LOKERMANN GRAND MIG 351 MULTI SYN User manual

USER MANUAL
INVERTER Based Welding Machines
IMPORTANT: Read this OPERATOR MANUAL together
with PRESCRIPTION AND COMPLIANCE MANUAL before
to use this equipment. In case of loss one of two parts
contact immediately your dealer.
Allow the operator to consult this manual.
GRAND MIG 351
MULTI SYN
GRAND MIG 501
MULTI SYN

GRAND MIG 351
MULTI SYN
1INSTALLATION WARNING
2OVERVIEW
2.1 Features
2.2 Technical Data
2.3 Brief Introduction
2.4 Duty cycle and Over-heat
2.5 Working Principle
2.6 Volt-Ampere Characteristic
3INSTALLATION & OPERATION
3.1 Machine Layout Description
3.1.1 Front and rear panel layout of welding machine
3.1.2 Front and rear panel layout of wire feeder
3.1.3 Front and rear panel layout of water cooling
3.2 Power supply input Connection
3.3 Installation & Operation for MMA Welding
3.3.1 Set up installation for MMA Welding
3.3.2 Operation for MMA Welding
3.3.3 MMA Welding trouble shooting
3.4 Installation & Operation for TIG Welding
3.4.1 Set up installation for TIG Welding
3.4.2 Operation for TIG Welding
3.4.3 TIG GUN Control
3.4.4 DC TIG welding trouble shooting
3.5 Installation & Operation for MIG Welding
3.5.1 Set up installation for MIG Welding
3.5.2 Wire Feed Roller Selection
3.5.3 Wire Installation and Set Up Guide
3.5.4 MIG Torch Liner Types and Information
3.5.5 Spool Gun Operation
3.5.6 MIG Welding
3.6 Welding trouble shooting
3.6.1 MIG welding trouble shooting
3.6.2 MIG wire feed trouble shooting
3.7 Welding parameters
3.8 Operation environment
3.9 Operation Notices
4MAINTENANCE & TROUBLESHOOTING
4.1 Maintenance
4.2 Troubleshooting
4.3 List of error code
4.4 Electrical schematic drawing
CONTENT
GRAND MIG 501
MULTI SYN

INSTALLATION WARNING
This machine is certified according to 60974-10:2014 Arc Welding Equipment Part 10: Electromagnetic
compatibility (EMC) requirement and the EUT belongs to Group 2 Class A.
WARNING: This Class A equipment is intended for industrial use and it is not intended for use in
residential locations where the elctrical power is provided by the public low-voltage supply system.
There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
WARNING: This equipment does not comply with IEC 61000-3-12. If it is connected to a public low-
voltage system, it is the responsability of the installer or user of the equipment to ensure, by consultation
with the distribution network operator if necessary, that the equipment may be connected.
Assessment of area
Before installing arc welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signalling and telephone cables, above, below and
adjacent to the arc welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, for example guarding of industrial equipment;
e) the health of the people around, for example the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment. The user shall ensure that other
equipment being used in the environment is compatible. This may require additional
protection measures;
h) the time of day that welding or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the building
and other activities that are taking place. The surrounding area may extend beyond the
boundaries of the premises.
Methods of reducing emissions-Public supply system
Arc welding equipment should be connected to the public supply system according to this manual
recommendations. If interference occurs, it may be necessary to takeadditional precautions such as
filtering of the public supply system. Consideration should be given to shielding the supply cable of
permanently installed arc welding equipment, in metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding should be connected to the welding power
source so that good electrical contact is maintained between the conduit and the welding power
source enclosure.
Maintenance of the arc welding equipment
The arc welding equipment should be routinely maintained according to this manual
recommendations. All access and service doors and covers should be closed and properly
fastened when the arc welding equipment is in operation. The arc welding equipment should
not be modified in any way, except for those changes and adjustments covered in this manaul. In
particular, the spark gaps of arc striking and stabilising devices
should be adjusted and maintained according to our recommendations.
Welding cables
The welding cables should be kept as short as possible and should be positioned close
together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic objects in the surrounding area should be considered. However,
metallic objects bonded to the work piece will increase the risk that the operator could receive
an electric shock by touching these metallic objects and the electrode at the same time. The
operator should be insulated from all such bonded metallic objects.
Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth
because of its size and position, for example, ship’s hull or building steelwork, a connection
bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other
electrical equipment. Where necessary, the connection of the workpiece to earth should be made by
a direct connection to the workpiece, but in some countries where direct connection is not permitted,
the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and shielding
Selective screening and shielding of other cables and equipment in the surrounding area may
alleviate problems of interference. Screening of the entire welding area may be considered for
special applications.

