SIP HG4500 User manual

36
Ref: 020916
Please dispose of packaging for the product in a responsible man-
ner. It is suitable for recycling. Help to protect the environ-
ment, take the packaging to the local amenity tip and place into the
appropriate recycling bin.
Never dispose of electrical equipment or batteries in with your do-
mestic waste. If your supplier offers a disposal facility please use it or
alternatively use a recognised re-cycling agent. This will allow the
recycling of raw materials and help protect the environment.
FOR HELP OR ADVICE ON THIS PRODUCT PLEASE CONTACT YOUR DISTRIBUTOR,
OR SIP DIRECTLY ON:
TEL: [phone]
EMAIL: [e-mail] or techni[email protected]om
www.sip-group.com
1
Please read and fully understand the instructions in this manual
before operation. Keep this manual safe for future reference.
05776
HG4500
MIG/Arc Inverter Welder

2
35
Declaration of Conformity
We
SIP (Industrial Products) Ltd
Gelders Hall Road
Shepshed
Loughborough
Leicestershire
LE12 9NH
England
As the manufacturer's authorised representative within the EC
declare that the
HG4500 Mig/Arc Inverter Welder - SIP Part No. 05776
Conforms to the requirements of the following directive(s), as indicated.
2006/95/EC Low Voltage Directive
2004/108/EC EMC Directive
2011/65/EU RoHS Directive
Signed: …………………………………...
Mr P. Ippaso - Managing Director - SIP (Industrial Products) Ltd
Date: 23/08/2016.
And the relevant harmonised standard(s), including
DECLARATION OF CONFORMITY
EN 60974-1:2012
EN 60974-10:2007

34
NOTES.
3
CONTENTS
Page No. Description
4. Safety Symbols Used Throughout This Manual
4. Safety Instructions
11. Electrical Connection
12. Guarantee
13. Technical Specification
14. Contents and Accessories
15. Getting to Know Your Welder
17. Operating Instructions
24. Maintenance
25. Troubleshooting
26. Wiring Diagram
27. Exploded Drawing - Welding Inverter
28. Parts List
29. Exploded Drawing - WFU & Interconnections
30. Parts List
31. Exploded Drawing - MIG Torch
32. Parts List
27. Declaration of Conformity

4
SAFETY SYMBOLS USED THROUGHOUT THIS MANUAL
SAFETY INSTRUCTIONS
IMPORTANT: Please read the following instructions carefully, failure to do
so could lead to serious personal injury and / or damage to the mig weld-
er.
Danger / Caution: Indicates risk of personal injury and/or the possibility of
damage.
Warning: Risk of electrical injury or damage!
Note: Supplementary information.
When using your inverter welder, basic safety precautions should always be followed to
reduce the risk of personal injury and / or damage to the welder.
Read all of these instructions before operating the welder and save this user manual for
future reference.
The welder should not be modified or used for any application other than that for
which it was designed.
This welder was designed to supply electric current for Mig or Arc welding.
If you are unsure of its relative applications do not hesitate to contact us and we will be
more than happy to advise you.
Before each use of the welder always check no parts are broken and that no parts are
missing.
Always operate the welder safely and correctly.
KNOW YOUR WELDER: Read and understand the owner's manual and labels affixed to
the welder. Learn its applications and limitations, as well as the potential hazards specif-
ic to it.
KEEP WORK AREA CLEAN AND WELL LIT: Cluttered work benches and dark areas invite
accidents. Floors must not be slippery due to oil, water or sawdust etc.
DO NOT USE THE WELDER IN DANGEROUS ENVIRONMENTS: Do not use the welder in
damp or wet locations, or expose it to rain. Provide adequate space surrounding the
33
NOTES.

