Strata EZIMIG 200 User manual

EZIMIG 200
OPERATING INSTRUCTIONS
MULTI-PROCESS MIG WELDER
www.strata.co.nz
230V 50HZ
SINGLE
PHASE
IGBT
INVERTER
TECHNOLOGY
DIRECT
CURRENT
OUTPUT
CONSTANT
CURRENT/
VOLTAGE
LIFT TIG
(OPTIONAL
TORCH)
SPIKE/
GENERATOR
SAFE
4 WHEEL
DRIVE WIRE
FEEDER
INTELLIGENT
PROTECTION
SYSTEM
IP23 CORROSION
& SALT SPRAY
RESISTANT

2www.strata.co.nz
EZIMIG 200
Congratulations on your new Strata product!
The Strata range from Euroquip uses latest technology design and engineering to produce
welding products that combine market leading value and features with durability. Designed
for discerning operators who seek professional results and product quality without the price
tag of a full professional setup. Design emphasis is placed on simple, functional design
and operation. Strata product is subject to stringent quality control and designed and
manufactured to NZ & Australian standards.
Common use of Strata products include:
 • LightEngineering
 • Automotive
 • Home/hobbyEngineering
 • Farming
 • IndustrialMaintenance&Repairs
Forindustrialweldingsolutions,checkouttheStratarangefromEuroquip:
www.strata.co.nz
Euroquip is a market leading provider of innovative power equipment solutions to a wide
range of industries across New Zealand and Australia. Key product categories are; welding
equipment, air compressors, power generators and cleaning equipment.
Euroquip’s slogan is ‘empowering industries’, find out more about the advantage Euroquip
brings at www.euroquip.co.nz.
Providing exceptional product support is a key component of Euroquip’s market leading
customer advantage focus. As part of this program, it is required for all products to be
registered with Euroquip to qualify for product support. Products not registered with Euroquip
are supported by a base 12 month warranty only. Spare parts and technical support will not
beavailableforanunregisteredproductoutsideofthisbasewarrantyperiod.IfaEuroquip
dealer has not already registered your product, please register it online at www.euroquip.
co.nz. To request a physical registration form, please download one at www.euroquip.co.nz
under the ‘Contact Us’ tab.

3
www.strata.co.nz
EZIMIG 200
Contents
KnowYourMachine..........................................................5
Quick Start Guide..............................................................7
Accessories & Spare Parts.................................................9
Wiring Diagram...............................................................11
Care&Maintenance.........................................................12
Welding Settings.............................................................13
Basic MIG Welding Guide..............................................14
MIGWeldingTroubleshooting........................................17
EffectsofMMAWeldingVariousMetals...........................19
BasicMMAWeldingGuide..............................................20
MMAWeldingTechniques...............................................21
OtherKnowledge&Resources........................................24
MMATroubleshooting.....................................................25
Safety..............................................................................26
Warranty........................................................................31

4www.strata.co.nz
EZIMIG 200
Ultra compact and easy to use, the EZIMIG 200 is ideal in automotive
workshops for repairs and maintenance. MIG and MMA (Stick) function
with hot start / anti-stick technology with spike protection, the EZIMIG
200 is built for rugged conditions in New Zealand workshops.
• IGBTInvertertechnologyforsmooth&stable 
welding output with increased reliability
• 4Rollgearedmetalwirefeedunitforapowerful
& smooth wire feed
• MIGwaveform(Inductance)controlgivesgreater
control of the arc and smoother welding results
• Damageresistantindustrialcasingwithfront 
panel protection
• Wireinchingandgaspurgecontrol
• Lightweight&compactdesignidealforportable
applications
• Strongenvironmentalprotectionagaintmoisture,
salt spray and corrosion
• Adjustablearcforce,automatichotstart&
anti stick control
• Dualdigitaldisplaymetersforaccuratepre-setting
and feedback of welding parameters & output
• Highquality&overspecifiedelectronic 
components for durability & reliability
• Temperature,voltageandcurrentsensorsfor 
increased reliability & safety
• Designedtoworkwithgeneratorpowersupply
and protect from power surges
• 15kg(D300)spoolcapable.
• EZIMIG 200 •
MULTI-PROCESS MIG WELDER
DIMENSIONS: WEIGHT: INPUT POWER MAX. INPUT GENERATOR OUTPUT MMA O/C DUTY STANDARDS: MMA ROD MAX WELD MIG WIRE MIG WIRE
SUPPLY: CURRENT: CAPACITY: CURRENT: VOLTAGE: CYCLE: SIZE: THICKNESS: SPOOL SIZE: SIZE:
618x240 20.5kg 230VAC15A 35A 8KVA MIG40-200A 63V MIG60%@155A EN60974-1:2012 1.6-5.0mm 10mm D200/D300 0.6-1.2
x445mm 50Hz
MMA10-160A MMA60%@140A 5kg/15kg