2
Overview
2.1
Features - New PWM technology and IGBT inverter technology.
- Intelligent digital wire feeder with all MIG controls and display
located on wire feeder control panel
- MMA function (Stick electrode)
- VRD (Voltage Reduction Device)
- Hot start (improves electrode starting)
- Adjustable Arc Force
- DC TIG
- Lift Arc ignition (prevents tungsten sticking during arc ignition)
- 2T /4T Trigger Control
- Adjustable Down slope
- Gas/air cooling mode
- Gas valve inside
- Synergic mig operation for optimum welding results every time
- MIG waveform (inductance) control for great arc control and
smoother welding results
- Wire inching and gas purge control for safe, simple set up and
ease of use
- Adjustable pre flow, post flow, burn back and soft start settings
- 2T/4T trigger operation with crater control settings
- Dual digital display meters for accurate pre-setting and
feedback of welding parameters & output.
- Internal 4 rolls wire feeder, gear driven for up to 300mm Ø spool
- Spool Gun Connection
2.2
Technical
Data
Models
Parameters
GRAND MIG 351
MULTI SYN
GRAND MIG 501
MULTI SYN
Input Voltage
（
V
）
3~380/400/415/440±10%
3~380/400/415/440±10%
Frequency (HZ)
50/60
50/60
MIG
TIG
MMA
MIG
TIG
MMA
Input Current
(I1max)
（
A
）
30 24 32 44 35 44
Input Power
（
KW
）
13.5 10.7 14.3 22.7 18 22.7
Welding Current
（
A
）
40-350 10-350 40-500 10-500
No-load Voltage
（
V
）
70 14 68 14
Welding Voltage
（V）16-35 (MIG) 16-50 (MIG)
Duty cycle（40℃）
60% 350A
100% 275A
60% 500A
100% 400A
Diameter (mm)
Fe:0.6/0.9/1.0/1.2
SS:0.8/0.9/1.0/1.2
Flux-
Cored:0.6/0.8/0.9/1.0/1.2
Fe:0.6/0.9/1.0/1.2/1.6
SS:0.8/0.9/1.0/1.2/1.6
Flux-
Cored:0.6/0.8/0.9/1.0/1.21.6
Protection class
IP23
IP23
Insulation class
H
H
Dimensions（mm）640*280*460 640*280*460
Weight
（
Kg
）
25
33.5

2.3
Brief
Introduction GRAND MIG adopts the latest Pulse Width Modulation (PWM) technology and the Insulated Gate
Bipolar Transistor (IGBT) power modules. It uses switching frequencies in the 20KHz-50KHz range so as
to replace the traditional line-frequency transformer type welding machines. Thus, machines are
characterized with excellent dynamic response, portability, small size, lightweight, low energy
consumption, etc.
MIG series of welding machines uses Mix gases as shielding gas to realize gas shielded welding, active
gas（Ar+O2、Ar+CO2）as shielded gas to realize MAG welding and inactive gas（Ar）as shielded gas to
realize MIG welding.
GRAND MIG has built-in automatic protection functions to protect the machines from over-voltage,
over-current and over-heat. If any one of the above problems happens, the alarm lamp on the front
panel will be lit and output current will be shut off automatically for the machine to protect itself and
prolong the equipment using life.
GRAND MIG Features:
1. Digital control system, real-time display the welding parameters;
2. High performance multifunction power source (MIG/MAG);
3. Waveform control, stable welding arc;
4. IGBT technology, low power consumption;
5. Rated Duty Cycle：
GRAND MIG 351 MULTI SYN = 350A @ 60%(40°C)
GRAND MIG 501 MULTI SYN = 500A @ 60%(40°C)
GRAND MIG is suitable for all positions welding for various plates made of stainless steel, carbon steel,
alloyed steel etc. Applications applied to pipe installment, petrochemical, architecture equipment,
car repair, bicycle repair, handicraft and common steel fabrication.
The letter “X” stands for Duty Cycle, which is defined as the portion of the time a welding machine
can weld continuously with it’s rated output current within a certain time cycle (10 minutes).
The relation between the duty cycle “X” and the output welding current “I” is shown as the right
figure. If the welding machine is overheating, the IGBT over-heat protection sensing will send a signal
to the welding machine control unit to cut the output welding current OFF and light the over-heat
pilot lamp on the front panel. In that case, the machine should not be welding for 10-15 minutes to
cool down with the fanrunning. When operating the machine again, the welding output current or
the duty cycle should be reduced.
Relation of welding current and duty cycle
for GRAND MIG 501 MULTI SYN
2.4
Duty cycle
and
Over-heat

2.5
Working
Principle
GRAND MIG has an excellent volt-ampere characteristic, whose graph is shown as the following figure.
The relation between the rated loading voltage U2 and welding current I2 is as follows: U2=14+0.05I2(V)
2.6
Volt-Ampere
Characteristic
The working principle of GRAND MIG is shown as the following figure. Three-phase 380V work
frequency AC is rectified into DC（530V）, then is converted to medium frequency AC (about 20KHz)
by inverter device (IGBT), after reducing voltage by medium transformer (the main transformer) and
rectifying by medium frequency rectifier (fast recovery diodes), and is outputted by inductance
filtering. The circuit adopts current feedback control technology to insure current output stably when
MMA or TIG. And adopts voltage feedback control technology to insure voltage output stably when
MIG. Meanwhile, the welding current parameter can be adjusted continuously and infinitely to meet
with the requirements of welding craft.
OVERVIEW
44
14
0 600 Io（A）
Uo（V）
Working point
Volt-ampere characteristic The relation between the rated loading
voltage and welding current