32
PARTS LIST- TORCH 05515 MB36
NOZZLES COMPONENTS
SIP
CODE
DESCRIPTION SIP
CODE
DESCRIPTION
A
09120 CONICAL SHROUD
1
09339 TIP ADAPTOR M6
3
09337 DIFFUSER BLACK
CONTACT TIPS
09115 DIFFUSER WHITE
B
09077 0.8MM CONTACT TIP M6
4
09335 SWAN NECK
09078 1.0MM CONTACT TIP M6
5
HANDLE LOCATOR
02653 1.2MM CONTACT TIP M6
6
LOCK NUT
09079 1.6MM CONTACT TIP M6
7
09341 CABLE SUPPORT
LINERS 8
09143 TRIGGER CABLE
CONNECTORS
D
06283 STEEL LINER 1.0 / 1.2MM
9
09324 HANDLE
09151 STEEL LINER 1.2 / 1.6MM
10
09332 TRIGGER
09173 TEFLON LINER
12
POWER CABLE
13
CABLE CONNECTORS
14
09144 CABLE SUPPORT
15
GUN PLUG HOUSING
16
GUN PLUG SCREW
17
09145 GUN PLUG NUT
18
TRIGGER PIN ASSEMBLY
19
09146 GUN PLUG BODY COMPLETE
20
09148 GUN PLUG O RING
21
09328 LINER NUT
5
SAFETY INSTRUCTIONS….cont
work area. Do not use in environments with a potentially explosive atmosphere.
KEEP CHILDREN AND UNTRAINED PERSONNEL AWAY FROM THE WORK AREA: All visi-
tors should be kept at a safe distance from the work area.
STORE THE WELDER SAFELY WHEN NOT IN USE: The welder should be stored in a dry
location and disconnected from the mains supply, and out of the reach of children.
USE SAFETY CLOTHING / EQUIPMENT: Use a CE approved welding mask at all times
with the correct shade of filter lens. A fume extractor should be used particularly where
there is little or no ventilation.
PROTECT YOURSELF FROM ELECTRIC SHOCK: When working with the welder, avoid
contact with any earthed items (e.g. pipes, radiators, hobs and refrigerators, etc.). It is
advisable wherever possible to use an RCD (residual current device) at the mains sock-
et.
STAY ALERT: Always watch what you are doing and use common sense. Do not operate
the welder when you are tired or under the influence of alcohol or drugs.
DISCONNECT THE WELDER FROM THE MAINS SUPPLY: When not in use and before
servicing.
AVOID UNINTENTIONAL STRIKING: Make sure the switch is in the OFF position before
connecting the welder to the mains supply.
NEVER LEAVE THE WELDER CONNECTED WHILST UNATTENDED: Turn the welder off
and disconnect it from the mains supply between jobs. Do not leave the welder con-
nected to the mains supply if no more welding is to be done.
DO NOT ABUSE THE MAINS LEAD: Never attempt to move the welder by the mains
lead or pull it to remove the plug from the mains socket. Keep the mains lead away
from heat, oil and sharp edges. If the mains lead is damaged, it must be replaced by the
manufacturer or its service agent or a similarly qualified person in order to avoid un-
wanted hazards. All extension cables must be checked at regular intervals and replaced
if damaged.
CHECK FOR DAMAGED PARTS: Before every use of the welder, any damage found
should be carefully checked to determine that it will operate correctly, safely and per-
form its intended function. Any damaged, split or missing parts that may affect its oper-
ation should be correctly repaired or replaced by an authorised service centre unless
otherwise indicated in this instruction manual.
KEEP ALL PANELS IN PLACE: Never operate the welder with the panels removed, this is
extremely dangerous.
MAINTAIN THE WELDER WITH CARE: Keep the earth clamp, mig tip & shroud clean for
the best and safest performance.
USE ONLY RECOMMENDED ACCESSORIES: Consult this user manual, your distributor or
SIP directly for recommended accessories. Follow the instructions that accompany the

