Rossi Welders WLDMIG195RSSACAA User manual

User manual
WARNING! Read and understand all
safety warnings and instructions carefully
before using this machine. Failure to
follow the warnings and instructions may
result in electric shock, fire and/or serious
injury. Save this manual for future
reference.
ATTENTION! Products covered by this
manual will vary in appearance, assembly,
inclusions, description and packaging.
NOTE! This manual covers multiple styles
of product as well as options / accessories
that may not be suitable for the machine
you have purchased.

Product Manual –Rossi Welders
Index
Index ............................................................................................................................................................1
Safety...........................................................................................................................................................2
General Safety ...........................................................................................................................................12
Parts Diagram ............................................................................................................................................13
Which welder do I need?............................................................................................................................22
Types of Welding........................................................................................................................................22
ARC / Stick Welding...................................................................................................................................................................... 22
MIG Welding / Gas Metal Arc Welding (GMAW)........................................................................................................................... 23
TIG Welding / Gas Tungsten Arc Welding (GTAW) ...................................................................................................................... 23
Pulsed TIG Welding...................................................................................................................................................................... 24
Plasma Cutting.............................................................................................................................................................................. 25
Getting Started...........................................................................................................................................26
TIG welding Basics....................................................................................................................................................................... 26
ARC Welding Basics..................................................................................................................................................................... 27
Installing MIG wire ........................................................................................................................................................................ 28
Troubleshooting..........................................................................................................................................31
Arc Welding Faults........................................................................................................................................................................ 33
Travel Speed Faults...................................................................................................................................................................... 33
Current Setting Faults................................................................................................................................................................... 34
TIG Welding Faults ....................................................................................................................................................................... 35
MIG Welding Faults ...................................................................................................................................................................... 36
Plasma Cutting Faults................................................................................................................................................................... 37
Specifications.............................................................................................................................................38
Glossary.....................................................................................................................................................42
Appendix ....................................................................................................................................................43

Product Manual –Rossi Welders
Safety
Only qualified persons should install, operate, maintain, and repair this unit.
ATTENTION! This manual is provided to assist the owner of the product to understand
the functions it provides and how to prepare the equipment. This manual does not seek
to teach the user how to perform the actual task it is used for. It is strongly
recommended that a comprehensive training course on the machines use, safe
handling and operation be completed before attempting to use this machine.
It is important you read
and understand the
instruction manual
before use and keep the
manual in a safe place for
future reference.
Safety precautions must
be observed to reduce
the risk of personal injury
when operating this
machine.
It is strongly
recommended that a
comprehensive training
course on machine use,
handling and operation
be completed before
attempting to use this
machine.
IMPORTANT! Like all power
equipment this unit must be
handled carefully.
DANGER! Electric Shock can
kill.
DANGER! Exposure to fumes
and gases can damage the
lungs and respiratory system or
cause asphyxiation.
Work area safety
Keep work area clean and well lit.
Cluttered or dark areas invite
accidents. Do not operate equipment in
explosive atmospheres, such as in the
presence of flammable liquids, gases
or dust. Equipment creates sparks
which may ignite. Keep children and
bystanders away while operating
equipment.
Personal safety
Stay alert, watch what you are doing
and use common sense when
operating equipment. Do not use
equipment while you are tired or under
the influence of drugs, alcohol or
medication. A moment of inattention
while operating equipment may result
in serious personal injury. Use personal
protective equipment. Always wear eye
protection. Protective equipment such
as dust mask, non-skid safety shoes,
hard hat, or hearing protection used for
appropriate conditions will reduce
personal injuries. Ensure the
equipment is switched off before
connecting to power source, picking up
or carrying the equipment. Never carry
equipment with your finger on the
switches or trigger. Remove any
adjusting key or wrench before turning
the equipment on. Do not overreach.
Keep proper footing and balance at all
times. This enables better control of the
equipment in unexpected situations.
Dress properly. Do not wear loose
clothing or jewellery. Keep your hair
and clothing away from the work area.
Loose clothes, jewellery or long hair
can be caught in moving parts. If
devices are provided for the connection
of dust and fume extraction and
collection facilities, ensure these are
connected and properly used.
Equipment use and care
Do not force the equipment. Use the
correct equipment for your application.
The correct equipment will do the job
better and safer at the rate for which it
was designed. Do not use the
equipment if it is found to be faulty,
faulty equipment that cannot be
controlled is dangerous and must be
repaired. Disconnect the plug from the
power source before making any
adjustments, changing accessories, or
storing equipment. Such preventive
safety measures reduce the risk of
starting the equipment accidentally.
Store idle equipment out of the reach of
children and do not allow persons
unfamiliar with the equipment or these
instructions to operate the equipment.
Electrical equipment is dangerous in
the hands of untrained users. Maintain
equipment. Check for misalignment or
binding of moving parts, breakage of
parts and any other condition that may
affect the equipment’s operation. If
damaged, have the equipment repaired
before use. Many accidents are
caused by poorly maintained
equipment. Use the equipment,
accessories and tool bits etc. in
accordance with these instructions,
taking into account the working
conditions and the work to be
performed. Use of the equipment for
operations different from those
intended could result in a hazardous
situation. Keep handles dry, clean and
free from oil and grease. Slippery
handles do not allow for safe handling
and control of the tool in unexpected
situations.
Electrical Safety.
Equipment plugs must match the outlet.
Never modify the plug in any way. Do
not use any adapter plugs with earthed
(grounded) equipment. 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 semi-
automatic 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. Keep your
gloves and other protective clothing,
dry and free of oil and grease. Never
coil or loop welding cables around your
body. 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. Don’t weld while standing on a
wet surface or while standing in water.
Use AC output ONLY if required for the
welding process. If AC output is
required, use remote output control if
present on unit.
Additional safety precautions are
required when any of the following
electrically hazardous conditions are
present: in damp locations or while
wearing wet clothing; on metal

