Migomag 315PS User manual

1
OPERATING
MANUAL FOR
MIGOMAG
CLASSIC WELDING
MACHINE
315PS
(ITEM # AAC315PS)

2
INDEX
FRONT COVER..........................................................1
INDEX..........................................................................2
INTRODUCTION.........................................................3
ASSEMBLY INSTRUCTIONS.....................................3
SETTING UP FOR OPERATION............................ 3-4
MACHINE CONTROLS...............................................4
SHEILDING GAS ........................................................5
WORK ENVIRONMENT..............................................5
OPERATION...............................................................5
SETTING UP GUN FOR WELDING ALUMINIUM......6
WELDING HINTS........................................................7
WELDING FAULTS.....................................................8
SAFETY................................................................... 8-9
SHEILDING GAS TABLE..........................................10
MACHINE BREAKDOWN.........................................11
WARRANTY..............................................................12
CONTACT DETAILS.................................................13

3
INTRODUCTION
A few minutes spent reading about your new MIGOMAG
MIG WELDING MACHINE will enable you to operate your
machine efficiently and benefit from its many features.
ASSSEMBLY INSTRUCTIONS
1. Fit the heavy-duty rubber tyred castor wheels and rear
wheels to the chassis of the welder.
2. Install the cable liner to the welding gun cable as
follows:
3. Lay the torch and liner out straight.
4. Check that the liner has no kinks in it.
5. Remove the liner positioning nut at the machine end
of the torch.
6. Remove nozzle, tip and nozzle holder if applicable.
7. Gently feed the liner down through the bicox cable
from the machine end of the torch, taking special care
not to kink it in the process. Once the liner reaches
the back of the swan neck it may be necessary to
gently twist it through.
8. With the liner now fully home, replace the liner
positioning nut. DON’T OVER TENSION. At the front
end of the torch there will now be approximately
300mm of liner protruding from the swan neck.
9. Gently stretch the liner a further 4mm and cut at the
tip of the neck with a sharp pair of cutters. The liner
will now spring back into the swan neck by 4mm.
10. Refit tip holder, tip and nozzle.
SETTING UP FOR OPERATION
1. Fit Torch To Machine
Carefully align gas connection tube and trigger
connection pins with central adaptor. Push in and tighten
the lock nut.
Open the wire feed pressure arm (FIG. 1) above the feed
roll.
Fit the feed roll to suit the diameter of wire to be used.
2. Feed Roll Changing (if required)
Remove the feed roll retaining screw. Pull off feed roll.
When replacing the feed roll, note the wire size which is
stamped on the face of the roll. The required size must
face outwards when the roll is re-fitted. Ensure that the
Woodruff Key is not lost.
Fit the feed roll and refit the retaining screw using thumb
and forefinger. DON’T OVER TIGHTEN.
3. Fit The Reel Of Welding Wire
Remove the hand nut from hub.
Place the reel of wire on hub so that the wire will be drawn
off the bottom from top of reel.
Ensure that the pin on the hub locates in the hole in the
side of the reel. Replace hub nut.
4. Overrun Adjustment
Tighten or unscrew the hub tension nut in the centre of
the wire reel hub until sufficient hub friction is achieved
to prevent overrun.
FIGURE 1.
5. Feed Roll Adjustment
Release the wire end from reel and cut off the bent wire
end, taking care that the wire does not unwind.
Remove the nozzle and contact tip from the welding
gun.
Straighten about 20cm of the wire and make sure that
the end is as blunt as possible (file off if necessary). A
sharp end could damage the cable liner and the contact
tip of the welding torch.
Ensure the wire is placed correctly on to the feed rolls.
6. Feed Roll Alignment
TOO LOW TOO HIGH CORRECT
To adjust, release the three screws holding motor drive
assembly and lower or raise to achieve correct
alignment.
Thread some wire through the feed rolls into the guide
tube and liner of the welding cable.
Close the wire feed pressure arm.
The pressure adjustment of the feed rolls must be set
so that the wire is fed evenly into the liner and light
restriction of the wire can be made without the feed rolls
slipping.
NOTE: Excessive pressure will cause flattening of
the wire, loosening of the wire coating and undue
wear of the rolls.
Switch on machine and set the wire feed speed dial on
a low setting.
Keep the cable of the welding torch straight and press
the switch on the torch until the wire end comes out of
the gooseneck. Replace the contact tip and nozzle.
7. Earth Connection
The earth connection from the welder should always be
made directly on to the piece to be welded. The contact
between the earth and the job should be as large and
as flat as possible and all rust and paint on the work
piece should be removed.
Connect the earth cable to the earth connection socket
(5). The MIGOMAG 315 Classic has two connection
sockets: (9) is for lighter welding applications
and (10) is for heavy welding applications.