3
Installation
& Operation
3.1
Machine
Layout
Description
3.1.1
Front and
rear panel
layout of
welding
machine
1. Negative (-) Welding Power Output Connection Socket
2. Remote Connection Plug
3. Tig Torch Gas Connect
4. Negative (+) Welding Power Output Connection Socket
5. Input power cable
6. Water Cooler Interface Connection
7. Wire Feeder Interconnect Data Connection Socket
8. Wire Feeder Interconnect Cable Power Connection (Positive +)
9. TIG Gas Inlet
10. Fan: Cooling the welding machine
11. Power Source Display Meter*
12. MMA Hot Start Indicator*
13. MMA/ TIG Current Indicator*
14. MMA Arc Force Indicator*
15. TIG Down Slope Indicator*
16. MIG Mode Indicator
17. MMA Mode Indicator
18. MMA VRD Mode Indicator
19. Lift TIG Mode Indicator
20. 2T Trigger Mode Indicator (Tig)
21. 4T Trigger Mode Indicator (Tig)
22. Water Cooling Mode Indicator (Tig)
23. Air Cooling Mode Indicator (Tig)
24. Water /Air Cooling Selector Button (Tig Mode)*
25. 2T /4T Selector Button (Tig Mode)*
26. Power Source Mode Select Button*
27. Power Source Parameter Adjust/ Select Knob*
28. Mains Power Switch
29. Water Cooling System Error Indicator *
30. Error/ Overload Indicator*
31. Mains Power Indicator
*Denotes more detailed explanation of function to follow.

Further Controls Explained
Power Source Display Meter (11)
Displays value for parameter adjusted by control knob (27). During welding, displays welding current or
voltage depending on welding mode.
MMA Hot Start (12)
MMA mode only, provides extra power when the weld starts to counteract the high resistance of the
electrode and workpiece as the arc is started. Select by pressing parameter control knob (27) and adjust
by turning knob. Adjust welding current for MMA and TIG welding modes. Select by pressing parameter
control knob (27) and adjust by turning knob.
MMA Arc Force (14)
An MMA welding power source is designed to produce constant output current (CC). This means with
different 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 effect will also cause the welding current to
increase. 0 is Arc Force off, 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. Select by pressing parameter control knob (27) and adjust by turning knob.
Down Slope (15)
When the trigger is released, the welding current will reduce gradually over the time selected down
to 0. This allows the operator to complete the weld without leaving a 'crater' at the end of the weld p
ool. Select by pressing parameter control knob (27) and adjust by turning knob.
Water/ Air Cooling Selection Button (24)
When using the integrated water cooling system with a water cooled torch, select the 'water' option.
This will activate the water cooler power and the water cooling protection system. If using air cooled
torch, select 'Air' option.
Note the welding machine comes standard with a water cooled torch system. Operating a water
cooled torch without water cooling will quickly cause serious damage to the torch. Damage to torch or
components due to lack of water is not covered under machine warranty.
2T /4T selector button (25)
2T mode the trigger is pulled and held on to activate the welding circuit, when the trigger is released,
the welding circuit stops. 4T is known as 'latching' mode. The trigger is pulled once and released to
activate the welding circuit, pulled and released again to stops the welding circuit. This function is useful
to longer welds as the trigger is not required to be held on continuously.
Mode Control Button (26)
Selects MIG (16), MMA (17), MMA VRD (18), lift TIG (19) mode.
Parameter Select/ Adjust Knob (27)
Switch between welding parameter settings by pressing this knob, adjust by turning the knob. Value of the
parameter selected will be shown on the digital multifunction display (11)
Water Cooling System Error Indicator (29)
When using the integrated water cooler, the system is equipped with a pressure sensor. If the coolant
pressure is insufficient, this indicator will light and the welding output will not be able to be active, in order
to protect the torch and cooling system.
Overload/ Error Indicator (30)
Lights when over voltage, over current, input phase loss 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 sufficiently and indicator lamp goes
out. May also trigger if machine experiences an internal power circuit failure
Tips and Tricks
MMA VRD Function
VRD stands for Voltage Reduction Device. This is a safety system that reduces the output voltage from
the welding terminals in MMA mode while the welding output is not in use, to reduce the risk of electric
shock from the live output voltage. The disadvantage of this system is that it makes the striking of the arc
more difficult, especially on restarts and with some types of electrode such as low hydrogen electrodes.
Lift TIG Mode
Lift TIG is an arc ignition system for basic TIG welding that removes the need to 'scratch' start or strike the
tungsten on the work piece to start the arc, which can have a negative effect on the weld quality due
to tungsten contamination. Lift arc starting works by lightly resting the tungsten on the work piece,
activating the torch trigger switch and then lifting the tungsten off. The control circuit will sense when
the tungsten is removed from the work piece and send a pulse of electricity through the torch that will
cause the TIG arc to initiate.