6
SAFETY INSTRUCTIONS….cont
accessories. The use of improper accessories may cause hazards and will invalidate any
warranty you may have.
SECURE THE WORK-PIECE: Always use welding clamps to secure the work piece. This
frees up both hands to operate the welder correctly.
DO NOT OVERREACH: Keep proper footing and balance at all times.
USE THE RIGHT TOOL: Do not use the welder to do a job for which it was not designed.
DO NOT OPERATE THE WELDER IN EXPLOSIVE ATMOSPHERES: Do not use the welder
in the presence of flammable liquids, gases, dust or other combustible sources. Weld-
ing will create sparks which can ignite the dust or fumes.
DO NOT EXPOSE THE WELDER TO RAIN OR USE IT IN WET CONDITIONS: Water enter-
ing the welder will greatly increase the risk of electric shock and equipment damage.
HAVE YOUR WELDER REPAIRED BY A QUALIFIED PERSON: The welder is in accordance
with the relevant safety requirements. Repairs should only be carried out by qualified
persons using original spare parts, otherwise this may result in considerable danger to
the user.
 Stop operation immediately if you notice anything abnormal.
 Always disconnect the plug from the mains supply before cleaning or servicing etc.
 Be alert at all times, especially during repetitive, monotonous operations; Don't be
lulled into a false sense of security.
 Use of improper accessories may cause damage to the inverter welder and surround-
ing area as well as increasing the risk of injury.
 Do not modify the inverter welder to do tasks other than those intended.
 To avoid injury, the work-piece should never be held with bare hands; The work-
piece will become hot during normal welding operations, and stay hot for a period
after the weld is complete.
 Appropriate personal protective equipment must be worn and must be designed to
protect against all hazards created. Severe permanent injury can result from using
inappropriate or insufficient protective equipment - Eyes in particular are at risk.
 The work should be clamped firmly whilst welding, If its loose it could result in per-
sonal injury or damage to the machine or item that is being welded.
 Do not attempt any repairs to the welder unless you are a competent electrician or
engineer.
 Ensure that the machine is connected to the correct supply voltage and protected by
a fuse or circuit breaker of the recommend rating.
 Never allow the earth clamp and electrode holder to come into contact with each
other.
 Understand the operating environment; Before each use the operator should assess,
31
EXPLODED DRAWING - TORCH

30
PARTS LIST WFU 05776
Ref. No. Description Sip Part No. Ref. No. Description Sip Part No.
1. Spool Cover WE02-00357 14. Wire Feed Motor WE02-00370
2. Torch Rest WE02-00358 15 Plastic Hinge WE02-00371
3. Enclosure WE02-00359 16 Dinse socket WE02-00372
4. Potentiometer WE02-00360 17 Reel Hub Assembly WE02-00373
5. Front panel WE02-00361 18. Control Socket WE02-00374
6. Potentiometer Knob WE02-00362 19. Cable Support WE02-00375
7. Wire Feed Pot Knob WE02-00363 20. Solenoid Valve WE02-00376
8. Push Fit Water Socket WE02-00364 21. Push Fit Water Socket WE02-00377
9. Plastic Euro Surround WE02-00365 22. Control Cable WE02-00378
10. Euro Torch Socket WE02-00366 23. Gas Hose WE02-00379
11. Castor Wheel WE02-00367 24. Connecting Cable WE02-00380
12. Bottom Frame WE02-00368 25. Earth Lead Complete WE02-00381
13. Left Side Panel WE02-00369
7
SAFETY INSTRUCTIONS….cont
ELECTRIC SHOCK
FIRE
Electric inverter welders have the potential to cause a shock that could lead to injury or
death. Touching electrically ‘hot’ parts can cause fatal shocks and severe burns; While
welding, all metal components connected to the welder are electrically ‘hot’.
 Keep your body and clothing dry. Never work in a damp area without adequate
insulation against electrical shock, stay on a dry duck board, or rubber mat when
dampness or sweat can not be avoided. Sweat, sea water or moisture between
the body and an electrically ’hot’ part or grounded metal reduces the body sur-
faces electrical resistance enabling dangerous and possibly lethal currents to flow
through the body.
 Never allow live metal parts to touch bare skin or any wet clothing, be sure weld-
ing gloves are dry.
 Before welding, check for continuity; Be sure the earth clamp is connected to the
work-piece as close to the welding areas as possible. Grounds connected to
building frame work or other remote locations from the welding area reduce effi-
ciency and increase the potential electric shock hazard. Avoid the possibility of
the welding current passing through lifting chains, crane cables or other electric
paths.
During normal operation, the heat and sparks created during the welding process have
the potential to ignite flammable liquids, gases or other combustible material.
 All inflammable materials must be removed from the area.
 Have a suitable fire extinguisher available close by.
 Causes of fire and explosion include; combustibles reached by the arc, flame, fly-
ing sparks, hot slag or heated material, misuse of compressed gases and cylin-
ders and short circuits.
 Flying sparks or falling slag can pass through cracks along pipes, through win-
dows or doors and through walls or floor openings and out of sight of the opera-
tor; Sparks and slag can fly up-to 10 metres.
 Keep equipment clean and operable; Free of oil, grease and of metallic particles
(in electrical parts) that can cause short circuits.
 If combustibles are in the area. Do not weld , move the work if practical to an
area free of combustibles, avoid paint spray rooms, dip tanks, storage areas and