4
8. Gas Flowmeter/Regulator
To fit the flowmeter/regulator to the gas cylinder, first
open the cylinder valve slightly to remove any dirt from
the valve socket and close valve.
Fit the regulator to the valve socket and hand tighten nut
with a suitable size spanner.
Back off the pressure regulator adjusting knob by turning
anti clockwise.
Fit hose tail and nut to the gas hose and hold captive with
the hose clamp, found in wire feed compartment of the
machine adjacent to the wire feed rolls.
Connect the gas hose to the regulator, open the cylinder
valve and adjust gas flow rate (see SHEILDING GAS for
flow rates).
PLUG MUST BE FITTED BY A QUALIFIED
ELECTRICIAN.
MACHINE CONTROLS
1. ON/OFF Switch
With this switch in the ON position, power is applied to
the fan and control circuits.
WARNING: THIS SWITCH DOES NOT ISOLATE
THE UNIT FROM THE MAINS ELECTRICAL SUPPLY.
2. T1 –‘ON’ TIME CONTROL for SPOT welding and
STITCH ‘ON’ time.
3. T2 –‘OFF TIME CONTROL for STITCH “OFF” time.
4. WIRE FEED SPEED (Current) CONTROL.
5. ERATH LEAD CONNECTION
6. VOLTAGE SELECTOR SWITCH Fine.
7. CENTRAL ADAPTOR
8. VOLTAGE SELECTOR SWITCH Course
9. INDUCTANCE SOCKET –Low.
10.INDUCTANCE SOCKET –High.
Welding Voltage Adjustment
The MIGOMAG 315CLASSIC welding voltage is
regulated by a 2-position switch for course control and a
6-position switch for fine control, a total of 12. Position
(8) and (6) on the front panel.
Voltage is selected to suit the thickness of the plate being
welded. (i.e.: heavier plate = higher voltage)
Warning: If the welding voltage is set too high, the
weld can burn through light guage sheet
metal. In this case the voltage should be
reduced. If set too low, the weld will have
little penetration and will just “sit on” the
plate.
Wire Feed Speed
The wire feed speed is regulated from 0-18m/min by
the potentiometer dial (4) above the voltage switch.
It is most important to select the wire feed speed in
relation to the voltage setting. The correct wire feed
speed/voltage setting is recognisable by:
1. A continuous regular ‘crackling’ sound when
welding, the characteristics of dip transfer or short-
arc welding method normally used by small/medium
sized MIG/MAG welders.
2. A correct shape weld bead not too high, or low, with
correct fusion along the edge of the weld without
undercut in the heat-affected zone.
Welding Mode Switch/Timer
Both ‘t1’ and ‘t2’ controls are used to control the welder
ON/OFF times during stitch welding and ‘t1’ is used
alone to control spot welding time (ON).
For normal continuous (trigger controlled) welding,
ensure both ‘t1’ and ‘t2’ controls are turned fully
anticlockwise to the OFF positions.
Protection Device
Protection against the effects of overheating is
provided by thermal protection devices mounted on the
transformer assembly.
In the event of overheating, power to the unit is
interupted.
The protection device automatically resets once the
unit cools.