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structures such as floors, gratings, or
scaffolds; when in cramped positions
such as sitting, kneeling, or lying; or
when there is a high risk of unavoidable
or accidental contact with the work
piece or ground. For these conditions,
use the following equipment in order
presented: 1) a semiautomatic DC
constant voltage (wire) welder, 2) a DC
manual (stick) welder, or 3) an AC
welder with reduced open-circuit
voltage. In most situations, use of a
DC, constant voltage wire welder is
recommended. Do not work alone!
Disconnect input power before
installing or servicing this equipment.
Properly install, ground, and operate
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. Keep cords
dry, free of oil and grease, and
protected from hot metal and sparks.
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. Do not touch
electrode holders connected to two
welding machines at the same time
since double open-circuit voltage will
be present. 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
connect more than one electrode or
work cable to any single weld output
terminal. SIGNIFICANT DC VOLTAGE
exists in inverter welding power
sources AFTER removal of input
power. Do not abuse the cord. Never
use the cord for carrying, pulling or
unplugging the equipment. Keep cord
away from heat, oil, sharp edges or
moving parts. Damaged or entangled
cords increase the risk of electric
shock. When operating equipment
outdoors, use an extension cord
suitable for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock. If operating
equipment in a damp location is
unavoidable, use a residual current
device (RCD) protected supply. Use of
an RCD reduces the risk of electric
shock. NOTE: The term “residual
current device (RCD)” may be replaced
by the term “ground fault circuit
interrupter (GFCI)” or “earth leakage
circuit breaker (ELCB)”.
Hot Parts can burn.
Don’t touch hot parts bare handed.
Allow cooling period before working on
equipment. To handle hot parts, use
proper tools and/or wear heavy,
insulated welding gloves and clothing
to prevent burns.
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 local forced ventilation at
the arc to remove welding fumes and
gases. If ventilation is poor, wear an
approved air-supplied respirator. Read
and understand 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 watch person
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, cleaning, or
spraying operations. The heat and rays
of the arc can react with vapours 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 while wearing an air-
supplied respirator. The coatings and
any metals containing these elements
can give off toxic fumes if welded.
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 an approved welding
helmet fitted with a proper shade of
filter lenses to protect your face and
eyes from arc rays and sparks when
welding or watching. Wear approved
safety glasses with side shields under
your helmet. Use protective screens or
barriers to protect others from flash,
glare and sparks; warn others not to
watch the arc. Wear protective clothing
made from durable, flame-resistant
material (leather, heavy cotton, or 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 metal objects can cause
sparks, explosion, overheating, or fire.
Check and be sure the area is safe
before doing any welding. Remove all
flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible,
tightly cover them with approved
covers. Do not weld where flying
sparks can strike flammable material.
Protect yourself and others from flying
sparks and hot metal. 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 containers that
have held combustibles, or on closed
containers such as tanks, drums, or
pipes unless they are properly
prepared according to AS 1674.1 and
AS 1674.2 "Safety in Welding and
Allied Processes". Do not weld where
the atmosphere may contain flammable
dust, gas, or liquid vapours (such as
gasoline). 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,
sparks, and fire 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 a butane lighter or matches, from
your person before doing any welding.
After completion of work, inspect area
to ensure it is free of sparks, glowing
embers, and flames. Use only correct
fuses or circuit breakers. Do not
oversize or bypass them. Always have
a fire watcher and extinguisher nearby.
Eye Protection
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. Flying Metal or Dirt can injure
eyes.
Gas Safety
Build-up of gas can injure or kill. Shut
off compressed gas supply when not in
use. Always ventilate confined spaces
or use approved air-supplied respirator.