3.1.2
Front and
rear panel
layout of
wire feeder
1. Euro Mig Torch/Spool Gun Connector
2. Spool Gun Power Supply Connection (9 Pin Remote Socket)
3. Torch Water Cooling Outlet Connection (blue)
4. Torch Water Cooling Return Connection (red)
5. Interconnect Cable Gas Inlet Connection
6. Interconnect Cable Water Cooling Inlet Connection (blue)
7. Interconnect Cable Water Cooling Return Connection (red)
8. Interconnect Data Cable Connection Socket
9. Interconnect Power Cable Connection Socket (Positive +)
10. Wire Feeder Lh Digital Display*
11. Wire Feeder Rh Digital Display*
12. Water Cooling System Error Indicator*
13. Spool Gun Indicator*
14. Error/ Overload Indicator*
15. Air Check Button
16. Water/ Air Cooling Selection Button (Mig Mode)*
17. 2T/4T Selector Button (Mig Mode)*
18. Manual Wire Button
19. Mig Parameter Selection Button*
20. Wave Control/ Inductance Adjustment Knob*
21. Lh Mig Parameter Adjustment/ Selector Knob *
22. Rh Mig Parameter Adjustment/ Selector Knob*
23. Spool holder assembly
24. Wire Feeder Inlet Guide
25. Drive Roller Retainer (x2)
26. Wire Drive Roller (x2)
27. Wire Feed Tension Arm (x2)
28. Wire Feed Tension Adjustment (x2)
29. Wire Feed Motor
30. Spool Gun Switch
*Denotes more detailed explanation of function to follow.
20

Further Controls Explained
Wire Feeder LH Digital Display (10)
Before welding, displays synergic program number (Pr), welding voltage (V), crater voltage or stitch
weld time (S), depending on the parameter being adjusted. During welding, displays welding voltage.
The parameter displayed is indicated by the LED below the display and can be changed pushing knob
21.
Using Pr1 is possible to weld in manual mode (without any synergy). In this case if a down slope is required,
S must be > 0. Vsto (Stop Voltage) and Asto (Stop Current) must be manual adjusted. If down slope is
not required S must be 0.
Using a synergy (Pr > 1 select the synergy number from the tab inside the black metal panel). V indicates
the Arc Lenght (O is the default parameter) during the setting and shows the real voltage during the
welding. Vsto is not available. S shows the time of down slope. S=0 means no down slope.
Wire Feeder RH Digital Display (11)
Before welding, displays wire feeding speed, crater wire speed or current, depending on the parameter
being adjusted. During welding, displays welding current. The parameter displayed is indicated by the
LED below the display and can be changed pushing knob 22.
Using Pr1 (manual mode) 20 shows the wire speed (m/min), Asto shows the stop current if the time of
down slope is active using a synergy. If you are using manual mode it shows the stop wire speed. A shows
the set current (real current during the welding). The Inductance is showed from
MIG Wave Control/ Inductance Knob (20)
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 effect can also be used to fine tune the arc to
produce less spatter. Wire speed, wire size and type, shielding gas will all change the effect that the
inductance setting has on the welding arc. Inductance change will have no practical effect on MIG
spray transfer process (as opposed to short circuit process).
Water Cooling System Error Indicator (12)
When using the integrated water cooler, the system is equipped with a pressure sensor. If the coolant
pressure is insufficient, this indicator will light and the welding output will not be able to be active, in
order to protect the torch and cooling system.
Spool Gun Indicator (13)
lights when the spool gun switch is activated.
Overload/ Error Indicator (14)
Lights when over voltage, over current, input phase loss 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 sufficiently and indicator lamp
goes out. May also trigger if machine experiences an internal power circuit failure
Water/ Air Cooling Selection Button (16)
When using the integrated water cooling system with a water cooled torch, select the 'water' option.
This will activate the water cooler power (the water cooler must also be switched on the rear panel) and
the water cooling protection system. If using air cooled torch, select 'Air' option.
2T /4T selector button (17)
2T mode the trigger is pulled and held on to activate the welding circuit, when the trigger is released,
the welding circuit stops. 4T is known as 'latching' mode. The trigger is pulled once and released to
activate the welding circuit, pulled and released again to stops the welding circuit. This function is useful
to longer welds as the trigger is not required to be held on continuously.
MIG Parameter Selection Button (19)
This button selects the following welding parameters, which are displayed on the LH display (10) and
adjusted using the LH control knob (21).
Gas Pre Flow
Controls the period shielding gas will flow for when the torch is triggered before the arc starts. This purges
the work area of atmospheric gas which could contaminate the weld before the weld starts.

Gas Post Flow
Controls the period of time the shielding gas continues to flow for after the arc is stopped. This protects
the weld area from contamination while it is still hot enough to react with atmospheric gases, after the
weld is finished
Soft Start
When a weld is started, the workpiece and the wire will be 'cold' compared to welding temperature, this
can cause an uneven and poor start to the weld using the voltage and wire feed speed selected as
optimal once the arc is establishe. This setting slows the wire speed down at the start of the weld which
improves the weld starting performance.
Burn Back
Burnback adjustment controls the short period of time that the wire feed will continue to run for after the
main welding current stops. If the wire feed and current is stopped exactly at the same time, the wire
will still be hot and 'burn' back and stick to the welding tip. If this problem is happening, increasing the
burn back adjustment will cause the wire feeder to run for longer after the arc has stopped. If the burn
back is adjustment is excessive, after a weld is stopped, the operator will be left with excess 'stickout' wire
length from the torch tip that will require correcting before starting the next weld
LH MIG Parameter Adjustment/ Selector Knob (21)
Control parameters displayed on the LH display screen (10). Pressing the knob will switch between
parameters displayed
RH MIG Parameter Adjustment/ Selector Knob (22)
Control parameters displayed on the RH display screen (11). Pressing the knob will switch between
parameters displayed
Tips and Tricks
MIG Voltage & Wire Speed Settings
Voltage is essentially the power in the 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 affected 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, ad-just 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)
Synergic Function
This makes the setup of MIG welding more simple, the operator simply sets the welding current like
MMA or TIG welding and the machine calculates the optimal voltage and wire speed for the material
type, wire type and size and shielding gas being used. Obviously other variables such as welding joint
type and thickness, air temperature affect the optimal volt-age and wire feed setting, so the program
provides a voltage fine tuning function for the synergic program selected. Once the voltage is
adjusted in a synergic program, it will stay fixed at this variation when the current setting is changed.
To reset the voltage for a synergic program back to factory default, change to another program
and back again.

