Magmate 180P User manual

180 P
OPERATING MANUAL

2
Welcome to a better way of welding
Congratulations on purchasing a MagMate 180P welding machine.
This operating manual provides the basic knowledge required for MIG Welding,
as well as highlighting important areas of how to operate the MagMate machine.
With normal use and by following these recommended steps, your
MagMate machine can provide you with years of trouble-free service.
MagMate equipment and technical support is available through the national BOC
Customer Service Centre or contact your local Gas&Gear outlet.
Important Notice: This document has been prepared by BOC Limited ABN 95 000 029 729 ('BOC'), as
general information and does not contain and is not to be taken as containing any specific recommendation.
The document has been prepared in good faith and is professional opinion only. Information in this document
has been derived from third parties, and though BOC believes it to be reliable as at the time of printing, BOC
makes no representation or warranty as to the accuracy, reliability or completeness of information in this
document and does not assume any responsibility for updating any information or correcting any error or
omission which may become apparent after the document has been issued. Neither BOC nor any of its agents
has independently verified the accuracy of the information contained in this document.The information in this
document is commercial in confidence and is not to be reproduced.The recipient acknowledges and agrees
that it must make its own independent investigation and should consider seeking appropriate professional
recommendation in reviewing and evaluating the information.This document does not take into account the
particular circumstances of the recipient and the recipient should not rely on this document in making any
decisions, including but not limited to business, safety or other operations decisions. Except insofar as liability
under any statute cannot be excluded, BOC and its affiliates, directors, employees, contractors and consultants
do not accept any liability (whether arising in contract, tort or otherwise) for any error or omission in this
document or for any resulting loss or damage (whether direct, indirect, consequential or otherwise) suffered by
the recipient of this document or any other person relying on the information contained herein.The recipient
agrees that it shall not seek to sue or hold BOC or their respective agents liable in any such respect for the
provision of this document or any other information.

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Contents
1.0 Recommended Safety Precautions 4
1.1 Health Hazard Information 4
1.2 Personal Protection 4
1.3 Electrical Shock 5
1.4 User Responsibility 5
2.0 MIG Operating Manual 6
2.1 Introduction to Metal Inert Gas (MIG) 6
2.2 Introduction to Flux Cored Arc Welding
(FCAW) 6
2.3 Introduction to Metal Cored Arc Welding
(MCAW) 8
2.4 Fundamentals of MIG, FCAW and MCAW 12
3.0 General Welding Information 14
3.1 Recommended Welding Parameters 14
4.0 Correct Application Techniques 15
5.0 Troubleshooting and Fault Finding 17
6.0 Machine Specifications 19
7.0 Operating Controls and Contents 20
7.1 Machine Setup 20
8.0 Periodic Maintenance 21
8.1 Power Source 21
9.0 Warranty Information 22
9.1 Terms of Warranty 22
9.2 Limitations on Warranty 22
9.3 Warranty Period 22
9.4 Warranty Repairs 22
10.0 Recommended Safety Guidelines 23

4
1.1 Health Hazard Information
The actual process of MIG welding is
one that can cause a variety of hazards.
All appropriate safety equipment should be
worn at all times, i.e. headwear, hand and body
protection. Electrical equipment should be
used in accordance with the manufacturer’s
recommendations.
Eyes:
The process produces ultra violet rays that
can injure and cause permanent damage.
Fumes can cause irritation.
Skin:
Arc rays are dangerous to uncovered skin.
Inhalation:
Welding fumes and gases are dangerous to
the health of the operator and to those in
close proximity.The aggravation of pre-existing
respiratory or allergic conditions may occur in
some workers. Excessive exposure may cause
conditions such as nausea, dizziness, dryness
and irritation of eyes, nose and throat.
1.2 Personal Protection
Respiratory
Confined space welding should be carried out
with the aid of a fume respirator or air supplied
respirator as per AS/NZS 1715 and AS/NZS
1716 Standards.
•Youmustalwayshaveenoughventilationin
confined spaces. Be alert to this at all times.
•Keepyourheadoutofthefumesrisingfrom
the arc.
•Fumesfromtheweldingofsomemetalscould
have an adverse effect on your health. Don’t
breathe them in. If you are welding on material
such as stainless steel, nickel, nickel alloys
or galvanised steel, further precautions are
necessary.
•Weararespiratorwhennaturalorforced
ventilation is not sufficient.
Eye protection
A welding helmet with the appropriate welding
filter lens for the operation must be worn at all
times in the work environment.The welding arc
and the reflecting arc flash gives out ultraviolet
and infrared rays. Protective welding screen and
goggles should be provided for others working
in the same area.
Recommended filter shades for
MIG welding
Less than 150 amps Shade 10*
150 to 250 amps Shade 11*
250 to 300 amps Shade 12
300 to 350 amps Shade 13
Over 350 amps Shade 14
*Use one shade darker for aluminium
Clothing
Suitable clothing must be worn to prevent
excessive exposure to UV radiation and
sparks.An adjustable helmet, flameproof loose
fitting cotton clothing buttoned to the neck,
protective leather gloves, spats, apron and steel
capped safety boots are highly recommended.
1.0 Recommended Safety Precautions