8
ventilators. If the work can not be moved, then move the combustibles at least
10 metres away and out of the reach of sparks and heat or protect against igni-
tion with suitable and snug fitting, fire resistant covers or shields.
 Walls touching combustibles on opposite sides should not be welded on, walls,
ceilings and the floor near the work area should be protected by heat resistant
covers or shields.
 Openings (concealed or visible) in floors or walls within 10 metres may expose
combustibles to sparks.
 Combustibles adjacent to walls, ceilings, roofs or metal partitions can be ignited
by radiant or conducted heat.
 After the work is done, check that the area is free of sparks, glowing embers and
flames.
 An empty container that has held combustibles, or that can produce flammable
or toxic vapours when heated, must never be welded, unless the container has
first been cleaned. Consult HSE INDG214, HSG250 and CS15. HSE document
CS15 includes information on cleaning by thorough steam or solvent/caustic
cleaning followed by purging and inserting with nitrogen, carbon dioxide or wa-
ter filling just below working level.
 A container with unknown contents should be treated as if it contained combus-
tibles (see previous paragraph), Do not depend on sense of smell or sight to de-
SAFETY INSTRUCTIONS….cont
The welding arc produces ultraviolet (UV) and infrared (IR) rays as well as extreme tem-
peratures that can cause injury to your eyes and skin. Do not look at the welding arc
without proper eye protection.
 The electric welding arc must not be observed with the naked eye. Always use a
welding mask; Ensure the welding mask is fitted with the correct shade of filter
lens for the welding current level, and covers the entire face from neck to the top
of the head.
 Welding gauntlet gloves should be worn to protect the hands from burns, non-
synthetic overalls with buttons at the neck and wrist, or similar clothing should
be worn. Greasy overalls should not be worn. Wear suitable protective footwear.
 Always wear correctly rated protective clothing which covers all areas of the
body; The operator should not weld with any bare skin showing to reduce the
chance of burns etc.
GLARE AND BURNS
29
EXPLODED DRAWING - WFU & INTERCONNECTIONS 05776
22
23
24
25
1

