Opticon MIG 100E User manual

INVERTER WELDER
MIG 100E/135E
WELDING MACHINE
USER MANUAL

Meet a better way of welding!
For your own and other people’s safety, please read the manual carefully before
operating. And the user manual must always be available near the welding machine.
Disclaimer and Warning
Thank you for purchasing our products. The content mentioned in this article concerns
your safety and legitimate rights and responsibilities.
The final interpretation of this document belongs to our company. It will be updated
without notice.
By using this product, you are deemed to have carefully read the disclaimer and
warning, understand, approve and accept all terms and contents of this statement.
You undertake to take full responsibility for the use of this product and any
consequences it may cause. You undertake to use the Product only for proper
purposes and agree to these terms and any relevant regulations, policies and
guidelines established by our company.
Version
Version: YF-TAE-0139, A8. Released on August 10, 2022
NOTE
The pictures in this manual are for reference only. If the pictures are inconsistent
with the actual product, the actual product shall govern.

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CONTENTS
1 Safety Guidelines and Precautions..................................................................................................................... 2
2Overview.................................................................................................................................................................. 6
2.1 Product Introduction....................................................................................................................................6
2.2 Technical Specifications............................................................................................................................ 7
3Installation................................................................................................................................................................ 9
3.1 Install the Output Cable..............................................................................................................................9
3.2 Install Accessories - braces (optional).....................................................................................................9
4 Operating Functions.............................................................................................................................................10
4.1 Control Panel and label............................................................................................................................10
4.2 Input/Output Panel....................................................................................................................................11
5 Operation............................................................................................................................................................... 12
6 Environment and Problems................................................................................................................................ 13
6.1 Environment...............................................................................................................................................13
6.2 Problems During Welding........................................................................................................................14
7 Daily Maintenance and Checking...................................................................................................................... 15
8 Trouble Shooting.................................................................................................................................................. 17
Appendix A Circuit Diagram...................................................................................................................................19

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1 Safety Guidelines and Precautions
Security Definitions
It indicates that ignoring safety warnings could result in a major accident, or
even death or serious injury.
It indicates that ignoring safety warnings could result in minor injuries or
property damage.
It indicates that ignoring safety warnings could result in equipment failure or
damage.
Personal Protection Precautions
The installation, operation, maintenance and repair of the power source must be
carried out by professionals or persons with relevant knowledge and skills.
Personal protective equipment (PPE), such as protective masks, overalls,
insulating gloves and insulating shoes, should be worn when working.
Keep fire extinguishing equipment at a handy location in the workshop.
Repair or replace defective cables immediately.
Never watch the arc except through lenses of the correct shade.
Supervisors shall be provided for working in high altitude or narrow places, such as
boxes, boilers, cabins, etc.
In confined spaces, adequate ventilation and constant observation are essential.
Those who use cardiac pacemakers shall not approach the power source in use
and welding workplaces without the permission of a physician.
The power source shall not be used for pipeline thawing, battery load or
motor start-up.

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Operational Safety Guidelines
Electrical Shock
Grounded all working materials.
Never touch ‘live’ electrical parts.
Always repair or replace worn or damaged parts.
Wearing dry insulated boots, and dry leather gloves.
Disconnect power source before performing any maintenance or service.
Never change electrodes with bare hands or wet gloves.
Never cool electrode holders in water.
Never hold the electrode and holder under your arm.
Never work in moist or damp areas. If necessary, the floor near the operating table
must be covered with rubber insulation pad.
Fumes and Gases
You must always have enough ventilation in confined spaces. Be alert to thisatall
times.
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.
Keep your head out of the fumes rising from the arc.
If necessary, use forced ventilation or local exhaust to remove fumes.
Wear a respirator when natural or forced ventilation is insufficient.

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Welding sparks can cause fire or explosion
Do not carry out welding operations in degreasing, cleaning and spraying areas.
Do not weld/cut gas-filled pipes, sealing grooves (boxes) and other devices,
otherwise explosions or fires are likely to occur.
Do not weld/cut near flammable gases or devices with flammable substances,
otherwise explosion or fire may occur.
When not welded, make sure that any component in the wire circuit does not
contact the workpiece or the earth, otherwise it may cause overheating and fire.
When the welding operation is stopped, remove the electrode in the welding pliers
or cut off the welding wire in the nozzle of the torch.
Arc falsh can burn eyes and injure skin
Make sure you’re wearing a helmet or safety glasses, gloves, welding
jackets to protect yourself.
Protective barriers are set around the welding site to prevent arc or welding spatter
from injuring others.
Electric and Magnetic Fields
Those who use cardiac pacemakers shall not approach the power source in use
and welding workplaces without the permission of a physician.
It is strictly forbidden to place or wrap welded cables around the body.
Do not place the body between the welding wire and the workpiece cable. If the
welding wire cable is on the right side of the body, the workpiece cable should also
be on the right side of the body.