5
SHEILDING GAS
The gas provides a shield over the weld pool to prevent
contamination from the surrounding air. The shielding
gas also contributes to arc stability, weld strength and
appearance, so care should be taken to ensure that the
correct gas type/mixture is selected for the metal being
welded. (Refer table page 10)
The gas flow rate, adjusted by the regulator, increases
with variations in welding gun diameter and should be 15
litres per minute for the MB15 welding gun to 25 litres per
minute for the MB36 welding gun with cylindrical nozzle.
Excessive gas flow rates should be avoided as they are
wasteful and, in some instances, can cause weld
porosity.
WORK ENVIRONMENT
The machine should be used indoors away from strong
draughts which may cause gas dissipation.
If the machine is to be covered, the natural cooling air
circulation must not be interrupted.
Before commencing welding, clear area of flammable
materials.
OPERATION
1. Continuous Welding
Ensure that both timer switches ‘t1’ and ‘t2’ are in the
‘OFF’position.
Set the voltage and wire feed controls to positions
suitable for welding the thickness of the material being
welded.
Welding current varies in direct relationship to wire feed
speed.
For low welding current output, the wire feed speed
control should be set at the low end of the wire feed
speed scale.
Turning the wire feed speed control knob clockwise will
result in increased wire feed speed and welding current.
Welding voltage is adjusted to match the wire feed speed
(welding current).
For welding in the low current range, set both voltage
switches to position number (1).
The MIGOMAG 315 CLASSIC model has two voltage
selection switches, a course control (8) and fine voltage
selection (6).
Progressively select higher voltage positions with
increases in wire feed speed.
Low wire feed speed settings for a given voltage will
cause a large ball to form on the end of the welding wire
and cause excessive spatter.
High wire feed speed settings for a given voltage will
cause wire stubbing.
Position the torch over the seam to be welded with the
nozzle approximately 70° to the work surface.
The nozzle to work distance should be approximately
10mm.
WARN BYSTANDERS TO SHIELD THEIR EYES.
Lower your helmet and press the welding gun trigger
switch to initiate an arc.
As the weld is deposited, push the torch from right to left
direction, slowly along the seam at a constant speed.
Using the wire feed speed control, adjust for a “crisp”
sounding arc.
2. Spot Welding
MIG spot welding is made from one side of the sheets
placed upon another so that the high welding current
penetrates through the upper sheet (max. 1.5mm) and
a part of the lower sheet.
A circular spot is produced each time the torch trigger
is pressed. The spot weld time ‘t1’ can be varied.
Select ‘spot’ welding by turning switch ‘t1’ only.
Fit spot weld nozzle to the torch.
Set voltage and wire feed speed controls to near
maximum settings and carry out test welds on scrap
materials as follows:
Position the legs of spot-welding nozzle over weld
position and depress torch trigger switch. At the
termination of the weld, check for weld penetration
(small dimple showing on underside of weld), and
adjust spot weld time for best results.
When welding sheets of unequal thickness, the thinner
sheet must be on top. Thicker sheets can be welded
together by drilling a hole in the top sheet and directing
the wire into hole –this is known as ‘plug welding’.
Spot welding requires ONLY LIGHT PRESSURE; the
sheets are pressed against each other with the legs of
the welding nozzle.
3. Stitch Welding
The wire feed output is switched on and off repeatedly.
This produces a lower heat input which is particularly
advantageous when welding thin or poor-quality
materials as well as bridging gaps.
Select ‘stitch’ welding by turning ’t1’ and ‘t2’ controls to
the halfway setting. Vary time to obtain the best results.
They do not have to be equal.
‘t1’ controls the welding or working cycle.
‘t2’ controls the pause cycle between welding.
Note: The trigger on the gun must be kept
depressed during both cycles.
Welding occurs during the working (ON) cycle; During
the pause cycle, the wire feed STOPS, and the arc will
extinguish. During the pause cycle the molten pool will
cool down. The arc will ignite again automatically at the
beginning of the following working cycle when the filler
wire makes contact with the molten pool. The welding
current is automatically switched on and off and the
shielding gas supply will remain on during the pause
cycle.
Note: Spot welding and stitch welding of
aluminium is not possible.