5
1.3 Electrical Shock
•Nevertouch‘live’electricalparts.
•Alwaysrepairorreplacewornor
damaged parts.
•Disconnectpowersourcebefore
performing any maintenance or service.
•Earthallworkmaterials.
•Neverworkinmoistordampareas.
Avoid electric shock by:
•Wearingdryinsulatedboots.
•Wearingdryleathergloves.
•Workingonadryinsulatedoor
where possible.
1.4 User Responsibility
•ReadtheOperatingManualpriorto
installation of this machine.
•Unauthorisedrepairstothisequipmentmay
endanger the technician and operator and will
void your warranty. Only qualified personnel
approved by BOC should perform repairs.
•Alwaysdisconnectmainspowerbefore
investigating equipment malfunctions.
•Partsthatarebroken,damaged,missingor
worn should be replaced immediately.
•Equipmentshouldbecleanedperiodically.
PLEASE NOTE that under no circumstances
should any equipment or parts be altered
or changed in any way from the standard
specification without written permission
given by BOC.To do so, will void the
Equipment Warranty.
Further information can be obtained
from Welding Institute of Australia
(WTIA) Technical Note No.7
‘Health and Safety Welding’
Published by WTIA,
PO Box 6165 Silverwater NSW 2128
Phone [phone].

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2.1 Introduction to Metal Inert
Gas (MIG)
MIG welding embraces a group of arc welding
processes in which a continuous electrode (the
wire) is fed by powered feed rolls (wire feeder)
into the weld pool.An electric arc is created
between the tip of the wire and the weld pool.
The wire is progressively melted at the same
speed at which it is being fed and forms part of
the weld pool. Both the arc and the weld pool
are protected from atmospheric contamination
by a shield of inert (non-reactive) gas, which is
delivered through a nozzle that is concentric
with the welding wire guide tube.
Operation
MIG welding is usually carried out with a
handheld gun as a semi-automatic process.
The MIG process can be suited to a variety
of job requirements by choosing the correct
shielding gas, electrode (wire) size and welding
parameters.Welding parameters include the
voltage, travel speed, arc (stick-out) length and
wire feed rate.The arc voltage and wire feed
rate will determine the filler metal transfer
method.
This application combines the advantages of
continuity, speed, comparative freedom from
distortion and the reliability of automatic
welding with the versatility and control of
manual welding.The process is also suitable for
mechanised set-ups, and its use in this respect
is increasing.
MIG welding can be carried out using solid
wire, flux cored, or a copper-coated solid wire
electrode.The shielding gas or gas mixture may
consist of the following:
Argon
■
Carbon dioxide■
Argon and carbon dioxide mixtures■
Argon mixtures with oxygen or helium■
mixtures
Each gas or gas mixture has specific advantages
and limitations. Other forms of MIG welding
include using a flux-cored continuous electrode
and carbon dioxide shielding gas, or using self-
shielding flux-cored wire, requiring no shielding.
2.2 Introduction to Flux Cored
Arc Welding (FCAW)
How it Works
Flux-cored arc welding (FCAW) uses the heat
generated by a DC electric arc to fuse the
metal in the joint area, the arc being struck
between a continuously fed consumable filler
wire and the workpiece, melting both the
filler wire and the workpiece in the immediate
vicinity.The entire arc area is covered by a
shielding gas, which protects the molten weld
pool from the atmosphere.
FCAW is a variant of the MIG process and
while there are many common features
between the two processes, there are also
several fundamental differences.
2.0 MIG Operating Manual
1
2
3
4
5
6
7
8
9
10
1Gun trigger 6Shroud
2Welding wire 7Gas diffuser
3Weld 8Contact tip
4Weld pool 9Shielding
5Gun 10 Droplets