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Noise produced during welding can easily cause hearing loss
In order to avoid the harm of noise to you and others, please wear the prescribed
protective equipment.
Matters needing attention in hoisting
The power source with strap or hand is prohibited from using strap or hand for
lifting.
When lifting power source with lifting forklift truck, in order to prevent dumping,
please fork-fit and fix it from side.
When lifting power source with crane, the cable should be tied to the suspension
ring, and the angle between the cable and the vertical direction should not exceed
15 degrees.
When the power source with cylinder and wire feeder is hoisted, the two
equipments should be unloaded from the power supply first. When moving the
power source on the ground, it is necessary to fix the cylinder with a strap or chain
to prevent dumping and injuring people.
If the wire feeder is hoisted by lifting lugs for welding, it is necessary to ensure that
it is firm and insulated.
STOP
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
our company. To do so, will void the Equipment Warranty.
Handle
Rings

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2 Overview
2.1 Product Introduction
The welding machine applies the most advanced inversion technology in the world.
The principle of inversion is to transform the power frequency of 50Hz/60Hzintodirect
current and invert it into high frequency through high-power device, then perform
voltage-drop and commutation with the output high-power D.C power supply via Pulse
Width Modulation (PWM). Since the switch power inversion technology is adopted, the
weight and volume decrease greatly while the conversion efficiency increased by more
than 30%
The machine is self-shielded flux cored welding machine, which is equipped with
unique electronic reactor circuit, which can precisely control the short-circuiting transfer
and mixed transfer resulting in better performance than other machines. Compared
with silicon-controlled welding machine and tapped welding, our products have the
following advantages: stable wire feed rate, portable, energy-saving, electromagnetic
noise free. Besides, our products spatter less, easier arc starting, deep welding pool,
high duty cycle etc.
This equipment is synergically designed. having merits of high-efficiency; power-saving
etc. It is especially suitable for family usage and need of different metals or techniques
demand.
Thank you for choosing our products. Please feel free to propose your valuable
suggestions; we will make efforts to perfect our products and service.
The machine is mainly used in industrial fields. It will cause radio interference if used
indoors. Please take through precaution measures.

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2.2 Technical Specifications
Type
Item
MIG 100E
Power supply（V）1 phases 110V±15% 1 phases 120V±15%
Frequency（Hz）50/60 50/60
No-load voltage(V) 50 55
Rated input current(A) 21.5 20
Output current range (A) 30 - 90 30 - 120
Output voltage range (V) 15.5 - 18.5 15.5 - 20
Duty cycle 25% @80A 25% @80A
Power factor >0.7 >0.7
Efficiency(%) ≥80 ≥80
Type of the wire feeder Internal Internal
Welding-wire diameter (mm) 0.8 0.8
Insulation grade F F
Protection grade IP21S IP21S
Weight without wire roller(kg) 5.5 5.5
Dimension
(L*W*H mm)
318*135*240 318*135*240
Note: If the weight is inconsistent with the actual weight, the actual weight shall prevail.

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Type
Item
MIG 135E
Power supply（V）1phases
120V±15%
1phases
220V±15%
1 phases
230V±15%
1phases
240V±15%
Frequency（Hz）50/60 50/60 50/60 50/60
No-load voltage(V) 55 56 58 61
Rated input current(A) 21.4 14 13.4 13
Output current range (A) 45 - 90 45-90 45-100 45-100
Output voltage range (V) 16.3 - 18.5 16.3-18.5 16.3 - 19 16.3 - 19
Duty cycle 20% @90A 20% @90A 20% @ 90A 20% @ 90A
Power factor >0.7 >0.7 >0.7 >0.7
Efficiency(%) ≥80 ≥80 ≥80 ≥80
Type of the wire feeder Internal Internal Internal Internal
Welding-wire diameter
(mm) 0.8 0.8 0.8 0.8
Insulation grade F F F F
Protection grade IP21S IP21S IP21S IP21S
Weight without wire
roller(kg) 5.4 5.4 5.4 5.4
Dimension
(L*W*H mm)
318*135*240 318*135*240 318*135*240 318*135*240
Note: If the weight is inconsistent with the actual weight, the actual weight shall prevail.