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Electric and Magnetic Fields
(EMP) can affect Implanted
Medical Devices.
Wearers of Pacemakers and other
Implanted Medical Devices should
keep away. Implanted Medical Device
wearers should consult their doctor and
the device manufacturer before going
near arc welding, spot welding,
gouging, plasma arc cutting, or
induction heating operations.
Ear Protection
Noise from some processes or
equipment can damage hearing. Wear
approved ear protection if noise level is
high.
Cylinders can explode if
damaged.
Compressed 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. Protect compressed gas
cylinders from excessive heat,
mechanical shocks, physical damage,
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 touch any cylinder. Never
weld on a pressurized cylinder −
explosion will result. Use only correct
compressed 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 in use or connected for use.
Use the right equipment, correct
procedures, and sufficient number of
persons to lift and move cylinders.
Refer to Australian Standard 4332-
1995 “The storage and handling of
gases in cylinders” for more detailed
guidance on the location and
construction of gas cylinder stores,
including ventilation, operational and
personnel safety and fire protection and
other emergency measures.
Fire or Explosion Safety
Do not install or place unit on, over, or
near combustible surfaces. 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 Equipment
Use lifting eye or handle 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. Keep
equipment (cables and cords) away
from moving vehicles when working
from an aerial location.
Overuse can cause Overheating
Allow cooling period; follow rated duty
cycle. Reduce current or reduce duty
cycle before starting to weld again.
Do not block or filter airflow to unit.
Flying Sparks can injure.
Wear a face shield to protect eyes and
face. Shape tungsten electrode only on
a grinder with proper guards in a safe
location wearing proper face, hand, and
body protection.
Sparks can cause fires —keep
flammables away.
Moving Parts can injure.
Keep away from moving parts. Keep
away from pinch points such as drive
rolls.
Welding Wire can injure.
Do not press gun trigger until instructed
to do so. Do not point gun toward any
part of the body, other people, or any
metal when threading welding wire.
Battery Explosion can injure.
Do not use welder to charge batteries
or jump start vehicles unless it has a
battery charging feature designed for
this purpose.
Moving Parts can injure.
Keep away from moving parts such as
fans. Keep all doors, panels, covers,
and guards closed and securely in
place. Have only qualified persons
remove doors, panels, covers, or
guards for maintenance and
troubleshooting as necessary. Reinstall
doors, panels, covers, or guards when
maintenance is finished and before
reconnecting input power.
EMF Information
Electric current flowing through any
conductor causes localized electric and
magnetic fields (EMF). Welding current
creates an EMF field around the
welding circuit and welding equipment.
EMF fields may interfere with some
medical implants, e.g. pacemakers.
Protective measures for persons
wearing medical implants have to be
taken. For example, restrict access for
passers−by or conduct individual risk
assessment for welders. All welders
should use the following procedures in
order to minimize exposure to EMF
fields from the welding circuit:
Keep cables close together by
twisting or taping them, or using a
cable cover.
Do not place your body between
welding cables. Arrange cables to
one side and away from the
operator.
Do not coil or drape cables around
your body.
Keep head and trunk as far away
from the equipment in the welding
circuit as possible.
Connect work clamp to work piece
as close to the weld as possible.
Do not work next to, sit or lean on
the welding power source.
Do not weld whilst carrying the
welding power source or wire
feeder.
Implanted Medical Device wearers
should consult their doctor and the
device manufacturer before performing
or going near arc welding, spot
welding, gouging, plasma arc cutting,
or induction heating operations. If
cleared by your doctor, then following
the above procedures is
recommended.
Service
Have your equipment serviced by a
qualified repair person using only
identical replacement parts. This will
ensure that the safety of the equipment
is maintained.
Additional Safety requirements
This appliance is not intended for use
by persons (including children) with
reduced physical, sensory or mental
capabilities, or lack of experience and
knowledge. Never allow children to
access the tool. If any non-consumable
part is damaged, it must be replaced by
the manufacturer, its service agent or
similarly qualified persons in order to
avoid a hazard. Read the instructions
carefully. Be familiar with the controls
and proper use of the equipment. Wear
eye protection. Never allow children to
access the machine. Avoid using the
equipment, while people, especially
children or pets, are nearby. Use the
equipment only in daylight or good
artificial light. Never operate the
equipment with damaged guards or
shields or without guards or shields in
place. Use only the manufacturer’s
recommended replacement parts and
accessories. Disconnect power from
the equipment before carrying out
maintenance or cleaning work. Inspect
and maintain the tool regularly. Have
the equipment repaired only by an
authorized repairer. Always ensure that
the ventilation openings are kept clear
of debris. When not in use, store the
equipment out of the reach of children.
Before using the machine and after any
impact, check for signs of wear or
damage and repair as necessary.
Maintenance
When not in use store the machine out
of the reach of children; After use,
disconnect the equipment & check for
damage; Use only manufacturers
recommended replacement parts and
accessories.