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As with MIG, direct current power sources
with constant voltage output characteristics
are normally employed to supply the welding
current.With flux-cored wires the terminal that
the filler wire is connected to depends on the
specific product being used, some wires running
electrode positive, others running electrode
negative.The work return is then connected to
the opposite terminal. It has also been found
that the output characteristics of the power
source can have an effect on the quality of the
welds produced.
The wire feed unit takes the filler wire from
a spool, and feeds it through the welding gun,
to the arc at a predetermined and accurately
controlled speed. Normally, special knurled feed
rolls are used with flux-cored wires to assist
feeding and to prevent crushing the consumable.
Unlike MIG, which uses a solid consumable
filler wire, the consumable used in FCAW is
of tubular construction, an outer metal sheath
being filled with fluxing agents plus metal
powder.The flux fill is also used to provide
alloying, arc stability, slag cover, de-oxidation,
and, with some wires, gas shielding.
In terms of gas shielding, there are two different
ways in which this may be achieved with the
FCAW process.
Additional gas-shielding supplied from an
■
external source, such as a gas cylinder
Production of a shielding gas by
■
decomposition of fluxing agents within the
wire, self-shielding
Gas shielded wires are available with either
a basic or rutile flux fill, while self-shielded
wires have a broadly basic-type flux fill.The
flux fill dictates the way the wire performs, the
properties obtainable, and suitable applications.
Gas-shielded Operation
Many cored wire consumables require an
auxiliary gas shield in the same way that solid
wire MIG consumables do.These types of wire
aregenerallyreferredtoas‘gas-shielded’.
Using an auxiliary gas shield enables the wire
designer to concentrate on the performance
characteristics, process tolerance, positional
capabilities, and mechanical properties of the
products.
In a flux cored wire the metal sheath is
generally thinner than that of a self-shielded
wire.The area of this metal sheath surrounding
the flux cored wire is much smaller than that of
a solid MIG wire.This means that the electrical
resistance within the flux cored wire is higher
than with solid MIG wires and it is this higher
electrical resistance that gives this type of wire
some of its novel operating properties.
One often quoted property of fluxed cored
wires are their higher deposition rates than
solid MIG wires.What is often not explained
is how they deliver these higher values and
whether these can be utilised. For example,
if a solid MIG wire is used at 250 amps, then
exchanged for a flux cored wire of the same
diameter, and welding power source controls
are left unchanged, then the current reading
would be much less than 250 amps, perhaps
as low as 220 amps.This is because of Ohms
Law that states that as the electrical resistance
increases if the voltage remains stable then the
current must fall.
To bring the welding current back to 250 amps
it is necessary to increase the wire feed speed,
effectively increasing the amount of wire
being pushed into the weld pool to make the
weld.Itisthisaffectthatproducesthe‘higher
deposition rates’ that the flux cored wire
manufacturers claim for this type of product.
Unfortunately in many instances the welder has
difficulty in utilising this higher wire feed speed
and must either increase the welding speed or
increase the size of the weld. Often in manual
applications neither of these changes can be
implemented and the welder simply reduces the
wire feed speed back to where it was and the
advantages are lost. However, if the process is
automated in some way then the process can
show improvements in productivity.

8
It is also common to use longer contact tip to
workplace distances with flux cored arc welding
than with solid wire MIG welding and this also
has the effect of increasing the resistive heating
on the wire further accentuating the drop in
welding current. Research has also shown that
increasing this distance can lead to an increase
in the ingress of nitrogen and hydrogen into
the weld pool, which can affect the quality of
the weld.
Flux cored arc welding has a lower efficiency
than solid wire MIG welding because part of the
wire fill contains slag forming agents.Although
the efficiency varies differs by wire type and
manufacturer it is typically between 75–85%.
Flux cored arc welding does, however, have
the same drawback as solid wire MIG in terms
of gas disruption by wind, and screening is
always necessary for site work. It also incurs
the extra cost of shielding gas, but this is often
outweighed by gains in productivity.
Self-shielded Operation
There are also self-shielded consumables
designed to operate without an additional gas
shield. In this type of product, arc shielding is
provided by gases generated by decomposition
of some constituents within the flux fill.These
typesofwirearereferredtoas‘self-shielded’.
If no external gas shield is required, then the
flux fill must provide sufficient gas to protect
the molten pool and to provide de-oxidisers
and nitride formers to cope with atmospheric
contamination.This leaves less scope to
address performance, arc stabilisation, and
process tolerance, so these tend to suffer when
compared with gas shielded types.
Wire efficiencies are also lower, at about 65%, in
this mode of operation than with gas-shielded
wires. However, the wires do have a distinct
advantage when it comes to site work in terms
of wind tolerance, as there is no external gas
shield to be disrupted.
Extended self shielded flux cored wire nozzle
When using self-shielded wires, external gas
supply is not required and, therefore, the gas
shroud is not necessary. However, an extension
nozzle is often used to support and direct the
long electrode extensions that are needed to
obtain high deposition rates.
2.3 Introduction to Metal Cored
Arc Welding (MCAW)
How it Works
Metal-cored arc welding (MCAW) uses the heat
generated by a DC electric arc to fuse metal
in the joint area, the arc being struck between
a continuously fed consumable filler wire and
the workpiece, melting both the filler wire and
the workpiece in the immediate vicinity.The
entire arc area is covered by a shielding gas,
which protects the molten weld pool from the
atmosphere.
As MCAW is a variant of the MIG welding
process there are many common features
between the two processes, but there are also
several fundamental differences.
As with MIG, direct current power sources
with constant voltage output characteristics
are normally employed to supply the welding
current.With metal-cored wires the terminal
the filler wire is connected to depends on
the specific product being used, some wires
designed to run on electrode positive, others
preferring electrode negative, and some which

