: DO NOT CLEAN BY BEATING THE TORCH.
Power source
The rectifier and transformer should be blown out with dry air occasionally;
otherwise the dust can affect the air circulation.
TROUBLESHOOTING
If you have any problems in setting up or operating, please first consult this
manual.
If you are still having difficulties after reading this manual, please contact Inverter
Fusion Ltd direct.

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PRODUCT WARRANTY
September 2010
This limited warranty supersedes all previous Inverter Fusion Limited warranties and
applies to sales of Inverter Fusion Limited equipment in the UK.
Warranty
Subject to the following terms and conditions, Inverter Fusion Limited warrants to the
original retail purchaser that new Inverter Fusion Limited equipment sold in the UK is free
of defects in material and workmanship at the time of its despatch from Inverter Fusion
Limited for the warranty period advertised for the product at the time of sale.
Within the warranty period as listed, Inverter Fusion Limited will repair or replace any
warranted parts or components that fail due to such defects in material or workmanship,
provided the warranty has been registered at the time of purchase.
Inverter Fusion Product Warranty shall not apply to:
• Consumable items and accessories supplied by Inverter Fusion Limited but
manufactured by others. These items will be covered by the manufacturer’s
warranty, if any.
• Electrodes, contactors and relays.
• Equipment that has been modified or repaired in any way
• Equipment that has been improperly installed, misused, improperly operated, or
used in a manner that does not comply with an industry standard.
• Equipment that has been used for a purpose outside the specifications for that
equipment
• Equipment that has not been maintained in a condition that would make it suitable
for use.
• Equipment which has been used in conjunction with parts or consumables which
affect the equipment operation which are deemed by Inverter Fusion Ltd to be of
inferior quality or no fit for that purpose
In the event of a valid warranty claim being made on any Inverter Fusion Limited product,
the exclusive remedies shall be, at the discretion of Inverter Fusion Limited, either the
repair or replacement of the product
To the extent permitted by Law, the remedies provided herein are the sole and exclusive
remedies.
Inverter Fusion Limited liability under this warranty shall not exceed the cost of correcting
the defect. In no event shall Inverter Fusion Limited be liable for direct, indirect, special,
incidental or consequential damages (including loss of profit), whether based on contract,
tort, or any other legal theory.

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Any express warranty not provided herein and any implied warranty, guarantee, or
representation as to the performance, and any remedy for breach of contract, tort or any
other legal theory which, but for this provision, might arise by implication, operation of
Law, Custom of Trade, or course of dealing, including and implied warranty or
merchantability for a particular purpose, with respect to any and all equipment furnished
by Inverter Fusion Limited, is excluded and disclaimed by Inverter Fusion Limited.
Warranty Registration
In order for any warranty to be valid, the Warranty Registration Card enclosed must be
completed and returned at the time of purchase in order to register the warranty with
Inverter Fusion Limited. Alternatively the warranty may be registered via the company’s
website www.inverterfusion.com
Warranty Claims Procedure
In the event of a claim, the claimant must first contact Inverter Fusion Limited for a
warranty claim authorization number. Following this, the Warranty Claim form, as printed
on the reverse side of this page should be completed with all the details as requested and
forwarded to Inverter Fusion Limited at the address below along with the faulty product
and a copy of the original purchase receipt. The claimant will be responsible for all
carriage, insurance and transportation costs in returning the product to Inverter Fusion
Limited.
Upon receipt and inspection of the product, if valid the product will be repaired or
replaced at the discretion of Inverter Fusion Limited. In the event of a repair being
required that is not considered to be a warranty issue, the claimant will be contacted for
his further instruction.
Following the completion of any authorized warranty claim work, the product will be
returned to the original claimant at the cost of Inverter Fusion Limited. (UK Customers
Only)
Failure to comply with the above procedure could invalidate or delay the completion of
any warranty work.
Improper use, abuse or any attempt to repair the product by an unauthorized third
party will invalidate any warranty claim.
Inverter Fusion Ltd
Heathpark Way
Heathpark Industrial Estate
Honiton
Devon EX14 1BB