The synergic programs are given a number from 1-24, this is accessed on the LH display (10) using the
LH knob (21), indicator 'Pr'. To select the relevant program for the welding application, check the chart
printed on the inside door of the wire feeder or further on in this manual.
Stitch Welding
This setting causes the arc to trigger for a short fixed period of time. This is useful for repetitive tack
welding or welding with short runs that limit heat input into the work.
3.1.3
Front and
rear panel
layout of
water
cooling
1. Water inlet
2. Water Cooling Outlet Connection (blue)
3. Water Cooling Return Connection (red)
4. Water Cooler Interface Connection
5. Water Cooling Return Connection (red)
6. Water Cooling Outlet Connection (blue)
351F 501F

3.2
Power
supply input
Connection
GRAND MIG is designed to operate on a 400V AC power supply.
When the power supply voltage is over the safe work voltage, there are over voltage and under
voltage protection inside the welder, the alarm light will on, at the same time, the current output will be
cut off.
If the power supply voltage continually goes beyond the safe work voltage range, it will shorten the
welder life-span. The below measures can be used:
- Change the power supply input net. Such as, connect the welder with the stable power supply
voltage of distributor;
- Induce the machines using power supply in the same time;
- Set the voltage stabilization device in the front of power cable input.
3.3
Installation
& Operation
for MMA
Welding
3.3.1
Set up
installation
for MMA
Welding
Connection of Output Cables Two sockets are available on this welding machine. For MMA welding
the electrode holder is shown be connected to the positive socket, while the earth lead (work piece)
is connected to the negative socket, this is known as DCEP. However various electrodes require a
different polarity for optimum results and careful attention should be paid to the polarity, refer to the
electrode manufacturers information for the correct polarity.
DCEP: Electrode connected to “+”output socket.
DCEN: Electrode connected to“-” output socket.
(1) Connect the earth lead to “-”, tighten clockwise;
(2) 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) Connect the electrode lead to “+”, tighten
clockwise;
(4) Each machine is equipped with a power cable
should be based on the input voltage welding
power cable connected to the appropriate position, not to pick the wrong voltage;
(5) With the corresponding input power supply terminal or socket good contact and prevent
oxidation;
(6) With a multi meter measure the input voltage is within the fluctuation range;
(7) The power ground is well grounded.

(1) According to the above method to install is correct, turn the power switch, so that the power
switch is “ON” position, then the power indicator light, the fan comes on, the device work properly.
(2) Select MMA or MMA VRD using the process select button (26).
(3) Set the hot start, welding current and arc force as required using the parameters control knob (27).
(following the instructions in the previous section).
(4) Place the electrode into the electrode holder and clamp tight.
(5) Strike the electrode against the work piece to create and arc and hold the electrode steady to
maintain the arc.
(6) Commence welding. If necessary, readjust the Welding parameters control knob to obtain the
welding condition required.
(7) After completion of welding the Power Source should be left turned ON for 2 to 3 minutes. This
allows the fan to run and cool the internal components.
(8) Switch the ON/OFF Switch (located on the rear panel) to the OFF position.
NOTE:
- Note the polarity of wiring, the general DC welding wire in two ways. Selected according to the
technical requirements of welding the appropriate connection, if you choose incorrectly will result in
arc instability and spatter large adhesion and other phenomena, such cases can be quickly reversed
to joints.
- If the work piece distance from the welding machine, the second line(electrode holder and ground)
is longer, so choose the appropriate conductor cross-sectional area should be larger to reduce cable
voltage drop.
3.3.2
Operation
for MMA
Welding
The following chart addresses some of the common problems of MMA welding. In all cases of equipment
malfunction, the manufacturer’s recommendations should be strictly adhered to and followed.
3.3.3
MMA
Welding
trouble
shooting
.
NO. Trouble Possible Reason Suggested Remedy
1 No arc
Incomplete welding circuit
Check earth lead is connected.
Check all cable connections.
No power supply
Check that the machine is switched
on and has a power supply
Wrong mode selected
Check the MMA selector switch is
selected
2
Porosity −small
cavities or holes
resulting from gas
pockets in weld
metal
Arc length too long
Shorten the arc length
Work piece dirty,
contaminated or moisture
Remove moisture and materials like
paint, grease, oil, and dirt, including
mill scale from base metal
Damp electrodes
Use only dry electrodes
3 Excessive Spatter Amperage too high
Decrease the amperage or choose a
larger electrode
Arc length too long
Shorten the arc length
4 Weld sits on top,
lack of fusion
Insufficient heat input
Increase the amperage or choose a
larger electrode
Work piece dirty,
contaminated or moisture
Remove moisture and materials like
paint, grease, oil, and dirt, including
mill scale from base metal
Poor welding technique
Use the correct welding technique or
seek assistance for the correct
technique
5 Lack of penetration
Insufficient heat input
Increase the amperage or choose a
larger electrode
Poor welding technique
Use the correct welding technique or
seek assistance for the correct
technique
Poor joint preparation
Check the joint design and fit up,
make sure the material is not too
thick. Seek assistance for the correct
joint design and fit u p
6
Excessive
penetration - burn
through
Excessive heat input
Reduce the amperage or use a
smaller electrode
Incorrect travel speed
Try increasing the weld trav el speed
7
Uneven weld
appearance
Unsteady hand, wavering
hand
Use two hands where possible to
steady up, practise your technique
8
Distortion −
movement of base
metal during
welding
Excessive heat input
Reduce the amperage or use a
smaller electrode
Poor welding technique
Use the correct welding technique or
seek assistance for the correct
technique
Poor joint preparation and or
joint design
Check the joint design and fit up,
make sure the material is not too
thick. Seek assistance for the correct
joint design and fit u p
9
Electrode welds
with different or
unusual arc
Incorrect polarity
Change the polarity, check the
electrode manufacturer for correct
polarity