28
Ref. No. Description Sip Part No. Ref. No. Description Sip Part No.
1. Support for wire feeder WE02-00308 27. Output load small PCB WE02-00334
2. Top cover WE02-00309 28. Output busbar WE02-00335
3. Power transformer WE02-00310 29. Front panel WE02-00336
4. power filter WE02-00311 30. Plastic frame surround WE02-00337
5. Main PCB WE02-00312 31. Dinse socket WE02-00338
6. Mounting plate WE02-00313 32. Wire feed Control
socket-6 Pin WE02-00339
7. 3 Phase rectifier bridge WE02-00314 33. Potentiometer knob WE02-00340
8. Gas bottle retaining chain WE02-00315 34. Handle WE02-00341
9. Mains power cable WE02-00316 35. Control panel WE02-00342
10. Cable gland WE02-00317 36. Output reactor / choke WE02-00343
11. back pane WE02-00318 37. Inductance Filter WE02-00344
12. Leakage protection switch WE02-00319 38. left side panel WE02-00345
13. Switch bracket WE02-00320 39. Main transformer WE02-00346
14. Fan WE02-00321 40. Heatshield WE02-00347
15. Perspex Insulating Screen WE02-00322 41. Heatshield insulator WE02-00348
16. right-side plate WE02-00323 42. IGBT WE02-00349
17. Heatsink WE02-00324 43. IGBT busbar WE02-00350
18. Fast Recovery Diode WE02-00325 44. Common inductor WE02-00351
19. Output rectifier board WE02-00326 45. Wire feed PCB WE02-00352
20. Rear wheel - single WE02-00327 46. PWM PCB WE02-00353
21. Bottle carrier WE02-00328 47. Capacitor fixing panel WE02-00354
22. Heatsink bracket WE02-00329 48. Capacitor filter WE02-00355
23. Bottom WE02-00330
24. Bottom baffle plate WE02-00331
25. Swivel Castor wheel WE02-00332
26. Heatsink Insulator WE02-00333
PARTS LIST - WELDING INVERTER 05776
9
SAFETY INSTRUCTIONS….cont
 Ventilation must be adequate to remove the smoke and fumes during welding
(see the relevant safety standard for acceptable levels).
 Toxic gases may be given off when welding, especially if zinc or cadmium coated
materials are involved, welding should be carried out in a well ventilated area
and the operator should always be alert to fume build-up.
 Areas with little or no ventilation should always use a fume extractor.
 Vapours of chlorinated solvents can form the toxic gas phosgene when exposed
to U.V radiation from an electric arc. All solvents, degreasers and potential
sources of these vapours must be removed from the arc area.
 Severe discomfort, illness or death can result from fumes, vapours, heat, oxygen
enrichment or depletion that welding (or cutting) may produce. This will be pre-
vented by adequate ventilation or using a fume extractor. NEVER ventilate with
oxygen.
 Lead, cadmium, zinc, mercury, beryllium bearing and similar materials when
welded may produce harmful concentrations of toxic fumes. Adequate ventila-
tion must be provided for every person in the area. The operator should also
wear an air supplied respirator, for beryllium both must be used.
 Metals coated with or containing materials that emit toxic fumes should not be
heated unless coating is removed from the work surface. The area should be well
ventilated or the operator should wear an air supplied respirator.
 Work in a confined space only while it is being ventilated and if necessary whilst
wearing an air supplied respirator.
 Gas leaks in a confined space should be avoided, leaking gas in large quantities
can change oxygen concentration dangerously. DO NOT bring gas cylinders into
a confined space.
VENTILATION
 Avoid oily or greasy clothing, a spark may ignite them.
 Hot metal such as electrode stubs and work-pieces should never be handled
without gloves.
 First aid facilities and a qualified first aid person should be available for each shift
unless medical facilities are close by for immediate treatment of flash burns to
the eyes and skin.
 Flammable hair products should not be used by persons intending to weld.
 Warn bystanders not to watch the arc and not to expose themselves to the weld-
ing arc rays or to hot metal.

10
SAFETY INSTRUCTIONS….cont
Some metals and metal composites have the potential to be highly
toxic; always wear a face mask .
When using the welder always ensure the operator as well as those in
the area use a welding mask with the correct shade filter lens.
CAUTION: The warnings and cautions mentioned in this user manual can not
cover all possible conditions and situations that may occur. It must be under-
stood by the operator that common sense and caution are factors which cannot
be built into this product, but must be applied.
 Leaving a confined space you must shut off the gas supply at the source to pre-
vent possible accumulation of gases in the space if down stream valves are left
open. Check to be sure that the space is safe before re-entering it.
 Vapours from chlorinated solvents can be decomposed by the heat of the arc (or
flame) to form phosgene a highly toxic gas and other lung and eye-irritating
products. The ultra violet (radiant) energy of the arc can also decompose trichlo-
27
EXPLODED DRAWING 05776
1
20
2

26
WIRING DIAGRAM 05776
11
ELECTRICAL CONNECTION
WARNING! It is the responsibility of the owner and the operator to read, understand
and comply with the following:
You must check all electrical products, before use, to ensure that they are safe.
You must inspect power cables, plugs, sockets and any other connectors for wear or
damage.
You must ensure that the risk of electric shock is minimised by the installation of ap-
propriate safety devices; A residual current circuit Breaker (RCCB) should be incorpo-
rated in the main distribution board. We also recommend that a residual current device
(RCD) is used. It is particularly important to use an RCD with portable products that are
05776 HG4500 (3 PHASE):
Warning: Never connect phase wires to the earth terminal. Only fit an
approved plug and the correct rated fuse. If in doubt consult a qualified
Note: Always make sure the electrical supply is of the correct voltage and
the correct fuse protection is used.
Connecting to the power supply:
The 05776 HG4500 inverter welder is supplied without a plug fitted, it must NOT be
connected to a 230V single phase supply; It requires a 400v 50hz 3 phase supply. Be-
fore using the welder, inspect the mains lead and plug (where applicable) to ensure
that neither are damaged. If any damage is visible have the welder inspected / repaired
by a suitably qualified person.
The wires for the plug / connection are coloured in the following way:
Yellow / green Earth
Brown Phase
Black Phase
Grey Phase

