PowerShip MIG-160MI User manual

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Operating Manual
INVERTER MIG/MMA WELDER
MIG-160MI MIG-250MI

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Table of Contents
SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS…………………..3
1.1 Symbol Usage…………………………………………………………….…...3
1.2 Arc Welding Hazards…………………………………………………….…....4
1.3 Additional Symbols for Installation, operation, and Maintenance…….…........8
1.4 California Prop 65………………………………………………………….…10
1.5 Principal Safety Standards………………………………………………...….10
1.6 Eye Protection…………………………………………………………..…….11
1.7 Protective Clothing…………………………………………………..….....…13
1.8 EMF Information…………………….…………………………………...…..15
1.9 General Precautionary Label……………………………………..…….….….16
SECTION 2: INTRODUCTION AND SPECIFICATIONS…………………………….17
2.1 Equipment Identification…………………………………………….……….17
2.2 Description…………………………………………………………….……...18
2.3 Specifications…………………………………………………………….…...18
2.4 Duty Cycle…………………………………………………………….……...19
2.5 Transportation Methods………………………………………...…….………19
SECTION 3: INSTALLATION..............................................................................19
3.1 Selecting a Location…………………………………………………….…….19
3.2 Environment…………………………………………………………………..20
3.3 Electrical Input Power………………………………………………….……..20
3.4 Electromagnetic Compatibility………………………………………….…….21
3.5 Setup for Welding……………………………………………………….…….23
3.6 MIG (GMAW) Setup…………………………………………………….……23
3.7 Flux Core (FCAW) Setup………………………………………………..…….24
3.8 Changing Between Processes…………………………………………..……...24
3.9 Installing Wire Rolls …………………………………………………..………25
SECTION 4: OPERATION………………………………………………….….…27
4.1 General Operation………………………………………………………..…….27
4.2 Front Panel/ Controls……………………………………………………..……27
4.3 Selecting Wire Types……………………………………………………..…….28
4.4 Back Panel/ Gas Connector………………………………………………..…..29
4.5 Holding &Positioning Welding Gun……………………………………..…….31
SECTION 5: MAINTENANCE AND TROUBLESHOOTING………………...32
5.1 Maintenance……………………………………………………………………32
5.2 Trouble shooting………………………………………………………....…….33
5.3 System Schematic………………………………………………………..…….33
5.4 Parts List……………………………………………………………….....……35

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SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
1.1 Symbol Usage
This manual contains important information that you need to know and understand in
order to assure YOUR SAFETY and PROPER OPERATION of EQUIPMENT. The
following symbols help you recognize this information. Please read the manual and
pay attention to these sections.
Save These Important Safety Instructions!
Read and understand all of these safety instructions. Be sure to retain them
for future use.
WARNING!
WARNINGS INDICATE A CERTAINTY OR STRONG POSSIBILITY OF
PERSONAL INJURY OR DEATH IF INSTRUCTIONS ARE NOT
FOLLOWED.
CAUTION:
CAUTIONS INDICATE A POSSIBILITY OF EQUIPMENT DEMAGE IF
INSTRUCTIONS ARE NOT FOLLOWED PROPERLY.
Note:
Note give helpful information
Welding products and welding processes can cause serious injury or death, or damage
to other equipment or property, if the operator does not strictly observe all safety rules
and take precautionary actions.
Safe practices are outlined in the American National Standard Z49.1
entitled:SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end
of these safety precautions. HAVE ALL INSTALLATION, OPERATION, REPAIR
WORK, AND MAINTENANCE PERFORMED BY QULIFIED PROFESSIONALS.

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1.2 Arc Welding Hazards
The symbols shown below are used throughout this manual to call attention to and
identify possible hazards. When you see the symbol, watch out, and follow the related
instructions to avoid the hazard. The safety information given below is only a
summary of the more complete safety information found in the Safety Standards listed
in Section 1-4. Read and follow all Safety Standards.
Electric Shock can kill.
Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the
output is on. The input power circuit and machine internal circuits
are also live when power is on. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly installed
or improperly grounded equipment is a hazard.
 Do not touch live electrical parts.
 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats or covers big
enough to prevent any physical contact with the work or ground.
 Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
 Use AC output ONLY if required for the welding process.
 If AC output is required; use remote output control if present on unit.
 Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147(see Safety Standards).
 Properly install and ground this equipment according to its Owner’s Manual and
national, state, and local codes.
 Always verify the supply ground-check and be sure that input power cord ground
wire is properly connected to ground terminal in disconnect box or that cord plug
is connected to a properly grounded receptacle outlet.
 When making input connections attach proper grounding conductor
first-double-check connections.
 Frequently inspect input power cord for damage or bare wiring-replace cord
immediately if damaged-bare wiring can kill.
 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
 If earth grounding of the work-piece is required, ground it directly with a separate
cable.
 Do not touch electrode if you are in contact with the work, ground, or another
electrode from a different machine.

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 Use only well-maintained equipment. Repair or replace damaged parts at once.
Maintain unit according to manual.
 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to work-piece or worktable
as near the weld as practical.
 Insulate work clamp when not connected to work-piece to prevent contact with
any metal object.
 Do not contact more than one electrode or work cable to any single weld output
terminal.
SIGNIFICANT DC VOLTAGE exists after removal of input power
 Turn Off inverter, disconnect input power, and discharge input capacitors
according to instructions in Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases
can be hazardous to your health.
 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and /or use exhaust at the arc to remove welding
fumes and gases.
 If ventilation is poor, use an approved air-supplied respirator.
 Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals. Consumables. Coatings, cleaners, and degreasers.
 Work in a confined space only if it is well ventilated, or while wearing an
air-supplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
 Do not weld in locations near degreasing, or spraying operations. The heat and
rays of the arc can react with vapors to form highly toxic and irritating gases.
 Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel,
unless the coating is removed from the weld area, the area is well ventilated, and
if necessary, while wearing an air-supplied respirator. The coatings and any
metals containing these elements can give off toxic fumes if welded.
 Shut off shielding gas supply when not in use.