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Warnings
Read the instructions carefully. Be
familiar with the controls and proper
use of the equipment. Welding Safety
Welding and cutting are both specialist
processes, and safety should always
be the number one priority.
Arc Radiation
Arc radiation is a result of ULTRA-
VIOLET (UV) and INFRA-RED (IR)
RAYS and exposure can cause:
- Skin Cancer
- Thermal Skin Burns (severe sun
burn)
- ARC FLASH (Welders Flash) or
EYE BURN which can result in
inflammation of the cornea,
cataracts or blindness.
A welding flash can occur by indirectly
viewing the arc even for a relatively
short time, for example:
1. Unconsciously looking out the
corner of the eye
2. Looking away from the arc
(close eyes then turn away).
3. Reflections of the arc from shiny
surfaces in the welding area.
Advised Protection Required
Includes:
An approved welding helmet with
the correct filter and shade
number.
Safety glasses which will help to
refract (bend away) the UV and IR
rays away, reducing the chances
of Arc Flash.
Always wear protective full covering
clothing to shield your body from
potential burns, for example:
Overalls-flame resistant wool or
cotton.
Leather apron or jacket.
Always wear leather gloves.
Skull cap (for overhead welding).
Screen the welding zone when
welding in open spaces.

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IMPORTANT! - Machine, Fuel handling or Electrical Safety; If you are not familiar with safe operation / handling of this machine, or are in any
way unsure of any part of this products suitability or correct use for your application you should complete training conducted by a person or organisation
qualified in safe use and training related to this product.

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DANGER! Fumes and Gases are caused by the melting, vaporisation and other reactions of the consumables, base metals and
gases (where applicable) involved in the welding arc.
Some common contaminants:
Contaminant
Source
Iron Fume
Vaporisation of iron from base metal and electrode coatings.
Chromium
Stainless steel, electrode coatings, platings.
Nickel
Stainless steel, nickel-clad steel.
Zinc Fume
Vaporisation of zinc alloys, electrode coatings galvanised steel, zinc-primed steel.
Copper Fume
Vaporisation of coatings on electrode wires, sheaths on air carbon arc gouging electrodes, copper alloys.
Vanadium, Manganese, Molybdenum
Welding rods, alloying elements in steels.
Tin
Tin-coated steel, some nonferrous alloys.
Cadmium
Plating
Lead
Fluxes, coatings on electrodes, flux in wires
Carbon Monoxide
Combustion products of gas metal arc welding, air carbon arc gouging, oxyfuel flames; exhaust from car engines.
Ozone
Gas metal arc welding, air carbon arc gouging; titanium and aluminium welding in inert gas atmospheres
Nitrogen Dioxide
Gas metal arc welding; oxy fuel flame processes.
Phosgene
Welding of metal covered with chlorinated hydrocarbon solvents.
DANGER! Exposure to fumes and gases can damage the lungs and respiratory system or cause asphyxiation.