Switch the ON/OFF Switch (located on the rear panel) to OFF.
(1) Connect the earth lead to “+”, tighten clockwise; 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) Connect the TIG torch cable to “-”, tighten clockwise.
(3) Connect TIG torch gas connection to the TIG gas outlet , ensuring all connections are tight.
(4) Connect TIG torch remote plug to remote socket，ensuring all connections are tight.
(5) If using a water cooled torch, Connect the water cooling lines from the TIG torch to the front of the
water cooler, ensuring the red and blue return and supply lines match the connectors.
(6) If using a water cooled torch, connect the water cooler interface cable from the rear of the power
source to the rear of the water cooler.
(7) Connect the gas regulator to the Gas Cylinder and connect the gas line to the Gas Regulator.
(8) Connect the gas line to the machine inlet gas connector via the quick push lock connector located
on the rear panel. Check for Leaks
(9) Each machine is equipped with a power cable should be based on the input voltage welding
power cable connected to the appropriate position, not to pick the wrong voltage;
(10) With the corresponding input power supply terminal or socket good contact and prevent oxidation;
(11) With a multi meter measure the input voltage is within the fluctuation range;
(12) The power ground is well grounded.
NOTE:
- Secure the gas cylinder in an upright position by chaining them to a stationary support to prevent
falling or tipping.
- Air cooling mode without cooling device and the water pipe is not needed for the air cooling mode.
3.4
Installation
&
Operation
for TIG
Welding
3.4.1
Set up
installation
for TIG
Welding

3.4.2
Operation
for TIG
Welding
(1) According to the above method to install is correct, turn the power switch to the “ON” position,
the power LED light should illuminate, the fan comes on, the device work properly.
(2) Carefully open the valve of the gas cylinder, set the required gas flow rate.
(3) Set the welding mode to ‘Lift TIG’
(4) Set torch operation 2T / 4T.
- When 2T operation is selected press trigger Gas starts, touch and lift arc start, release trigger Gas and
Arc stops.
- When 4T operation is selected press and release trigger Gas starts, touch and lift arc start, press and
release trigger Gas and Arc stops.
(5) Select cooling mode air / water on the front panel.
(2) Carefully open the valve of the gas (3) Select Lift TIG function using the key.
cylinder, set the required gas flow rate.
LIFT ARC DC TIG Operation
Lift Arc ignition allows the arc to be started easily in DC TIG by simply touching the tungsten to the work
piece and lifting it up to start the arc. This prevents the tungsten tip sticking to the work piece and
breaking the tip from the tungsten electrode. There is a particular technique called “rocking the cup”
used in the Lift Arc process that provides easy use of the Lift Arc function.
(6) Select welding current and Down slope Time as required on the front panel. The selected welding
current and Down slope Time will show on the digital meter.
(7) Assemble front end parts of the TIG torch making sure they are correctly assembled, use the correct
size and type of tungsten electrode for the job, the tungsten electrode requires a sharpened point
for DC welding.
(8) Lay the outside edge of the Gas Cup on the work piece with the Tungsten Electrode 1- 2mm from
the work piece. Press and hold the torch switch to activate to gas flow and welding power.
(9) With a small movement rotate the Gas Cup forward so that the Tungsten Electrode touches the
work piece.
(10) Now rotate the Gas Cup in the reverse direction to lift the Tungsten electrode from the work piece
to create the arc.
(11) Release the trigger to stop the welding.
(12) After completion of welding the Power Source should be left turned ON for 2 to 3 minutes. This allows
the fan to run and cool the internal components.
(13) Switch the ON/OFF Switch (located on the rear panel) to the OFF.
IMPORTANT! - We strongly recommend that you check for gas leaks prior to operation of your
machine. We recommend that you close the cylinder valve when the machine is not in use.
Remote Control Socket
TRIGGER
SWICH
MAX
MIN
REMOTE AMPS
10K
Socket Pin Function
1
Not connected
2
Trigger Switch Input
3
Trigger Switch Input
4
Not connected
5
10k ohm (maximum) connection to 10k ohm remote control potentiometer
6
Zero ohm (minimum) connection to 10k ohm remote control potentiometer
7
Wiper arm connection to 10k ohm remote control potentiometer
8
Not connected
9
Not connected
10
Not connected
11
Not connected
12
Not connected
3.4.3
TIG GUN
Control