6
SETTING UP GUN FOR ALUMINIUM WELDING
1. The Welding Gun
Remove the liner positioning nut from the adaptor block
at the wire feed end of the gun cable, remove the gas
nozzle, contact tip holder, gas diffuser/contact tip from
the welding torch and remove existing liner if fitted.
Carefully push the teflon liner through the gun cable until
the end of the liner protrudes from the swan neck and
withdraw the liner back into the swan neck.
Replace the contact tip holder, gas diffuser/contact tip
and gently push the liner to seat it into the back of the
contact tip holder/contact tip. Replace the gas nozzle.
At the adaptor block end of the gun cable, slide the brass
nipple and ‘O’ ring over the liner until they are located in
the recess in the adaptor block and replace the liner
retaining nut.
DO NOT CUT THE TEFLON LINER YET!!!!
FIGURE 2.
2. The Welding Machine
With a pair of long nosed pliers, remove the steel inlet
guide tube from the central adaptor on the front face of
the welding machine.
With the teflon liner still protruding from the adaptor
block, feed the liner through the inlet of the central
adaptor until the adaptor block is butted against the
central adaptor. Fasten into position with adaptor block
lock nut.
Cut the liner in the shape of a ‘V’, using a sharp knife so
that it butts up to the feed rollers as pictured. (FIG 2.)
Remove the welding gun from the machine and cut the
brass support tube so that it is 3mm shorter than the
protruding teflon liner.
Slide the brass support tube over the liner and enter the
teflon liner with brass support tube fitted into the inlet in
the central adaptor, feed through until the adaptor block
is butted against the central adaptor and tighten the lock
nut.
Reduce the wire hub tension by backing off the nut in the
centre of the hub until the nut is positioned at the end of
the stud.
After confirming the wire feed roll is correct size for the
aluminium wire being used, and that the wire is fed
through the gun cable, back off the wire feed roll
pressure screw until the feed roll no longer feeds the wire
and re-tighten approximately 2 turns. Too much
pressure will deform the soft aluminium wire and cause
the wire to jamb in the contact tip. Note: To help
prevent deformation, a ‘U’ groove feed roller is a
better alternative than a ‘V’ groove feed roller.
3. Contact Tip
Aluminium welding requires a contact tip with greater
clearance than that used for steel. Special clearance
contact tips are available for welding aluminium and are
designed with an A suffix. E.g. 0.9A, 1.2A.
PARTS LIST
PART NUMBER DESCRIPTION
1260005 Teflon Liner 1.0mm
1260021 Teflon Liner 1.2mm
1290461 Brass Support Tube for Teflon Liner
1310001 Nipple for Teflon Liner
86003020 Drive Roll 0.9/1.0-1.2mm Al
1410004 Contact Tip 0.9mm Aluminium
1410006 Contact Tip 1.0mm Aluminium
1410010 Contact Tip 1.2mm Aluminium
WELDING HINTS
Gasless Wire Welding (Flux Cored)
An optional Reverse Polarity Kit is available for gasless
welding wire requiring reverse polarity. When fitted, the
flexible welding cable extending from the front panel of
the machine should be plugged into the Negative
socket and the work lead into the Positive socket for
gasless wire welding.
For solid wire welding with Shielding Gas, simply
reverse these connections.
Gasless welding wire requires lower wire feed speeds
and voltage when compared to solid wires.
To ensure a positive wire feed, knurled feed rolls
appropriate to the wire size being used should be fitted
in place of smooth feed rolls.
Wire Size mm 0.8-1.0
Feed Roll Part # 86003016
Feed Roll Type Smooth ‘V’
Wire Size mm 1.2-1.6
Feed Roll Part # 86003018
Feed Roll Type Knurled
Aluminium Welding
Select a voltage setting approx. halfway through the
low range on your machine e.g.: 3-4 of 6 or 3-4 of 12.
Set the wire feed speed to approx. 20-25 litres per
minute when welding.
Remove oxide coating from weldments with a
stainless-steel wire brush. Initiate arc and lift the torch
nozzle away from the weld pool until the nozzle/weld
distance is 12-15 times the diameter of the wire e.g.:
11-14mm for 0.9mm wire. Direction of travel should be
from right to left by pushing the gun.
ALWAYS TEST SETTINGS ON A SCRAP PIECE OF
MATERIAL FIRST.
Stainless Steel Welding
Always use a clearance size liner e.g.: 1.2mm liner for
0.9mm wire. Wire and voltage feed settings will be
similar to those used for welding mild steel; however,
the different gas will increase the arc temperature.
Set the Gas Flow Meter to approx. 20 litres per minute.
Ensure when welding that the torch nozzle is lifted
away from the weld pool until the nozzle/weld pool
distance is 12-15 times the diameter of the wire. A
clearance size contact tip may be necessary in some
situations of high torch heat e.g.: 0.9Amm tip for 0.9mm
wire or 1.2Amm tip for 1.2mm wire.

7
WELDING FAULTS
FAULT
POSSIBLE CAUSE & REMEDY
Weld deposit 'stringy' and incomplete
1. Torch moved over work piece too quickly
2. Gas mixture incorrect
Weld deposit too thick
1. Torch moved over work piece too slowly
2. Welding voltage too low
Arc unstable, excessive spatter and weld porosity
1. Torch held too far from the workpiece
2. Rust, grease or paint on workpiece
3. Insufficient shielding gas: check gas contents gauge,
regulator setting and operation of gas valve
Wire repeatedly burns back
1. Torch held too close to the workpiece
2. Intermittent break in the welding circuit caused by:
i Contact tip loose - tighten
ii Contact tip damaged –replace
iii Welding wire or liner corroded –replace wire or liner
3. Wire feed slipping cause by:
iRestriction in liner (such as kinks) or contact tip –
check and replace if necessary
ii Worn feed rolls –replace
iii Guide tube or pressure roll alignments incorrect
Burning holes in the workpiece
1. Torch moved too quickly or erratically
2. Welding volts too high
3. Wire feed speed too high
Lack of penetration
1. Torch moved too fast
2. Welding volts too low
3. Wire feed speed too low
SPOT WELDING FAULTS
FAULT
POSSIBLE CAUSE & REMEDY
Insufficient penetration
1. Spot weld time too short
2. Gap between metals to be joined too wide
3. Switch position too low
4. Welding settings too low
Holes burnt through workpiece
1. Spot weld time too long
2. Gap between metals to be joined too wide
3. Weld is too close to the edge of the material
4. Welding settings too high
Wire sticks to contact tip or workpiece at end of the
weld
1. Burn off time incorrect –expert assistance required
since burn back must be accurately timed
Wire burns back
1. Poor gas coverage
2. Burn back time incorrect