9
will run on either.The work return lead is then
connected to the opposite terminal. Electrode
negative operation will usually give better
positional welding characteristics.The output
characteristics of the power source can have an
effect on the quality of the welds produced.
The wire feed unit takes the filler wire from
a spool or bulk pack, and feeds it through the
welding gun, to the arc at a predetermined and
accurately controlled speed. Normally, special
knurled feed rolls are used with metal-cored
wires to assist feeding and to prevent crushing
the consumable.
Unlike MIG, which uses a solid consumable
filler wire, the consumable used in MCAW is
of tubular construction, an outer metal sheath
being filled entirely with metal powder except
for a small amount of non-metallic compounds.
These are added to provide some arc stability
and de-oxidation.
MCAW consumables always require an auxiliary
gas shield in the same way that solid MIG wires
do.Wires are normally designed to operate in
argon-carbon dioxide or argon-carbon dioxide-
oxygen mixtures or carbon dioxide.Argon rich
mixtures tend to produce lower fume levels
than carbon dioxide.
As with MIG, the consumable filler wire and
the shielding gas are directed into the arc area
by the welding gun. In the head of the gun, the
welding current is transferred to the wire by
means of a copper alloy contact tip, and a gas
diffuser distributes the shielding gas evenly
around a shroud which then allows the gas
to flow over the weld area.The position of
the contact tip relative to the gas shroud may
be adjusted to limit the minimum electrode
extension.
Modes of metal transfer with MCAW are very
similar to those obtained in MIG welding, the
processbeingoperableinboth‘diptransfer’
and‘spraytransfer’modes.Metal-coredwires
may also be used in pulse transfer mode at low
mean currents, but this has not been widely
exploited.
Process Schematic Diagram for MIG / FCAW and MCAW
1Gas hose 7Power cable
2Gas cylinder 8Gun conduit
3Power source 9Welding gun
4Return cable 10 Arc
5Continous wire 11 Workpiece
6Wire feed unit 12 Earth clamp
1
2
3
4
5
6
7
8
11
12
9
10
Circuit diagram of MIG process
Modes of Metal Transfer
The mode or type of metal transfer in MIG
welding depends upon the current, arc voltage,
electrode diameter and type of shielding gas
used. In general, there are four modes of metal
transfer.
Modes of metal transfer with FCAW are similar
to those obtained in MIG welding, but here the
mode of transfer is heavily dependent on the
composition of the flux fill, as well as on current
and voltage.
The most common modes of transfer in
FCAW are:
Dip transfer
■
Globular transfer■
Spray transfer■
Pulsed arc transfer operation has been■
applied to flux-cored wires but, as yet, is
not widely used because the other transfer
modes are giving users what they require, in
most cases.
Dip Transfer
Also known as short-circuiting arc or short-
arc, this is an all-positional process, using low
heat input.The use of relatively low current