3.4.6
TIG Welding
trouble
shooting
3.4.7
DC TIG
welding
trouble
shooting
The following chart addresses some of the common problems of DC TIG welding. In all cases of
equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and
followed.
5 Unstable Arc
during DC welding
Torch connected to DC +
Connect the torch to the DC- output
terminal
Contaminated base metal
Remove materials like paint,
grease, oil, and dirt, including mill
scale from base metal.
Tungsten is contaminated
Remove 10mm of contaminated
tungsten and re grind the tungsten
Arc length too long
Lower torch so that the tungsten is
off of the work piece 2 - 5mm
6 Arc wanders
during DC welding
Poor gas flow
Check and set the gas flow between
10 - 15 l/min flow rate
Incorrect arc length Lower torch so that the tungsten is
off of the work piece 2 - 5mm
Tungsten incorrect or in poor
condition
Check that correct type of tungsten
is being used. Remove 10mm from
the weld end of the tungsten and re
sharpen the tungsten
Poorly prepared tungsten
Grind marks should run lengthwise
with tungsten, not circular. Use
proper grinding method and wheel.
Contaminated base metal or
filler wire
Remove contaminating materials
like paint, grease, oil, and dirt,
including mill scale from base
metal. Remove all grease, oil, or
moisture from filler metal
7
Arc difficult to
start or will not
start DC welding
Incorrect machine set up
Check machine set up is correct
No gas, incorrect gas flow
Check the gas is connected and
cylinder valve open, check hoses,
gas valve and torch are not
restricted. Set the gas flow between
10 - 15 l/min flow rate
Incorrect tungsten size or
type
Check and change the size and or
the tungsten if required
Loose connection
Check all connectors and tighten
Earth clamp not connected to
work
Connect the earth clamp directly to
the work piece wherever possible
NO. Trouble Possible Reason Suggested Remedy
1 Tungsten burning
away quickly
Incorrect Gas or No Gas
Use pure Argon. Check cylinder
has gas, connected, turned on and
torch valve is open
Inadequate gas flow
Check the gas is connected, check
hoses, gas valve and torch are not
restricted.
Back cap not fitted correctly
Make sure the torch back cap is
fitted so that the o-ring is inside the
torch body
Torch connected to DC +
Connect the torch to the DC- output
terminal
Incorrect tungsten being
used
Check and change the tungsten
type if necessary
Tungsten being oxidised
after weld is finished
Keep shielding gas flowing 10–15
seconds after arc stoppage. 1
second for each 10amps of weld
current.
2 Contaminated
tungsten
Touching tungsten into the
weld pool
Keep tungsten from contacting
weld puddle. Raise the torch so that
the tungsten is off of the work
piece 2 - 5mm
Touching the filler wire to
the tungsten
Keep the filler wire from touching
the tungsten during welding, feed
the filler wire into the leading edge
of the weld pool in front of the
tungsten
3
Porosity - poor
weld appearance
and colour
Wrong gas / poor gas flow
/gas leak
Use pure argon. Gas is connected,
check hoses, gas valve and torch
are not restricted. Set the gas flow
between 6-12 l/min. Check hoses
and fittings for holes, leaks et
Contaminated base metal
Remove moisture and materials
like paint, grease, oil, and dirt from
base metal
Contaminated filler wire
Remove all grease, oil, or moisture
from filler metal
Incorrect filler wire
Check the filler wire and change if
necessary
4
Yellowish residue /
smoke on the
alumina nozzle &
discoloured
tungsten
Incorrect Gas
Use pure Argon gas
Inadequate gas flow
Set the gas flow between 10 - 15
l/min flow rate
Alumina gas nozzle too
small
Increase the size of the alumina gas
nozzle
3.4.4
DC TIG
welding
trouble
shooting

3.5
Installation
&
Operation
for MIG
Welding
3.5.1
Set up
installation
for MIG
Welding
(1) Connect the earth cable quick connector to the negative welding power output socket.
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) Connect the MIG Torch Euro Connector to the MIG torch Euro connection socket on the front of the
wire feeder. Secure by firmly hand tightening the threaded collar on the MIG Torch connector
clockwise.
IMPORTANT : When connecting the torch be sure to tighten the connection. A loose connection can
result in the connector arcing and damaging the machine and gun connector.
(3) Connect the torch water cooling lines in the interconnect cable to the front of the wire feeder,
ensuring the red and blue return and supply lines match the connectors (Water cooled model only).
(4) Connect the quick connect gas line from the interconnect lead to the wire feeder gas inlet.
Check for Leaks!
(5) Connect the water cooling lines in the interconnect cable to the rear of the wire feeder and the
ends with the long terminations to the front of the water cooler, ensuring the red and blue return
and supply lines match the connectors(Water cooled model only).
(6) Connect interconnect data cables to the rear of the wire feeder using the end of the interconnect
cable with the shortest terminations. Connect data cables from the other end of the interconnect
lead to the sockets on the rear of the power source.
(7) Connect interconnect lead power to the rear of the wire feeder using the end of the interconnect
cable with the shortest terminations. Connect power cables from the other end of the interconnect
lead to the sockets on the rear of the power source.
(8) Connect the gas regulator to a gas cylinder (not included with machine) and connect the quick
connect gas line from the interconnect lead to the Gas Regulator. Check for Leaks!
(9) Connect the water cooler interface cable from the rear of the power source to the rear of the water
cooler (Water cooled model only).
(10) Connect the machine to suitable mains power using the mains input power lead.
NOTE: Air cooling mode without cooling device，and the water pipe is not needed for the air cooling
mode.
NOTE: If a water cooled torch and water cooler is used, check the water cooler has sufficient coolant
level and all connections are firmly secured, then switch on the water cooler power switch on the
rear of the water cooler. Set the water/ air setting on the wire feeder to 'water'. The water cooler
should now start operating. If using an air cooled torch, set the button to 'air' setting.