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3Installation
3.1 Install the Output Cable
The machine is flux-cored welding. The torch and earth clamp are already fixed well in
the machine.
The welding equipment is equipped with power voltage compensation device.Itkeeps
the machine work normally when power voltage fluctuates ±15% of rated voltage.
When using long cable, in order to reduce voltage drop, big section cable is suggested.
If the cable is too long, it will affect the performance of arcing and other system
functions, it is suggested to use the recommended length.
3.2 Install Accessories - braces (optional)
Note: Some machines can be equipped with braces. Please refer to the following figure
for installation steps.
Braces Components Installation Procedure

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4 Operating Functions
4.1 Control Panel and label
The panel components are described in the following table.
Icons Name Description
Adjusting Knob
Used to adjust welding current.
The power source is synergically designed, After the
current is configured, the machine automatically
matches the feeding speed.
When the pointer points to “stand-by”, the power turn
off.
Abnormal Indicator When an abnormal occurs, the indicator lights up, the
abnormal is eliminated, and the indicator lights out.
Power Indicator Connect input power. When the adjusting knob is
adjusted to “1” or above, the indicator light will be on.
Fan as needed
The power source with this label has the function of fan
sleep.
For machines with this function, the fan does not work
after startup. When the internal temperature of the
machine reaches above the limit value, the fan starts to
work. When the temperature drops below the limit, the
fan stops running.
Note: This table contains all panel components of MIG series power source. If it is inconsistent with
the machine, the physical object shall prevail.
The adjustment knobs of some machines are provided with scales, and the
corresponding relationship between scales and current is shown in the table below.
Scale Current Scale Current
145-60A 680-85 A
260-65 A 785-90 A
365-70 A 890-95 A
470-75 A 995-100 A
575-80 A - -
Note: Ignore this information for machines with no scales on the adjustment knob.

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4.2 Input/Output Panel
Output Terminals
No. Name
1 Negative output terminal
2 Positive output terminal
Input Cable
The I1eff determines the input cable, correct plug and input current required for each
machine.
Note: Please check the nameplate or the section “2.2 Technical Specifications” for the value of I1eff.
The above pictures are for reference only. If they are different from the real object, the real
object shall prevail.
Max. effective supply current (I1eff)Input cable size
I1eff ≤10 A 1.5-2.5 mm2
I1eff ≤16 A 1.5-4 mm2
I1eff ≤25 A 2.5-6 mm2
I1eff ≤35 A 4-10 mm2
I1eff ≤50 A 6-16 mm2
I1eff ≤63 A 10-25 mm2
Input cable

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5Operation
Instructions of Operation Steps
Steps Description
1Connect the
power supply
After connecting the power supply, the machine is in standby state when
the pointer points to “stand-by”, and the power indicator lights on when
the pointer is adjusted to 1 or more.
2Star wire inching
The welding machine is installed with internal wire feeder. Open the side
panel, fix the wire spool to the roller in the direction that it could rotate
anticlockwise. Match the driving roller with your wire type and size. Turn
the plastic roller holder anticlockwise to take it off. Then change the
driving roller.Insert the wire through the plastic tube then into the driving
rollers and push it till the machine output connector. Lock the driving rolls
properly. As shown in the figure below.
The welding torch is installed well already, press the torch switch. In this
case the wire is pushed slowly at speed 8 m/min. Release the switch, it
stops wire inching.
Pay attention, welding wire coming out of the current contact tube may
hurt the hand, the eyes or the face.
3Set the welding
value
Adjusting knob
Turn the knob to set the current. The power source is synergically
designed, After the current is configured, the machine automatically
matches the feeding speed.
Abnormal indicator
The led is flash when over current, and light on when over heat.
4Start Welding
The machine is self-shielded flux-cored welding. Connect the earth to
the workpiece. Press the torch switch, start welding. Release it, stop
welding.

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6 Environment and Problems
6.1 Environment
Note: The power source should not be used in rain or snow environment.
The recommended external environment for welding is as follows:
Please place the power source in a horizontal position. The inclination of the power
source shall not exceed 10°.
The environment where the equipment is stored should be clean and protectedby
sand and dust.
Dust, acids, corrosive gases or substances in the surrounding air do not exceed
normal levels, except those produced by the welding process.
The environment where the equipment is stored needs to be dry. The air relative
humidity requirements are as follows:
No more than 50% at 40℃.
No more than 90% at 20℃.
The environment where the equipment is placed should not be surrounded by heat,
fire and welding spatter. The ambient temperature requirements are as follows:
During welding: -10℃~+40
℃.
During transportation and storage: -20℃~+55
℃.

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6.2 Problems During Welding
Fittings, welding materials, environment factors, supply powers maybe have something
to do with welding. User must try to improve welding environment.
No. Problems Solutions
1Arc starting is difficult and easy to
break.
1. Examine whether grounding wire clamp
contacts with the work pieces well.
2. Examine whether each joint has improper
contact.
2 Output current not to rated value
1. The deviation of power voltage from rated
value may cause that the output current
does not accord with adjusted value.
When the power voltage is lower than
rated value, the maximum output current
may be lower than rated value.
3Current is not stabilizing when
machine is being operated
This situation may relate to the following
factors:
The voltage of electric power network
changes.
Serious interference from electric power
network or other electric facilities.