5
www.strata.co.nz
EZIMIG 200
*Denotes more detailed explanation of function to follow.
1. MIGWireFeedSpeed/MMA
Current Control Knob*
2. MIGVoltage/MMAArcForceAdjustmentKnob*
3. MMAModeIndicator
4. MIGModeIndicator
5. WireFeedSpeed/CurrentDisplayMeter*
6. DisplayValueIndicator-WireFeedingSpeed
7. DisplayValueIndicator-Current
8. Voltage/ArcForceDisplayMeter*
9. DisplayValueIndicator-Voltage
10.DisplayValueIndicator-ArcForce
11. PowerIndicator.LightsWhenInputPower
 ConnectedandMachineSwitchedOn.
12. Error/OverloadIndicator*
13. MigWaveControl/InductanceKnob*
14. WireInching/GasPurgeSwitch
15. Negative(-)WeldingPowerOutputConnection
Socket.
16. MigTorchPolarityChangePowerConnection
17. Positive(+)WeldingPowerOutputConnection
Socket
18. MigTorchEuroConnectSocket
Wire Feeder
19. WireFeederInletGuide
20. WireFeedTensionAdjustment(2x)
21. WireFeedTensionArm(2x)
22. WireDriceRoller(2x)
23. DriveRollerRetainer(2x)
Further Controls Explained
MIG Wire Feed Speed/ MMA
Current Control Knob
InMIGmodethisknobsetsthewirefeedingspeedin
MMAmode,setsMMAweldingcurrent
Know Your Machine 10
12
15
1
2
3
4
56
7
8911
13
14
16
17
18
19
20
21
22
23
20
MIG Voltage/ MMA Arc Force
Adjustment Knob
InMIGmodethisknobsetstheweldingvoltage.In
MMAmode,setsarcforce.
Wire Feed Speed/ Current Display Meter
InMIGmode,displayswirefeedingspeedinm/minute
prior to welding, during welding displays welding cur-
rentoutput.InMMAmode,displaysweldingcurrent.
The display meter mode is shown by the indicator
(6/7)thatislit.