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Advised Protection Required Includes:
- Adequate ventilation.
- Keep your head out of and away from the fumes.
- Use a welding fume respirator, or an air supplied respirator (especially in confined space).
- Use a fume extraction unit/or gun.
NOTE! Welding fume fever caused by breathing fumes formed by the welding of
various metals can occur a few hours after exposure and can last several days.
Symptoms Include:
- Nausea
- Fatigue
- Fever
- Dry nose and throat
- Chills
- Metallic taste in mouth
- Weakness
- Joint and muscle pain
Note: If any of these symptoms are observed please seek professional medical
attention.
Heat, Fire & Sparks
WARNING! Heat, Fire & Sparks are caused by welding and related processes,
operators are at continual risk of burns by hot and molten metal, sparks and heat
radiated from the arc.
WARNING! Welding sparks can travel long distances and have been known to reach up to 15
metres away from the source of welding on the ground and even further when working in elevated
positions.
DANGER! Sparks can reach combustible materials and start fires, as well as burning unprotected
skin.
DANGER! Burns can result from handling hot just welded work (the most common of welding
burns) and molten weld metal (spatter) falling or spitting onto exposed skin.
Advised Protection Required Includes:
- Always wear protective clothing.
- Keep safety glasses on your head where they belong.
- Always mark just welded work with the word “HOT”.
- Know where the nearest fire extinguisher or fire hose is and how to use them.
- Remove combustible materials away from the welding area. (at least 15 metres or 50 feet
away).
- If in an elevated position, post a person on the ground as a fire-watcher.
- Never connect the earth lead to electrical circuits of pipes containing gases or flammable
liquids.

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Proper Grounding
Grounding of electrical circuits is a safety practice that is documented in various codes and standards.
A typical arc welding setup may consist of several electrical circuits. Applying and maintaining proper
grounding methods within the welding area is important to promote electrical safety in the workplace.
Associated processes such as plasma cutting will also benefit from proper grounding.
Where welding machines that use a plug on the end of a power cord, the grounding conductor
connection is made automatically when the welding machine is plugged into the receptacle. The
grounding pin of the plug makes a connection within the receptacle.
IMPORTANT! You must still earth your work piece / job.
WARNING! The use of adapters that effectively remove the grounding pin
connection at the plug is not recommended.
WARNING! Do not cut off or remove the grounding pin from the plug. All safety
benefit of the grounding conductor is lost without the connection.
Grounding the Work Piece / Job
The welding circuit consists of all conductive material through which the welding current is intended to
flow. Welding current flows through the welding machine terminals, welding cables, work piece / job
connection, gun, torch, electrode holder and work piece / job itself; the welding circuit is not
connected to ground within the welding machine, but is isolated from ground. How do we ground the
welding circuit?
The work piece / job or the metal table that the work piece / job rests upon must be grounded. We
must connect the work piece / job or work
table to a suitable ground, such as a metal
building frame. The ground connection should
be independent or separate from the welding
circuit connection.
Grounding the work piece / job has similar
benefit to grounding the welding machine
enclosure. When the work piece is grounded,
it is at the same potential as other grounded
objects in the area. In the event of insulation
failure in the arc welding machine or other
equipment, the voltage between the work
piece and ground will be limited.
WARNING! Welding Circuit Shock Hazards.
Utilising proper grounding in the welding environment is a good practice, but it does not remove all
possibility of electrical shock. The welding circuit is energised by welding voltage. A person will
receive a shock if they become the electrical path across the welding circuit. Precautions must be
taken to insulate the welder from the welding circuit. Use dry insulating gloves and other insulating
means. Also maintain insulation on weld cables, electrode holders, guns and torches to provide
protection.