12
ELECTRICAL CONNECTION….cont
Note: If an extension lead is required in order to reach the electrical supply;
ensure that this too is rated for the correct voltage and fuse rating.
Guarantee:
This SIP inverter welder is covered by a 24 month parts and labour warranty covering
failure due to manufacturers defects. This does not cover failure due to misuse or oper-
ating the welder outside the scope of this manual - any claims deemed to be outside
the scope of the warranty may be subject to charges Including, but not limited to parts,
labour and carriage costs.
Failure to regularly clean your welder will shorten its working life and reduce perfor-
mance. The warranty does not cover consumable items such as tips, shrouds & clamps
GUARANTEE
Note: Proof of purchase will be required before any warranty can be hon-
oured.
25
TROUBLESHOOTING
Note: If none of the above solutions work then contact your local distribu-
tor for repair, or contact SIP technical for more advise.

24
MAINTENANCE
 Clear dust from the machine at regular intervals, if used in a dirty environment
the machine should be cleaned once a month.
 Check all connections are clean and tight, if there is any oxidization clean the
connection with a mild abrasive or wire brush.
 Check all cable for damaged or degradation to the insulation, replace if any
found.
 Check earth clamp condition ensure they clamp tightly, replace if damaged or
loose.
 If the machine is not to be used for a long time, store it in the original packing a
dry place.
 Mig tip and shroud must be cleaned frequently to removes spatter.
 Replace the torch Mig tip regularly good electrical contact between the tip and
wire is essential.
REPLACING THE LINER
 Remove the liner nut from the torch.
 Pull the old liner completely out.
 Hold the torch as straight as possible.
 Push the new liner back through the torch.
 Re-fit the liner nut.
Liner nut
Liner
13
TECHNICAL SPECIFICATION
Model SIP HG4500 (3 phase)
Input Voltage 400V ~ 50Hz
Input Current 20A
Output Current - MIG 40A - 350A
Output Voltage - MIG 16.0V - 31.5V
Output Current - ARC 30A - 350A
Output Voltage - ARC 21.6V - 34V
Wire Diameter 0.8mm - 1.6mm
Wire Spool Size 5Kg - 15Kg
Wire Type Solid / Flux cored
Duty Cycle @ 20°C
350 amps @ 80% - MIG
350 amps @ 80% - Arc
271 amps @100% - MIG
271 amps @100% - Arc
Duty Cycle @ 40°C
350 amps @ 60% - MIG
350 amps @ 60% - Arc
271 amps @ 100% - MIG
271 amps @ 100% - Arc
Insulation Class H
Protection IP21S

14
CONTENTS AND ACCESSORIES
Note: If any of the above are missing or damaged, contact your distributor
immediately.
HG 4500 MIG/Arc Welder
1 x 4m MB36 MIG Torch c/w 1.2mm contact tip 1 x 3m earth cable with earth clamp
1 x 5m Interconnecting Harness 1 x 1.2mm contact tip; 1 x Hose clamp
1 x pair 0.8/1.0mm wire feed rollers 1 x pair 1.2/1.6mm wire feed rollers
Instruction Manual
23
OPERATING INSTRUCTIONS….cont
 Connect the electrode lead (+) and earth lead (-) to the appropriate terminal on
the front of the welder.
 Fit the required electrode securely into the electrode holder.
 Switch the welder on.
 Select the ARC welding mode, press the arrow button up on the welding selector
switch.
 Set the amperage control to match your electrode size.
Note: Be aware that the electrode is now live, simply touching any part of
the workpiece will create a spark.
 Place a welding shield / mask over your face.
 Bring the electrode into contact with the workpiece using a light stroking action,
strike the arc and withdraw to create a gap of 1.5 mm –3.0 mm.
 When the arc is created, proceed steadily in one direction keeping the gap be-
tween the electrode and the workpiece constant.
ARC WELDING
Caution: Ensure all protective equipment is worn and bystanders are not in
the vicinity.