(11) Check spool gun switch is in the 'off' position.
(12) Place the Wire Spool onto the Spool Holder. Snip the wire from the spool being sure to hold the
wire to prevent rapid uncoiling. Feed the wire into the wire feeder inlet guide tube through to
the drive roller.
(13) Carefully feed the wire over the drive roller into the outlet guide tube, feed through about
150mm into the torch receptacle. Check that the drive roller size is compatible with the wire
diameter, replace the roller if necessary.
(14) Align the wire into the groove of the drive roller and close down the top roller making sure the
wire is in the groove of the bottom drive roller, lock the pressure arm into place. Apply a medium
amount of pressure to the drive roller.
(15) Remove the gas nozzle and contact tip from the torch neck.
(16) Press and hold the manual wire key to feed the wire through to the torch neck, release the
manual wire key when the wire exits the torch neck.
(17) Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip
holder of the torch head and nip it up tightly.
(18) Fit the gas nozzle to the torch head.
(19) Open gas cylinder valve and adjust regulator, flow should be between 10-25 I/min depending
on application. Re-check regulator flow pressure using the gas test button on the wire feeder
control panel as static gas flow setting may drop once gas is flowing.
(20) Set the welding parameters as required following the instructions in the previous section. You are
now ready to weld.
(14) Close down the top roller bracket and clip (15) Remove the gas nozzle and contact
the pressure arm into place with a medium tip from the front end of the mig torch.
amount of pressure applied.
(12) Place wire onto spool holder - (spool retaining (13) Feed wire over the drive roller into
nut is left hand thread ) Feed the wire through the the outlet guide tube, Push the wire
inlet guide tube on to the drive roller. through approx 150mm.
(16) Press and hold the manual wire key (17) Fit the correct size contact tip over the
to feed the wire down the torch cable wire and fasten tightly into the tip holder.
through to the torch head.
(18) Fit the gas nozzle to the torch head. (19) Carefully open the gas cylinder valve
and set the required gas flow rate.

3.5.2
Wire Feed
Roller
Selection The importance of smooth consistent wire feeding during MIG welding cannot be emphasized enough.
Simply put the smoother the wire feed then the better the welding will be.
Feed rollers or drive rollers are used to feed the wire mechanically along the length of the welding gun.
Feed rollers are designed to be used for certain types of welding wire and they have different types of
grooves machined in them to accommodate the different types of wire. The wire is held in the groove
by the top roller of the wire drive unit and is referred to as the pressure roller, pressure is applied by a
tension arm that can be adjusted to increase or decrease the pressure as required. The type of wire will
determine how much pressure can be applied and what type of drive roller is best suited to obtain
optimum wire feed.
Solid Hard Wire - like Steel, Stainless Steel require a drive roller with a V shape groove for optimum grip
and drive capability. Solid wires can have more tension applied to the wire from the top pressure roller
that holds the wire in the groove and the V shape groove is more suited for this. Solid wires are more
forgiving to feed due to their higher cross sectional column strength, they are stiffer and don’t bend
so easy.
Soft Wire - like Aluminium requires a U shape groove. Aluminium wire has a lot less column strength,
can bend easily and is therefore more difficult to feed. Soft wires can easily buckle at the wire feeder
where the wire is fed into inlet guide tube of the torch. The U-shaped roller offers more surface area grip
and traction to help feed the softer wire. Softer wires also require less tension from the top pressure roller
to avoid deforming the shape of the wire, too much tension will push the wire out of shape and cause it
to catch in the contact tip.
Flux Core / Gasless Wire - these wires are made up of a thin metal sheath that has fluxig and metal
compounds layered onto it and then rolled into a cylinder to form the finished wire. The wire cannot take
too much pressure from the top roller as it can be crushed and deformed if too much pressure is applied.
A knurled drive roller has been developed and it has small serrations in the groove, the serrations grip the
wire and assist to drive it without too much pressure from the top roller. The down side to the knurled wire
feed roller on flux cored wire is it will slowly over time bit by bit eat away at the surface of the welding
wire, and these small pieces will eventually go down into the liner. This will cause clogging in the liner
and added friction that will lead to welding wire feed problems. A U groove wire can also be used for
flux core wire without the wire particles coming of the wire surface. However it is considered that the
knurled roller will give a more positive feed of flux core wire without any deformation of the wire shape.