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Shielding Gas Safety
This article is intended to give users some basic information about the recommended safety
procedures concerning the use of mig/tig welding shielding gases. It does not cover the use of other
gases such as Oxygen or Acetylene as those need much more careful transporting, storage and
handling procedures than shielding gases.
Cylinder identification: Welding shielding gases are commonly one of three types, argon, argon &
carbon dioxide mixes of various compositions and carbon dioxide.
Cylinders are colour coded;
- Argon cylinders are green
- Argon/co2 mix cylinders are green with a bright green shoulder
- Carbon dioxide cylinders are black with a silver/grey shoulder.
Some carbon dioxide cylinders contain a Dip tube to extract the liquid from the cylinder. The tube
runs down the centre of the cylinder and draws the liquid carbon dioxide up through the valve. These
can be identified by the white stripe down the side - they are not suitable for use with regulators.
All the three basic types of shielding gases are heavier than air and are asphyxiants so should only be
used in well-ventilated areas.
Industrial gas cylinders typically have to be tested every 10 years to ensure they are in good order
with some having a test period of 5 years.
Transporting and Handling:
- The transporting of gas cylinders is covered by the Carriage of Dangerous Goods and Use of
Transportable Pressure Receptacles Regulations.
- A 2KG fire extinguisher is required by law to be carried whenever you are transporting any
type of gas cylinder.
- Cylinders come in several sizes and fill pressures with some being filled to 300 bar (4350 psi)
so therefore they need careful handling, storage and use.
- Although not required for non-trade users, it is recommended to display a compressed gas
warning diamond on your vehicle whenever you have a cylinder on board to help the
emergency services evaluate any potential hazard in the event of an incident. Removing it
when you don't have a cylinder on board will reduce the likelihood of being stopped by the
authorities.
Basic cylinder safety advice:
- Only keep as much gas as you actually need. More cylinders = more risk
- Always wear appropriate hand and foot protection when moving or transporting cylinders.
- When transporting cylinders, always have an appropriate Material Safety Data Sheet (MSDS)
available and be familiar with the properties of the particular gas you are transporting.
- Always secure cylinders while transporting and wherever possible, transport them upright and
in an open vehicle.
- If transporting cylinders in an enclosed vehicle, always ensure you have adequate ventilation,
i.e. an open window.
- If you suspect a cylinder has developed a leak during transport, park the vehicle in a safe
place with the windows down and telephone the agent or the supplier for advice.
- If you are involved in a road accident, advise the emergency services that gas cylinders are
being carried and show them any information relating to the cylinders, e.g. the Material Safety
Data Sheet (MSDS)

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- Remove the cylinder from the vehicle at the earliest opportunity, place in the proper storage
area and secure it.
- Visually inspect the cylinder for damage to the body and the valve assembly, if there is any
sign of damage, do not use it and inform your supplier immediately.
- Before using any gas cylinder, check that the seal is intact, also check for the proper labelling
to ensure that the gas the correct one you asked for before you remove the seal.
Cylinder Use:
- Store cylinders in a well-protected, dry and well-ventilated area ensuring they do not block
entry or exit routes and are protected from physical damage from striking or falling objects
and from any potential tampering.
- Cylinders should also be stored out of direct sunlight.
- Use cylinders in the order in which they were received, i.e. first in - first out.
- Ensure the valve seat and regulator thread/seat are free from any foreign matter including
dirt, oil or grease. Remove any foreign matter by wiping with a clean, dry cloth, by using
compressed air or by briefly opening and closing the valve (known as "snifting" or "cracking").
When using compressed air or 'snifting', wear eye and ear protection and always ensure that
you point the cylinder valve or air blowgun away from yourself and others.
- Fit the regulator then open the cylinder valve slowly at arm’s length. Check for leaks using
soapy water.
- Always store cylinders in an upright position and secure with a chain or strap above the
centre of the body.
- If a cylinder key is required to open a cylinder, always leave it in place to make it easier to
close the valve after use or in an emergency. Always use the correct key, they cost no more
than a few dollars at most.
- Always close the cylinder valve after use.
- Always close the valve when the cylinder is empty to prevent air or moisture from entering the
cylinder.
Do not attempt to lift a large cylinder single-
handed.
Do not roll a cylinder horizontally to move it.
Do not carry a cylinder by the valve.
Do not leave an open cylinder unattended.
Do not leave a cylinder unsecured.
Do not leave cylinders in hot cars.
Do not force incorrect fittings onto the wrong
cylinder.
Do not disguise any damage to cylinders.
Do not attempt to refill a cylinder or decant
gas from one cylinder to another. This is
especially important with pub type CO2
cylinders; they can suffer from severe internal
corrosion due to any beer or soft drinks in the
gas line being forced into the old cylinder
when a new cylinder is connected.
Do not attempt to mix gases in a cylinder.
Do not fill a cylinder with a gas different to the
one it originally contained.
Do not remove or deface cylinder content
identification labels.
Do not tamper with cylinders in any way.
Do not attempt to repair a cylinder.
Do not repaint cylinders in a different colour to
the original.
Do not discard cylinders; return them to the
correct agent or supplier.
Do not use grease, oil or Teflon tape on the
regulator or valve thread/seat.
Do not use a co2 regulator on an argon or
argon mix cylinder unless the regulator is
specifically designed to handle the higher
pressure.
Disposal of used cylinders:
When you enter into a rental agreement, you are only purchasing the contents of the cylinder, not the
cylinder itself which always remains the property of the supplier (not the agent). Empty cylinders
should be returned to their respective suppliers. If the agent will not accept a returned cylinder, maybe
due to age, missing labels, unknown contents, damage, etc., contact the supplier for assistance. If the
supplier cannot help then it should be taken to a recycling centre for proper disposal.