10
and arc voltage settings cause the electrode to
intermittently short-circuit with the weld pool
at a controlled frequency. Metal is transferred
by the wire tip actually dipping into the weld
pool and the short-circuit current is sufficient
to allow the arc to be re-established.This short-
circuiting mode of metal transfer effectively
extends the range of MIG welding to lower
currents so thin sheet material can readily
be welded.The low heat input makes this
technique well-suited to the positional welding
of root runs on thick plate, butt welds for
bridging over large gaps and for certain difficult
materials where heat input is critical. Each
short-circuit causes the current to rise and the
metal fuses off the end of the electrode.A high
short-circuiting frequency gives low heat input.
Dip transfer occurs between ±70-220A, 14–23
arc volts. It is achieved using shielding gases
based on carbon dioxide and argon.
1Short circuit 5Arc gap shortens
2Necking 6Short circuit
3Arc re-ignition 7Current (A)
4Arc established 8Voltage (V)
1 2 63 4 5
Time
Short circuit cycle Arcing cycle
7
8
Schematic of Dip Transfer
Metal-cored wires transfer metal in dip mode
at low currents just like solid MIG wires.This
transfer mode is used for all positional work
with these types of wire.
Globular Transfer
Metal transfer is controlled by slow ejection
resultinginlarge,irregularly-shaped‘globs’
falling into the weld pool under the action of
gravity. Carbon dioxide gas drops are dispersed
haphazardly.With argon-based gases, the
drops are not as large and are transferred
in a more axial direction.There is a lot of
spatter, especially in carbon dioxide, resulting
in greater wire consumption, poor penetration
and poor appearance. Globular transfer occurs
between the dip and spray ranges.This mode
of transfer is not recommended for normal
welding applications and may be corrected
when encountered by either decreasing the arc
voltage or increasing the amperage. Globular
transfer can take place with any electrode
diameter.
1Large droplet
2Splatter
3Workpiece
1 2
3
Schematic of Globular Transfer
Basic flux-cored wires tend to operate in a
globular mode or in a globular-spray transfer
mode where larger than normal spray droplets
are propelled across the arc, but they never
achieve a true spray transfer mode.This transfer
mode is sometimes referred to as non-axial
globular transfer.
Self-shielded flux-cored wires operate in a
predominantly globular transfer mode although
athighcurrentsthewireoften‘explodes’
across the arc.
Spray Transfer
In spray transfer, metal is projected by an
electromagnetic force from the wire tip in
the form of a continuous stream of discrete
droplets approximately the same size as the

11
wire diameter. High deposition rates are
possible and weld appearance and reliability
are good. Most metals can be welded, but
the technique is limited generally to plate
thicknesses greater than 6mm. Spray transfer,
due to the tendency of the large weld pool to
spill over, cannot normally be used for positional
welding.The main exception is aluminium and
its alloys where, primarily because of its low
density and high thermal conductivity, spray
transfer in position can be carried out.
The current flows continuously because of the
high voltage maintaining a long arc and short-
circuiting cannot take place. It occurs best with
argon-based gases.
1
2
6
3
4
5
1Gas shroud 4Droplets
2Wire 5Weld
3Shielding gas 6Workpiece
Schematic of Spray Transfer
In solid wire MIG, as the current is increased,
dip transfer passes into spray transfer via a
transitional globular transfer mode.With metal-
cored wires there is virtually a direct transition
from dip transfer to spray transfer as the
current is increased.
For metal cored wire spray transfer occurs
as the current density increases and an arc is
formed at the end of the filler wire, producing
a stream of small metal droplets. Often the
outside sheath of the wire will melt first and
the powder in the centre flows as a stream of
smaller droplet into the weld pool.This effect
seems to give much better transfer of alloying
elements into the weld.
In spray transfer, as the current density
increases, an arc is formed at the end of the
filler wire, producing a stream of small metal
droplets. In solid wire MIG this transfer mode
occurs at higher currents. Flux-cored wires do
not achieve a completely true spray transfer
mode but a transfer mode that is almost true
spray may occur at higher currents and can
occur at relatively low currents depending on
the composition of the flux.
Rutile flux-cored wires will operate in this
almost-spray transfer mode, at all practicable
current levels.They are also able to operate
in this mode for positional welding too. Basic
flux-cored and self-shielded flux-cored wires do
not operate in anything approaching true spray
transfer mode.
Pulsed Transfer
Pulsed arc welding is a controlled method of
spray transfer, using currents lower than those
possible with the spray transfer technique,
thereby extending the applications of MIG
welding into the range of material thickness
where dip transfer is not entirely suitable.
The pulsed arc equipment effectively combines
two power sources into one integrated unit.
One side of the power source supplies a
background current which keeps the tip of the
wire molten.The other side produces pulses
of a higher current that detach and accelerate
the droplets of metal into the weld pool.The
transfer frequency of these droplets is regulated
primarily by the relationship between the two
currents. Pulsed arc welding occurs between
±50-220A, 23–35 arc volts and only with argon
and argon-based gases. It enables welding to be
carried out in all positions.