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7 Daily Maintenance and Checking
Daily Maintenance
In maintenance of the unit, take into consideration the rate of use and the environment
it is used in. When the unit is used properly and serviced regularly you will avoid
unnecessary disturbances in use and production.
Check electrical connections of unit at least twice a year. Repair or replace
broken/damaged cables.
Clean oxidised connections and tighten.
Inner parts of machine should be cleaned with a vacuum cleaner and soft brush.
Avoid water or moisture in the machine, if water or moisture should be blown dry in
time, and use megohm meter to measure the insulation condition, qualified before
use.
If it is not used after welding for a long time, it should be returned to the original
packing box and placed in a dry environment without direct sunlight.
Daily Checking
WELDING TORCH
Position Checking keys Remarks
Loophole
If installment fixed, the front
distorted Causes of air hole.
Attach splash or not. Causes of burning the torch.
（can use splash-proof material ）
Electric hole
If installment fixed Causes of torch screw thread damage
Damage of its head and hole
blocked nor not Causes of unstable arc and broken arc
Wire sending
tube
Check the extended size of
the pipe
Have to be changed when less than
6mm, when the extended part too
small, the arc will be unstable.
Wire diameter and the tube
inner diameter match or not
Causes of unstable arc, please use the
suitable tube.
Partial winding and extended Causes of poor wires sending and

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WELDING TORCH
unstable arc, please change.
Block caused by dirt in the
tube, and the remains of the
wire plating lay.
Causes of poor wire sending and
unstable arc, (use kerosene to wipe or
change new one.)
Wire sending tube broken O
circle wear out
1.Pyrocondensation tube broken,
change new tube
2.Change new O circle
CABLE
Position Checking keys Remarks
Torch
cable
If torch cable over bended.
If the metal connecting point of mobile
plug loosen.
Cause poor wire sending.
Unstable arc if cable over
bended.
Output
cable
Wearing-out of the cable insulated
material.
Cable connecting head naked(insulation
damage),or loosens(the end of power
supply, and cable of main material
connecting point.)
For life security and stable
welding, adopt suitable
methods to check according to
working place.
Simple check daily
Careful and in-depth check
on fixed period
Input
cable
If the connection of power supply input,
protective equipment input and the output
end fixed or not.
If the security equipment cable reliably
connected.
If the power input end cable fixed.
If the input cable is worn out and bares the
conductor.
-
Earth
cable
If the earth cable that connects the power
supply is broken and connect tightly.
If the earth cable that connects the main
part is broken and connected tightly.
To prevent creep age and
ensure security, please make
daily check.

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8 Trouble Shooting
IMPORTANT: Only authorised repair agents with valid certifications should carry out
repairs and internal servicing.
Fault symptom Remedy
Power indicator is
not lit, no welding
output
1. Make sure the power cord is connected.
2. Check if electric wire net is working.
3. Some of heat-variable resistors(four) of power panel is damaged,
when it happens, general DC14V relay is open or connectors are
poor contact.
4. Power panel (bottom board) is damaged, DC 130V voltage cannot be
output.
(1) Silicon bridge is broken or connector of silicon bridge poor
contact.
(2) Power panel has been burned up.
(3) Check contact and insert cable from power cord to power panel
are poor contact, check contact and insert cable from power
panel to IGBT board are connected reliably.
5. Auxiliary power of control panel is in fault.
Power indicator is
lit, no welding
output
1. Check if all kinds of cables of inter-machine are in poor contact.
2. Output connector is cut off
3. Output connector is cut off or poor contacted.
4. Control circuit is broken.
Power indicator is
lit, abnormal
indicator is lit.
1. Maybe it is overheating protection, please turn off machine first, then
turn on the machine again after abnormal indicator is off.
2. Maybe it is overheating protection, wait for 2-3 minutes.
3. Maybe inverter circuit is in fault, please pull up the supply power plug

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Fault symptom Remedy
of main transformer which is on IGBT board then open the machine
again:
1) If abnormal indicator is still lit, some of fieldistor of IGBT board
are damaged, find out and replace them with same model.
2) If abnormal indicator is not lit:
a.Maybe transformer of middle board is damaged, measure
inductance volume and Q volume of main transformer by
inductance bridge. If volume is too low, please replace it.
b.Maybe secondary rectifier tube of transformer is damaged,
find out faults and replace rectifier tube with it.