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General Safety

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Parts Diagram
ATTENTION! Products covered by this manual will vary in appearance, assembly,
inclusions, description and packaging.
A Typical Metal inert gas (MIG) / Flux-cored arc welding (FCAW) and Metal-cored
Arc Welding (MCAW) setup
NOTE! The wire feed unit is shown separately for clarity. Most welders have wire feed units built into
the welder.

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Typical MMA (Stick) Welding setup
Typical TIG setup

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SUPER 200P AC/DC Welders
IMPORTANT! ARC Welding uses a negative ground (earth) connection. TIG / Plasma
Cut use a positive ground (earth).
IMPORTANT! This welder is fitted with overheating protection. If the welder overheats it
will go into protection mode and stop working with the O.C. indicator illuminated. If this
happens do not turn off the machine; leave it on so the welder’s internal fan can continue
running and cool the machine down. Once the O.C. indicator light shuts off you can
continue using your machine as normal.
ARC = Negative
Earth TIG = Positive Earth PLASMA CUTTER = Positive Earth

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1. “TIG Earth”clamp connection & “ARC rod holder”connection.
2. “Plasma Earth”Clamp.
3. DIN Socket: High frequency start control.
4. “Plasma Torch”connection.
5. “TIG Torch”connection & “ARC earth”clamp connection.
6. Post flow (Gas): The length of time the torch gas flows after the arc terminates.
7. Clean area width (Phase Balance): Applies to AC welding and sets the proportion of time the weld current is
positive, during which time the current has an "oxide penetrating" effect on the aluminium alloy weld pool surface, but
which also tends to heat up and melt the tungsten electrode rather than the weld pool. Maximum heat is delivered to
the work piece/job when the electrode is negative so this setting is used to achieve the best compromise when
welding aluminium.
8. Pulse Duty (duty cycle): The number of minutes out of a 10-minute time period an arc welding machine can be
operated at maximum rated output. An example would be 60% duty cycle at 300 amps. This would mean that at 300
amps the welding machine can be used for 6 minutes and then must be allowed to cool with the fan motor running for
4 minutes.
9. Pulse Frequency: The sequencing and controlling of the amount of current, frequency and duration of the welding
arc.
10. Arc Force: This function enables operators to tailor the shape of the volt/amp curve to better suit the different joint
configurations and electrode types.
11. Main Power On/Off Switch.
12. Voltage display: Welding voltage display when machine is working. Only shows information when welder is in use.
13. Power indicator: Displays if power supply is on or off.
14. O/C: Overheating alert indicator, this can also indicate power issues.
15. Post Flow: The length of time the torch gas flows before the arc starts.
16. Peak current (pulse) –Peak current is the nominal current for the high energy pulse. It is adjusted to a level that is
set consistently above the globular to spray transition current. Peak current is expressed in units of ampere. During
the time when the peak current is delivered, the molten droplet detaches from the electrode. An increase in peak
current increases the average welding current and the weld penetration.
17. Basic current (Amperage): The amount of electricity flowing past a point in a conductor every second. Basic current
is background current and is the low side of the pulse (1/2, 1/4 or even 1/10 of the peak current).
18. Down-Slope Time: Allows the current to decrease at whatever rate you set on the knob.
19. Pulse/No Pulse switch: For thin welding plate and up-welding etc. place the switch at PULSE position (for normal
TIG welding set at no pulse).
20. Welding Process Selection: This button selects between MMA (ARC), TIG and CUT modes.
21. AC/DC Selector Switch: Select “AC” for Aluminium and Aluminium Alloys. Select “DC” for Stainless Steel, Steel,
and Cast Iron etc.
22. 2T/4T Switch:
2T:for using a switch on the torch handle…when you plug in the foot pedal or torch amperage control, most TIG
inverters are designed to bypass the 2t and 4t settings because the amperage control overrides all the upslope and
downslope. The 2t setting pretty much turns the torch switch into a 2 position switch. Press the switch, you get an
arc, release the switch, arc goes out.
4T: The 4T position is most always used in conjunction with upslope and downslope settings.
For example;
a) Press the button and you get an arc.
b) Release the button and set the arc up-slopes to whatever the main amperage is set to.
c) Press the button and arc down-slopes to lower amperage.
d) Release the button and arc stops.
e) Some machines are different but this is the general principle of 4t operation