12
Process Dip Transfer Globular Transfer Spray Transfer Pulsed Transfer
Metal Inert Gas
(MIG) ● ● ●
Flux Cored
(Gas Shielded) ● ● *
Flux Cored
(Self Shielded) ● ●
Metal Cored ● ● ●
* Not True Spray
2.4 Fundamentals of MIG, FCAW
and MCAW
Welding Technique
Successful welding depends on the following
factors:
Selection of correct consumables1
Selection of the correct power source2
Selection of the correct polarity on the3
power source
Selection of the correct shielding gas4
Selection of the correct application5
techniques
aCorrect angle of electrode to work
bCorrect electrical stickout
cCorrect travel speed
Selection of the welding preparation6
Selection of Correct Consumable
Chemical composition
As a general rule the selection of a wire is
straightforward, in that it is only a matter of
selecting an electrode of similar composition
to the parent material. It will be found,
however, that there are certain applications
that electrodes will be selected on the basis of
its mechanical properties or level of residual
hydrogen in the weldmetal. Solid MIG wires are
all considered to be of the 'low Hydrogen type'
consumables.
The following table gives a general overview of
the selection of some of the BOC range of MIG
wires for the most common materials.
Common Materials Welded with BOC MIG Wire
Material BOC MIG Wire
AS2074 C1,C2,C3,
C4-1,C4-2,C5,C6
BOC Mild Steel MIG Wire
BS3100 AW1,A2,A3 BOC Mild Steel MIG Wire
BS1504-430,480,540 BOC Mild Steel MIG Wire
ASTM
A36,A106,EN8,8A
BOC Mild Steel MIG Wire
Stainless Steel
Grade 304 BOC Stainless Steel 308LSi
Grade 309 BOC Stainless Steel 309LSi
Grade 316 BOC Stainless Steel 316LSi
Physical condition
Surface condition
The welding wire must be free from any surface
contamination including mechanical damage
such as scratch marks.
A simple test for checking the surface condition
is to run the wire through a cloth that has been
dampened with acetone for 20secs. If a black
residue is found on the cloth the surface of the
wire is not properly cleaned.
Cast and Helix
The cast and helix of the wire has a major
influence on the feedability of MIG wire.
Cast
Helix
Cast – Diameter of the circle
Helix – Vertical height

13
If the cast is too large the wire will move in an
upward direction from the tip when welding
and if too small the wire will dip down from the
tip.The result of this is excessive tip wear and
increased wear in the liners.
If the helix is too large the wire will leave the
tip with a corkscrew effect.
Selection of the Correct Power Source
Power sources for MIG welding is selected on a
number of different criteria, including:
Maximum output of the machine1
Duty cycle2
Output control (voltage selection, wire feed3
speed control)
Portability4
The following table gives an indication of the
operating amperage for different size wires.
Wire Size Amperage Range (A)
0.8 mm 60–180
0.9 mm 70–250
1.0 mm 90–280
1.2 mm 120–340
Selection of the Correct Polarity on the
Power Source
Many power sources are fitted with an optional
reverse polarity dinse connector.
To achieve the optimum welding it is important
to adhere to the consumable manufacturer's
instruction to select the polarity.
As a general rule all solid and metal cored wires
are welded on electrode positive. (Work return
lead fitted to the negative connector.)
Some grades of self shielded flux cored wires
(i.e. E71T-11, E71T-GS etc) needs to be welded
on electrode negative. (Work return lead fitted
to the positive connector.)
Selection of the Correct Shielding Gas
The selection of the shielding gas has a direct
influence on the appearance and quality of the
weldbead.
The thickness of the material to be welded will
determine the type of shielding gas that has to
be selected.As a general rule the thicker the
material (C-Mn and Alloy steels) are the higher
the percentage of CO2in the shielding gas
mixture.
Different grades of shielding are required for
materials such as stainless steel, aluminium
and copper.
The following table gives an indication of the
most common shielding gases used for Carbon
Manganese and alloy steel.
Material thickness Recommended
shielding gas
1–8 mm Argoshield Light
5–12 mm Argoshield Universal
>12 mm Argoshield Heavy
More detailed selection charts, including
recommendations for welding parameters
(voltage, amperage, electrical stickout,
travelspeed and gasflow rate) can be found in
the following pages.