6www.strata.co.nz
EZIMIG 200
Voltage/ Arc Force Display Meter
In MIG mode, displays welding voltage. In MMA
mode, displays arc force adjustment. The display me-
termodeisshownbytheindicator(9/10)thatislit.
Overload/ Error Indicator
Lightswhenovervoltage,overcurrentorelectrical
overheating(duetoexceedingdutycycle)isdetected
and protection is activated. When protection is acti-
vated, welding output will be disabled until the safety
system senses the overload has reduced sufficiently
andindicatorlampgoesout.Mayalsotriggerifma-
chine experiences an internal power circuit failure.
When protection is activated, welding output will be
disabled until the safety system senses the overload
has reduced sufficiently and indicator lamp goes out.
Mayalsotriggerifmachineexperiencesaninternal
power circuit failure.
Tips & Tricks
Duty Cycle Rating
Welding duty cycle is the percentage of actual weld-
ing time that can occur in a ten minute cycle. E.g.
20%at160amps-thismeanstheweldercanweldat
160ampsfor2minutesandthentheunitwillneedto
be rested for 8 minutes.
All duty cycle ratings are based on an ambient air
temperatureof40°Cwith50%humidity,whichisthe
internationalstandardforsucharating.Inanenvi-
ronmentwithtemperaturesexceeding40°C,theduty
cyclewillbelessthanstated.Inambienttemperature
lessthan40°C,dutycycleperformancewillbehigher.
MIG Voltage & Wire Speed Settings
The voltage control is essentially the power in the
welding arc that sets the heat. The wire speed feed
simply controls the rate at which the welding wire is
fedintotheweldpool.Foranyvoltagepositionset-
ting, there will be a specific corresponding ‘sweet
spot’ in the wire feeding speed that will give the
smoothest and most stable welding arc. The correct
wire feeding speed for a given voltage setting is af-
fected by welding wire type and size, shielding gas,
weldingmaterialand jointtype.It isrecommended
to set the welding voltage as desired and then slowly
adjust the wire speed until the arc is smooth and sta-
ble.Whenreachingthispoint,ifthepenetration/heat
inputistoomuch/notenough,adjustthevoltageset-
tingandrepeattheprocess.Iftheoperatorisnotable
to achieve a smooth and stable arc with the desired
heat input for the weld, it is likely that a change in wire
sizeand/orshieldinggastypeisrequired(assuming
allotherfactorsarecorrect).
Wave Control
ThissettingchangestheMIGwaveformtosimulate
changing the inductance of the welding circuit. In-
ductance controls the rate of the current rise and fall
astheweldingwirecontactstheworkpiece(knownas
ashortcircuit).Moreinductanceincreasestheshort
circuit time and decreases the short circuit frequency
rate. This causes a wider and more penetrating arc,
useful for thicker weld joints. Less inductance will
create a narrow more focused arc. This effect can also
be used to fine tune the arc to produce less splatter.
Wire speed, wire size and type, shielding gas will
all change the effect that the inductance setting has
ontheweldingarc.Inductancechangewillhaveno
practicaleffectonMIGspraytransferprocess(asop-
posedtoshortcircuitprocess),MMAorTIGwelding
process.
Arc Force Control
AnMMAweldingpowersourceisdesignedtopro-
duceconstantoutputcurrent(CC).Thismeanswith
different types of electrode and arc length; the weld-
ing voltage varies to keep the current constant. This
can cause instability in some welding conditions as
MMAweldingelectrodeswillhaveaminimumvoltage
they can operate with and still have a stable arc. Arc
Forcecontrolbooststheweldingpowerifitssenses
the welding voltage is getting too low. The higher the
arc force adjustment, the higher the minimum voltage
that the power source will allow. This effect will also
causetheweldingcurrenttoincrease.0isArcForce
off,10ismaximumArcForce.Thisispracticallyuse-
ful for electrode types that have a higher operating
voltage requirement or joint types that require a short
arc length such as out of position welds.