22
OPERATING INSTRUCTIONS….cont
There are no hard and fast rules by which a particular gauge of electrode is selected,
usually this is determined by the type of welding required and the thickness of the
workpiece e.g. a butt weld in 1.5mm (1/16”) sheet metal can be done by a 1.6mm or
2.0mm electrode, the difference being that the 2.0mm electrode will do the job more
quickly.
The table below gives a guide as to which electrode is most suitable according to the
material thickness. This table is only a guide, and values given are an indication only.
Electrode Size mm Material Thickness mm Welding Current (A)
1.6 1 - 1.6 25 - 40
2.0 1.6 - 2.6 40 - 70
2.5 2.6 - 4.0 60 - 100
3.25 3.0 - 5.0 80 - 130
4.0 5.0 - 7.0 130 - 170
Note: The above is a guide only; always try a short weld test at the setting
selected. It is normal to make minor adjustments to achieve the required
weld.
The welder should be set to a specific amperage to match the electrode size (see above
table).
The amperage control is operated by rotating the output current control on the front of
the welder; Rotate the knob clockwise to increase the amperage and anti-clockwise to
reduce the amperage. Once the amperage control is set do a short weld and check for
AMPERAGE CONTROL
 Clean the area to be welded, and the earthing point of all rust, paint and con-
taminants etc.
 Place the earth clamp on to a cleaned area of the workpiece.
PREPARATION FOR WELDING
ARC WELDING
15
GETTING TO KNOW YOUR WELDER
Rear Panel
Wire Feed Unit
Wire Feed Unit Panel
Welder Front Panel
1
2
3
4
5
6
7
8
9
10
11
12 13 14
15
16
17
18
19
20
21
22
23
24
25 26
27 28

16
GETTING TO KNOW YOUR WELDER….cont
Ref. No. Description Ref. No. Description
A. Shroud E. Swan Neck
B. MIG Contact Tip F. Torch Handle
C. Tip Adaptor G. Trigger Switch
D. Gas Diffuser
Ref. Description Ref. Description
1. 4 Roll Wire Feed Unit 15. MIG / ARC Selector
2. Interconnecting Harness 16. 2T / 4T Trigger Mode
3. Inverter Welding Unit 17. Manual / Synergic Selector
4. Welding Torch 18. Gas Purge On / Off
5. Large Bottle Carrier 19. Gas Type Selector
6. Mains Lead 20. Welding Wire Size Selector
7. On / Off Switch 21. MIG Inductance Control
8. Bottle Chain 22.
ARC Force Adj in ARC / Crater Fill
Current Adj in MIG (4T ONLY)
9. Fan Cooling Inlet 23.
Welding Current Adj in ARC / Crater
Fill Volts in MIG (4T ONLY)
10. Output Current Display 24.
Welding Current Adj (Wire Feed
Speed)
11. Output Volts Display 25. Wire Feed ‘inching’ Button
12. Supply Volts Indicator 26. Welding Volts Adjustment
13. Thermal Over Load / Fault Light 27. Wire Spool Holder
14. Output Volts Indicator 28. Wire Feed Motor & Assy
MIG Torch
A
G
F
F
G
A
B
C
DE
21
OPERATING INSTRUCTIONS….cont
 Clean the area to be welded, and the earthing point of all rust, paint and con-
taminants etc.
 Place the earth clamp on to a cleaned area of the work piece.
PREPARATION FOR WELDING
 Use the main On/Off switch on the rear of the welder to turn it on.
 Select MIG symbol on the front panel.
 Select MAN.
 Select gas type; CO2 or MIX (Argon & CO2)
 Select wire size; 0.8mm, 1.0mm or 1.2mm
 Set the Weld Voltage, Wire Speed (Current Control), and the inductance by turn-
ing the appropriate controls.
 Press the torch trigger and feed the wire out a little.
 Cut the wire about 3mm from the MIG contact tip.
 Turn the gas on .
 Place a welding mask/shield over your face (not supplied).
WELDING—Manual MIG
Note: If the welder has a humming sound and a blob forms on the tip end, then you have insufficient wire
feed speed and it should be increased. If the welder has an erratic sound and the torch feels that the wire is
hitting against the work, then you have the wire feed speed to high and it should be reduced, when the wire
feed speed is correct you should get a steady crackling sound.
Note: For future reference make a note of the voltage and wire speed set-
ting for the material that has been welded.
WELDING—Synergic MIG
 Select SYN.
 Select gas type; CO2 or MIX (Argon & CO2)
 Select wire size; 0.8mm, 1.0mm or 1.2mm
 Set the Weld Voltage, Wire Speed (Current Control), and the inductance by turn-
ing the appropriate controls.
 Perform a weld test until you are happy with the welding condition selected.
There is no need to adjust the “Weld Voltage” knob again.
 By turning the “Weld Current” knob the welding power and wire feed will auto-
matically adjust together. This enables the power range to be adjusted quickly
making it versatile for jobs requiring several power settings.
 NOTE:- Adjustments CANNOT be made during welding.