14
3.0 General Welding Information
3.1 Recommended Welding Parameters
Argoshield Light Gas Code 060 (Australia) 500 (New Zealand)
Indicative Welding Parameters
Dip Transfer Spray Transfer
Material thickness (mm) 1–1.6 2 3 4 3
Welding position Horizontal /
Vertical
Horizontal /
Vertical
Horizontal /
Vertical
Horizontal /
Vertical
Horizontal
Wire diameter (mm) 0.8–0.9 0.8–0.9 0.8–0.9 0.9–1.0 0.8
Current (amps) 45–80 60–100 80–120 80–150 160–180
Voltage (volts) 14–16 16–17 16–18 16–18 23–25
Wire feed speed (m/min) 3.5–5.0 4.0–7.0 4.0–7.0 4.0–7.0 7.5–9.0
Gas rate flow (L/min) 15 15 15 15 15
Travel speed (mm/min) 350–500 350–500 320–500 280–450 800–1000
Stainshield Gas Code 075 (Australia)
Stainshield Light Gas Code 503 (New Zealand)
Indicative Welding Parameters
Dip Transfer
Material thickness (mm) 4 6 8
Welding position Horizontal / Vertical Horizontal / Vertical Horizontal / Vertical
Wire diameter (mm) 0.9–1.0 0.9–1.0 0.9–1.0
Current (amps) 100–125 120–150 120–150
Voltage (volts) 17–19 18–20 18–20
Wire feed speed (m/min) 5.0–6.5 6.0–7.5 6.0–8.0
Gas flow rate (L/min) 15 15 18
Travel speed (mm/min) 400–600 280–500 280–450

15
4.0 Correct Application Techniques
Correct Application Techniques
Direction of welding.
MIG welding with solid wires takes place
normally with a push technique.The welding
gun is tilted at an angle of 10° towards the
direction of welding. (Push technique)
10°
The influence of changing the torch angle and
the welding direction on the weld bead profile
can be seen below.
Torch perpendicular to workpiece Narrow
bead width with increased reinforcement.
10°
Torch positioned at a drag angle of 10° Narrow
bead with excessive reinforcement.
Flux cored welding with cored wires takes place
normally with the drag technique ("when there
is slag in your drag").The welding gun is tilted
at an angle of 10° away from the direction of
welding. For all other applications the gun angle
remains the same.
90° 90°
0–15°
Torch position for butt welds
When welding butt welds the torch should
be positioned within the centre of the groove
and tilted at an angle of ±15° from the vertical
plane.Welding is still performed in the push
technique.
0–15°
45°
45°
Torch position for fillet welds
When welding fillet welds the torch should be
positioned at an angle of 45° from the bottom
plate with the wire pointing into the fillet
corner.Welding is still performed in the push
technique.

16
Electrical stickout
1Gas Nozzle 6Contact Tube
2Contact Tube Setback 7Visible Stickout
3Consumable Electrode 8Arc length
4Workpiece 9Electrical Stickout
5Standoff Distance
1
2
3
5
6
7
8
9
4
The electrical stickout is the distance between
the end of the contact tip and the end of the
wire.An increase in the electrical stickout
results in an increase in the electrical resistance.
The resultant increase in temperature has
a positive influence in the melt-off rate of
the wire that will have an influence on the
weldbead profile.
Short Normal Lon
g
Short Normal Lon
g
Short Normal Lon
g
Influence of the change in electrical stickout
length on the weldbead profile.
Travel speed
Slow Normal Fast
Slow Normal Fast
Slow Normal Fast
The travel speed will have an influence on the
weldbead profile and the reinforcement height.
If the travel speed is too slow a wide weldbead
with excessive rollover will result. Contrary if
the travel speed is too high a narrow weldbead
with excessive reinforcement will result.
Recommendation about travel speed are
contained in the detailed gases datasheets found
on page 14 of this manual.

17
Power source
Component Fault symptom Cause
Primary cable No or low welding output Bad or incorrect primary
connection, lost phase
Earth cable and clamp Arc will not initiate Damaged, loose or undersized
cables and clamps
Connectors and lugs Overheating of connectors
and lugs
Loose or badly crimped
connectors
Switches Erratic or no output control Switches damaged or incorrectly
set for the application
Wire feeder
Component Fault symptom Cause
Gas solenoid valve No gas flow or gas flows
continuously
Gas valve faulty or sticking in open
position
Wire feed rolls Wire slippage, wire deformation Incorrect feed roll size, incorrect
tension adjustment, misalignment
Inlet, outlet guides Wire shaving or snarling Incorrect wire guide sizes,
misalignment
Universal adaptor Wire restriction, gas leaks, no
trigger control
Universal adaptor not correctly
mounted or secured, incorrect size
of internal guide, bent contact pins
Wire feed speed control No control over wire feed speed,
no amperage control
Faulty wire speed feed
potentiometer, wire feed motor in
overload or trip condition
Wire inch switch Wire live when feeding through
cable and gun before welding
Faulty wire inch switch,
inappropriate use of gun trigger
switch
Spindle Wire spool drags or overruns Spindle brake set too tight or too
loose, spool not properly located
on spindle
5.0 Troubleshooting and Fault Finding