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ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet
and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
 Wear a welding helmet fitted with a proper shade of filter to protect your face and
eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety
Standards1.4).
 Wear approved safety glasses with side shields under your helmet.
 Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
 Wear protective clothing made from durable, flame-resistant
material(leather and wool) and foot protection.
Welding can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow
up. Sparks can fly off from the welding arc. The flying sparks, hot work-piece, and
hot equipment can cause fires and burns. Accidental contact of electrode to mental
objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
 Protect yourself and others from flying sparks and hot metal.
 Do not weld where flying sparks can strike flammable material.
 Removal all flammables within 35ft. (10.7m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
 Be alert that welding sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas.
 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
 Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1(see
Safety Standards).
 Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and causing
electric shock and hazards.
 Do not use welder to thaw frozen pipes.
 Remove stick electrode from holder or cut off welding wire at contact tip when
not in use.
 Wear oil-free protective garments such as leather gloves, heavy shirt, cuff less
trousers, high shoes, and a cap.
 Remove any combustibles, such as butane lighters or matches, from your person

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before doing any welding
FLYING MENTAL can injure eyes.
 Welding, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool, they can throw off
slag.
 Wear approved safety glasses with side shields even under
your welding helmet.
HOT PARTS can cause severe burns.
 Do not touch hot bare handed.
 Allow cooling period before working on gun or torch.
MAGNETIC FIELDS can affect pacemakers.
 Pacemaker wearers keep away.
 Wearers should consult their doctor before going near arc welding, gouging, or
spot welding operations.
NOISE can damage hearing.
 Excessive noise from some processes or equipment can damage
hearing.
 Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.

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 Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
 Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
 Keep cylinders away from any welding or other electrical circuits.
 Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to torch any cylinder.
 Never weld on a pressurized cylinder-explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
 Turn face away from valve outlet when opening cylinder
valve.
 Keep protective cap in place over valve except when cylinder
is use or connected for use.
 Read and follow instruction on compressed gas cylinders,
associated equipment , and CGA publication P-1listed in
Safety Standards.
1.3 Additional Symbols for Installation, Operation, and Maintenance.
FIRE OR EXPLOSION hazard.
 Do not install or place unit on, over, or near combustible surface.
 Do not install unit near flammables.
 Do not overload building wiring-be sure power supply system is properly sized,
rated, and protected to handle this unit.
FALLING UNIT can cause injury.
 Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other
accessories.
 Use equipment of adequate capacity to lift and support unit.
 If using lift forks to move unit, be sure forks are long enough to extend beyond
opposite side of unit.
OVERUSE can cause OVERHEARTING
 Allow cooling period ; follow rated duty cycle.
 Reduce current or duty cycle before starting to weld again.
 Do not block or filter airflow to unit.

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STATIC (ESD) candamage PC boards.
 Put on grounded wrist strap BEFORE handling boards or parts.
 Use proper static-proof bags and boxes to store, move, or ship
PC boards.
MOVING PARTS can cause injury.
 Keep away from moving parts.
 Keep away from pinch points such as drive rolls.
WELDING WIRE can cause injury.
 Do not press gun trigger until instructed to do so.
 Do not point gun toward any parts of the body, other people,
or any metal when threading welding wire.
MOVING PARTS can cause injury.
 Keep away from moving parts such as fans.
 Keep all doors, panels, covers, and guards closed and securely in place.
H.F RADIATION can cause interference.
 High-frequency (H.F) can interfere with radio navigation, safety services,
computers, and communications equipment.
 Have only qualified persons familiar with electronic equipment perform this
installation.

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 The user is responsible for having a qualified electrician promptly correct any
interference problem resulting from the installation.
 If notified by the FCC about interference, stop using the equipment at once.
 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep spark gaps at
correct setting, and use grounding and shielding to minimize the possibility of
interference.
ARC WELDING can cause interference.
 Electromagnetic energy can interfere with sensitive electronic equipment such as
computers and computer-driven equipment such as robot.
 Be sure all equipment in the welding area is electromagnetically compatible.
 To reduce possible interference. Keep weld cables as short as possible, close
together, and down low. such as on the floor.
 Locate welding operation 100 meters from any sensitive electronic equipment.
 Be sure this welding machine is installed and grounded according to this manual.
 If interference still occurs, the user must take extra measures such as moving the
welding machine, using shielded cables. Using line filters. or shielding the work
area.
1.4 California Proposition 65 Warning
 Welding or cutting equipment produces fumes or gases which contain chemicals
known to the state of California to cause birth defects and, in some cases,
cancer.(California Health & Safety Code Section 25249.5 et. seq.)
1.5 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from
American Welding Society, 550 N.W LeJeune Rd., Miami,
FL33126 .
Safety and Health Standards.OSHA 29 CFR 1910 ,from
Superintendent of Documents, U.S Government Printing Office, Washington, D.C
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of
Containers That Have Held Hazardous Substances. American Welding Society
Standard AWS F4.1, from American Welding Society, 550 N.W Lejeune rd. Miami,
FL33126.
National Electrical Code, NFPA Standard 70,from National Fire protection
Association, Battery march Park, Quincy, MA02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington,
VA 22202.
Code for Safety in Welding and Cutting.CSA Standard W117.2 , from Canadian
Standards Association, Standards Sales,178 Rexdale Blvd, Rexdale Ontario,