8

9
Open cylinder valve and check the
cylinder pressure (Must be greater than
10bar (150lb/in2))
Close cylinder valve
Fit gas hose to regulator and open
cylinder valve. Set flow to 15 lt/min.
Larger torch may need 20 lt/min.

10
SHEILDING GAS TABLE MIG WELDING
Metal
Gas
Remarks
Mild Steel
Aluminium
Stainless Steel
Copper, Nickel & Alloys
Argon + CO2
Argon + CO2 + Oxygen
Argon
Argo Helium
Argon + CO2 + Oxygen
Argon + Oxygen
Argon
Argon Helium
Argon controls spatter
Oxygen improves arc stability
Stable arc –sound welds
Higher heat input suitable for heavy
sections
Arc stability
Minimum spatter
Suitable for light gauges
Higher heat input
Suitable for heavy sections

11
MIGOMAG 315PS CLASSIC MACHINE BREAKDOWN & PARTS DESCRIPTION
FIG
PART NO.
DESCRIPTION
FIG
PART NO.
DESCRIPTION
2
86001079B
Left Hand Side Panel
23
86001019
Main Contactor DIL-K7-10
3
86001079A
Right Hand Side Panel
26
86001030
Fan PAPST
5
86001042B
Rear Wheel Assy
27
86001029
Fan Guard
6
86001038
Rubber Wheel Dia. 160mm
28
86002054P
Fuse 2.5AMP 30 x 6 (10pkt)
7
86001050A
Front Whhel Assy
29
86002052P
Fuse Holder 1AMP 20 x 5 (10pkt)
8
86001051
Rubber Wheel Dia. 100mm
30
86002062P
Fuse 6.3AMP 30 x 6 (10pkt)
9
86001082
Handle Support Bracket
31
86002070
Fuse Holder
10
86001085
Handle Pipe
33
P5110014
Dinse Socket 35
11
86004043
Transformer Main
34
86001097
Gas Socket
12
86001031
Thermoswitch 110C
35
86001097
Nut 3/8”
13
86004004
Choke
36
P5110015
Dinse Plug 35
14
86004015
Transformer Auxilary
37
MEC500
Earth Clamp
16
86005001
Diode IR
40
86001005
Switch ON/OFF
16
86005000
Diode 2003
41
86001046
Knob for Voltage Selector Switch
17
86005012
Heatsink M20 x 1.5
42
86001011
Switch 3 Position
18
86005012A
Heatsink M20 x 1.5 + M4
43
86001004
Switch 8 Position
19
86005013A
Heatsink Holder
44
86003080
Amphenol Adaptor Head (10pk)
20
86001031A
Thermoswitch 80C
45
86003081
Body for Amphenol Adaptor

12
WARRANTY
MIGOMAG WELDING SUPPLIES warrants NEW Migomag MIG welding machines against defects in
material or manufacture, provided machines are used within the Migomag published specification limits.
Within the limits of the warranty defective part will be replaced by a new part, or, where possible, the
defective part will be repaired free of charge.
The warranty does not compensate for damage due to improper use, neglect or normal wear.
Travelling costs, freight or postage charges are not covered by the warranty.
Warranty repairs must be carried out at the premises of Migomag Welding Supplies or its authorised
Service Repatr Agent. Repairs by unauthorised persons will void this warranty.
The warranty period is effective from the date of purchase for the following periods:
•Main Transformers & Choke 3 years
•Auxiliary Transformer & Rectifier 3 years
•AU Other Components of the Welding Machine 1 year
Welding guns, gas flowmeters and accessories are NOT included in this warranty.
Contact: [e-mail]

13
Lawvale Pty Ltd trading as:
MIGOMAG WELDING SUPPLIES
A.B.N. 50 007 120 603
THE LARGEST INDEPENDENT WELDING
EQUIPMENT SUPPLIER IN AUSTRALIA
668 Somerville Road Sunshine Victoria 3020
Phone: [phone] Fax: [phone]
63 Douro Street North Geelong Victoria 3215
Phone: [phone] Fax: [phone]
Email: [email protected].au
www.migomag.com.au