18
Welding gun
Component Fault symptom Cause
Type Welding gun overheats Welding gun underrated for
welding application
Liners Erratic wire feed, wire snarls up at
outlet guide
Liner of incorrect type and size
for wire in use, worn or dirty liner,
liner too long or too short
Gas distributor Inadequate gas flow, contaminated
or porous weld
Damaged or blocked distributor
Nozzle Inadequate gas cover, restricted
joint accessibility
Nozzle too large or too small,
incorrect length or shape
Contact tip Erratic feeding, wire shudder, wire
burnback, unstable arc, spatter
Incorrect size of contact tip,
incorrect contact tip to nozzle
distance for metal transfer mode,
inferior contact tip material
Nozzle insulator Arcing between contact tip and
nozzle and between nozzle and
workpiece
No nozzle insulator fitted
Regulator / flowmeter
Component Fault symptom Cause
Inlet stem No gas flow, gas leaks at regulator
body or cylinder valve
Blocked inlet stem, leaking inlet
stem to body thread, bullnose not
properly seated in cylinder case
Gas hose and fitting Leaks at connections or in the
hose, porosity in the weld
Poorly fitted “o” clips, damaged
hose, air drawn into gas stream
Shielding gas
Component Fault symptom Cause
Cylinder, MCPs No gas flow, porosity in the weld Gas cylinder closed or empty, faulty
cylinder valves
Bulk No gas flow, change in welding
conditions
Bulk tank empty, incorrectly set
mixing panel
Welding wire
Component Fault symptom Cause
Wire basket and spool Erratic wire feeding or wire
stoppages
Damaged wire basket, loose
spooling, random-wound wire
Wire Wire sticks in contact tip, erratic
feeding
Varying wire diameter, copper
flaking, surface damage
Wire Weld has excessive amount of
spatter
Wrong polarity has been selected

19
MagMate 180P
Part No. MAG180P
Input Power (V) 240 ±15% Single Phase
Frequency (Hz) 50 / 60
Rated input current (A) 20.3
Output current adjustment (A) 50–180
Output voltage adjustment (V) 14–26
Duty Cycle (%) 60
Power Factor 0.73
Efficiency (%) 80
Type of wirefeeder machine Compact
Wire speed (m / min) 2–15
Post flow (s) 1
Maximum spool size (mm) 200
Wire diameter (mm) 0.6/0.8/0.9
Housing shielding grade IP21
Insulation grade F
Suitable thickness (mm) Above 0.6
Weight (kg) 20
Dimensions (mm) 482 x 197 x 466
6.0 Machine Specifications

20
7.0 Operating Controls and Contents
1Wire Inch Switch
2PressureAdjustingKnob
3Flexible Conduit
4Torch Connector
5Conduit
6Roller
7Posititive Terminal
8Negative Terminal
9Spool Holder
10 Gas Inlet
11 Wire speed (voltage control) 14–26V
12 Fully adjustable current setting from 20–180A
13 Fully adjustable, infinitely controllable inductance
14 High/low speed adjustment. Extends the wire feed speed
capability for larger diameter wires
7.1 Machine Setup
Connect the MIG welding torch (supplied)1
to the machine by connecting the backend
to the universal fitting on the machine.
Ensure that the torch is screwed in tight.
The MagMate 180P is designed for D2002
(5 kg) spools maximum. Fit the spool onto
the spool holder and ensure that the
locating nut is replaced and tightened.
Feed the wire through the system by utilising3
the Wire Inch Switch.An inbuilt safety
override will ensure that the wire feed speed
is not excessive.
Adjust the pressure adjusting knob to ensure4
that the wire is fed evenly. Over tightening
the adjusting knob will cause undue strain on
the wire feed motor.
Select the wire speed selector switch to high5
speed for 0.6 and 0.8mm wires and at low
speed for 0.9 and 1.0mm wires.
If a solid gas-assisted wire is used, connect6
the gas hose to the gas inlet connection
situated at the back of the machine.
Using the table supplied in this manual, adjust7
the voltage and amperage depending on the
diameter of the wire.
Improved arc characteristics can be obtained
by changing the infinite variable inductance.
If welding certain grades of flux-cored wires
that require the polarity of the machine to
be changed, this can be achieved by changing
the wire positions on the positive/negative
terminals.
WARNING: When changing the polarity on
the machine, it needs to switched off and the
primary cable unplugged from the mains socket.
For solid wires, the wires and terminals are
clearly marked (red on positive terminal).
ILLUSTRATION
1
2
3
5
4
6
7
8 9 10
13
14
12
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