7
www.strata.co.nz
EZIMIG 200
Electrical Connection
TheEZIMIG200isdesignedtooperateona15A230V
ACpowersupply.Ifanextensioncordmustbeused,
it should be a heavy duty version with a minimum
cablecoresizeof2.5mm2.Itisrecommendedtouse
theEuroquipindustrialduty15Aextensionlead,part
number;16895.
Operating Environment
Adequate ventilation is required to provide proper
coolingfortheEZIMIG200.Ensurethatthemachine
is placed on a stable level surface where clean cool
aircaneasilyflowthroughtheunit.TheEZIMIG200
has electrical components and control circuit boards
which may be damaged by excessive dust and dirt, so
a clean operating environment is important for reli-
able product life.
Basic Operation
1. Fitting Wire Spool & Loading Wire Feeder
1.1 Open the wire compartment cover. Unthread the
wire spool retainer. Fit the wire spool to spool
holder shaft, ensuring that the wire exits the spool
towards the bottom the spool.
1.2 Set the spool brake tension by adjusting the
spool tension adjustment screw before replacing
the wire spool retainer. The spool brake tension
should be set so that the spool can rotate freely,
but does not continue to rotate once the wire feed
stops. This may need to be adjusted as the wire is
used up and the spool weight decreases.
WARNING! Excessive spool brake tension will
cause wire feeding issues and affect welding per-
formanceas wellaspremature failure/wear of
wire feed components.
1.3 Feed the wire from the spool through the wire
driveinletguide(19)intothewirefeeder.
Quick Start Guide - Welder Installation
1.4 Releasethe wirefeedtension arms(21) bypiv-
otingthewirefeedtensionadjustmentlever(20)
from the vertical to the horizontal position.
1.5 Checkthewiredriveroller(22)groovesmatchthe
selectedMIGwiretypeandsize.Thedriveroller
will have two different sized grooves; the size of the
groove in use is stamped on the side of the drive
roller.Forfluxcored‘soft’wire,suchasthatused
ingaslessMIGwelding,thedriverollergroovehas
a serrated profile (known as knurled). For solid
core‘hard’MIGwire,thedriverollergrooveused
hasa‘V’shapedprofile.ForAluminiumsolidcore
‘soft’MIGwire,thedriverollerrequiredhasa‘u’
shapedgroove.Ifnecessary,removeandchange
the drive roller by unthreading the drive roller re-
tainer(23).
1.6 Once the correct drive rollers (22) are selected
and fitted, manually feed the wire through the
wiredriveinletguide(19)throughthedriveroller
grooves and into the brass outlet wire guide tube.
Ensuring that the wire is correctly seated in the
drive roller grooves, replace the wire feed tension
arms(21)andlockthemintoplacebyrotatingthe
wirefeedtensionadjustmentlever(20)backtothe
vertical position.
Adjusting wire feed tension: this is accomplished by
windingtheknobonthetensionadjustmentlever(20).
Clockwisewillincreasetension,anti-clockwisewillde-
creasedrivetension.Idealtensionisaslittleaspossible,
while maintaining a consistent wire feed with no drive
roller slippage.
Check all other causes of excess wire feeding friction
causing slippage first, such as; incorrect/ worn drive
roller, worn/ damaged torch consumables, blocked/
damaged torch wire guide liner, before increasing wire
feed tension. There is a number scale on the tension ad-
justmentlever(20)toindicatetheadjustmentposition.
The higher the number indicated, the higher the tension
that is set.
WARNING! Before changing the feed roller or wire
spool, ensure that the mains power is switched
off.