20
FITTING THE GAS PIPE
Note: Be sure the wire feeds from the bottom of the spool and not from the
top.
Note: In order to use gas you will need to purchase gas, gas hose fitting and
a gas regulator suitable for the type of welding required.
the guide tube (you may need to straighten the first 50mm or so of wire if it
doesn't fit in to the guide tube easily).
 Lower the tension arms and ensure the wire sits in the groove of the wire feed
roller.
 Push the pressure adjustment knobs back over the tension arms.
 Screw the pressure adjustment knob down, but not too tight as it will crush the
wire.
 Plug the welder in to the mains supply and turn it on.
 Set the mode selector switch to Mig mode.
 Lay the mig torch out as straight as possible.
OPERATING INSTRUCTIONS….cont
Caution: Ensure that no body parts are in line with the torch when the wire
comes out as the wire could be sharp.
17
OPERATING INSTRUCTIONS
MIG WELDING
Connect the torch to the welder:
 Align the 2 torch pins on the welding torch with the 2 connector holes on the euro
adaptor.
 Fit the swivel support to the welder and place the wire feed unit on the swivel point.
 Connect the 5 metre interconnecting harness to the rear of the wire feed unit and to
the front of the welder.
 Connect the earth lead dinse plug to the negative socket on the front of the welder
(-).
Fitting and connecting the Wire Feed Unit the welder:
Locking ring Euro adaptor
Torch pins
Holes

18
OPERATING INSTRUCTIONS….cont
Loading the welding wire:
 Open the door of the Wire Feed Unit and lift up the wire reel cover.
Retaining Nut
 Fit the welding wire over the spool holder so that the wire will feed from the
bottom of the roll.
 Refit the retaining nut, and secure in place by tightening it (turn anti-clockwise).
Feeding the welding wire:
Before feeding the wire, you should ensure that the correct wire feed rollers are fitted.
To check / change the roller:
Pull the pressure adjustment knob on the wire feed motor forwards so it takes
the pressure off of the tension arms, (see picture on page 20).
 Loosen and remove the roller retaining screw.
 The size of the roller should be clearly marked on the side.
 Change as required by simply pulling the roller from the roller shaft.
 To refit the roller ensure that the 2 roller drive pins line up with the 2 holes on
the roller.
19
OPERATING INSTRUCTIONS….cont
The wire can now be fed through the torch:
 Remove the shroud from the torch by rotating the shroud clockwise and pulling
at the same time.
 Remove the MIG contact tip.
 Pull both pressure adjustment knobs on the wire feed motor forwards so it takes
the pressure from the tension arms (see above, left).
 Remove the free end of the MIG wire from the side of the wire spool, trim off the
distorted end of the wire with a pair of wire cutters; Hold the wire carefully as it
will try to unwind from the spool.
 Feed the wire through the inlet guide spring, over the wire feed rollers and into
 Refit and tighten the retaining screw to secure the roller in place.
Roller Retaining Screw
Roller
Drive Pins
Inlet Guide Spring Guide Tube
Roller
Tension Arm
Pressure Adjust Knob
Pressure Adjust Knob