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TC-205 AC/DC Welders
1. Welding Process Selection: This button selects between MMA/TIG and CUT modes.
2. 2T/4T Switch:
2T:for using a switch on the torch handle…when you plug in the foot pedal or torch amperage control,
most TIG inverters are designed to bypass the 2t and 4t settings because the amperage control overrides
all the upslope and downslope. The 2t setting pretty much turns the torch switch into a 2 position switch.
Press the switch, you get an arc, release the switch, arc goes out.
4T: The 4T position is most always used in conjunction with upslope and downslope settings.
For example;
a. Press the button and you get an arc.
b. Release the button and set the arc up-slopes to whatever the main amperage is set to.
c. Press the button and arc down-slopes to lower amperage.
d. Release the button and arc stops.
e. Some machines are different but this is the general principle of 4t operation
3. AC/DC Selector Switch: Select “AC” for Aluminium and Aluminium Alloys. Select “DC” for Stainless Steel, Steel,
and Cast Iron etc.
4. Pulse selector switch; Selection of the Pulse mode switch provides pulsed welding current output.
5. Voltage display: Welding voltage display when machine is working.
6. Base Current: - Set the amount of electricity flowing past a point in a conductor every second.
7. Power indicator: Displays if power supply is on or off.
8. Pulse Current: is the nominal current for the high energy pulse. It is adjusted to a level that is set consistently above
the globular to spray transition current. Peak current is expressed in units of ampere. During the time when the peak
current is delivered, the molten droplet detaches from the electrode. An increase in peak current increases the
average welding current and the weld penetration.
9. O/C: Overheating alert indicator, this can also indicate power issues.
10. Pulse Frequency: The sequencing and controlling of the amount of current, frequency and duration of the welding
arc.
11. Post Flow: The length of time the torch gas flows after the arc terminates.
12. Down-slope: Allows the current to decrease at whatever rate you set on the knob.
13. Pulse width: The time the high pulse amperage stays on. Also known as Pule % on time.
14. AC Frequency: The A/C frequency knob allows you to weld with a much higher frequency. That option stiffens and
focuses the TIG welding arc pinpoints the heat
15. AC Balance: This knob is used to balance DCEP (reverse polarity) and DCEN (straight polarity).
16. “TIG Earth”clamp connection & “ARC rod holder”connection.
17. Remote control connection
18. Torch Control connector
19. Cut Torch Gas Outlet
20. “TIG Torch”connection & “ARC earth”clamp connection.

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MT 200 Welders
1. O/C: Overheating alert indicator, this can also indicate power issues.
2. Power indicator: Displays if power supply is on or off.
3. Welding Process Selection: This button selects between MMA/TIG and CUT modes.
4. Amperage (current) display: Welding Amperage display during welding.
5. Wire Speed / Speed: The speed at which wire is fed out of the machine.
6. Arc Force: This function enables operators to tailor the shape of the volt/amp curve to better suit the different joint
configurations and electrode types. Higher settings make more dig and a "crisper" arc. Lower makes a smoother
arc.
7. Post flow (Gas): The length of time the torch gas flows after the arc terminates.
8. Voltage Adjustment.
9. Voltage display: Welding voltage display when machine is working.
10. Torch connection.
11. NA.
12. Wire feeder spool.
13. Positive connection.
14. Negative (Earth) connection.

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WELD-MIG185E Welders
1. Current (Amperage) display: Welding Current display during welding.
2. Overheating alert: This indicator, this can also indicate power issues.
3. Welding Process Selection: This button selects between MMA and MIG.
4. Wire Speed / Speed: The speed at which wire is fed out of the machine.
5. Voltage Adjustment
6. Amperage (current) Adjustment
7. Negative (Earth) connection.
8. Positive connection.
9. Torch connection.
WELD-MIG220BZ Welders
1. Amperage (current) Adjustment
2. Wire Speed / Speed: The speed at which wire is fed out of the machine.
3. Overheating alert: This indicator, this can also indicate power issues.
4. Power indicator: Displays if power supply is on or off.
5. Slow/Quick: -
6. Welding Process Selection: This button selects between MMA and TIG.
7. Welding Process Selection: This button selects between TIG and MIG.
8. Inching: This button helps feed wire through the MIG and Torch instead of doing so by hand.
9. Negative (Earth) connection.
10. Torch connection.
11. DIN High frequency out.
12. Positive connection.