8www.strata.co.nz
EZIMIG 200
WARNING! The use of excessive feed tension
will cause rapid and premature wear of the drive
roller,thesupportbearingandthedrivemotor/
gearbox.
1.7 Connect the MIG Torch Euro Connector to the
MIGtorch Euro connection socket(18) on the
front of the machine. Secure by firmly hand tight-
eningthethreadedcollarontheMIGTorchcon-
nector clockwise.
1.8 CheckthatthecorrectmatchingMIGwire,drive
rollers(22)andMIGtorchtiparefitted.
1.9 Connect the machine to suitable mains power us-
ing the mains input power lead. Switch the mains
power switch to ‘on’ to power up the machine.
SelecttheweldingmodebuttonsoMIGmodein-
dicator(4)islit.Adjustthewirefeedspeedcon-
trol(1)tomaximum.
1.10 Youarenowreadytofeedthewirethroughthe
torch. With the wire feeder cover open, pull the
triggeroftheMIGtorchtocheckthatthewireis
feeding smoothly through the feeder and into the
torch.
1.11 With the tip removed from the torch and the torch
laid out as straight as possible, activate the torch
trigger until the wire feeds out through the end
oftheMIGtorch.Alternatively,thewirefeeding
switchonthecontrolpanel(14)maybeusedto
activethewirefeeder.ReplacethetipontheMIG
torch and trim off any excess wire.
2. Gasless Welding Operation
2.1 Connect the earth cable quick connector to the
positiveweldingpoweroutputsocket(17).Con-
nect the earth clamp to the work piece. Contact
with the work piece must be firm contact with
clean, bare metal, with no corrosion, paint or
scale at the contact point.
2.2 ConnecttheMIGpowerconnectionlead(16)to
thenegativeweldingpoweroutputsocket(15).
Note if this connection is not made, there will be
no electrical connection to the welding torch!
2.3 Settheweldingvoltageadjustmentknob(2),wire
speed control knob (1) and wave control knob
(13)tothedesiredpositions.Youarenowready
to weld!
3. Gas Shielded Welding Operation
3.1 Connect the earth cable quick connector to the
negativeweldingpoweroutputsocket(15)Con-
nect the earth clamp to the work piece. Contact
with the work piece must be firm contact with
clean, bare metal, with no corrosion, paint or
scale at the contact point.
3.2 ConnecttheMIGpowerconnectionlead(16)to
thenegativeweldingpoweroutputsocket(17).
Note if this connection is not made, there will be
no electrical connection to the welding torch!
3.3 Assemble the female gas quick connector to the
gas line and to the regulator outlet fitting. Con-
nectthegasregulatortoagascylinder(notin-
cluded with machine) and connect the female
quick connector to the male gas inlet on the rear
of the machine. Ensure all connections are tight.
Open gas cylinder valve and adjust regulator, flow
shouldbebetween10-25l/mindependingonap-
plication.Re-checkregulatorflowpressureusing
thegastestswitch(14)asstaticgasflowsetting
may drop once gas is flowing.
3.4 Settheweldingvoltageadjustmentknob(2),wire
speed control knob (1) and wave control knob
(13)tothedesiredpositions.Youarenowready
to weld!
Note: MIG welding with aluminium provides a unique
challenge, due to the low column strength of the wire.
This causes the wire to deform more as it is pushed
through the feed mechanism and the torch wire deliv-
eryliner,greatlyincreasingfriction.BecausegoodMIG
welding results are dependent on a smooth wire feed,
certain changes must be made to the wire feed system
to minimise friction caused issues.
Forastandard‘push’fedtorch, alengthofnolonger
than 3m cable may be used, as well as the torch feed
liner must be changed to a special Teflon/ PVC liner,
rather than the conventional steel liner. Also the correct

9
www.strata.co.nz
EZIMIG 200
style drive roller must be used and specific Aluminium
ratedtorchcontacttip(orastandardtipinonesizeover-
size,e.g.0.8mmaluminiumwire,usestandard1.0mm
contacttip).Forthisreason,itisquitecommonforop-
eratorstohaveanextraMIGtorchspecificallysetupfor
aluminium use, if the machine is used for welding steel
as well.
Withtheheavyduty4rollgearedwirefeeder,theEzi-
Mig200 willhave amore steadyand consistentwire
feed when ‘push’ feeding soft wire, than other machines
with standard 2 roll wire feed units. Another option to
overcome the friction issues is using a spool gun, which
will give better results than a 3m push torch when weld-
ing aluminium. Spool gun option is only available on the
StrataAdvanceMigseries.
4. ARC/ MMA Welding Operation
4.1 Connecttheearthcablequickconnector tothe
negativeweldingpoweroutputsocket(15)Con-
nect the earth clamp to the work piece. Contact
with the work piece must be firm contact with
clean, bare metal, with no corrosion, paint or
scale at the contact point.
4.2 Insertanelectrodeintotheelectrodeholderand
connect the electrode holder and work lead to the
positiveweldingpoweroutputsocket(17).
Note: This polarity connection configuration is valid for
mostGP(GeneralPurpose)MMAelectrodes.Thereare
variancestothis.Ifindoubt,checktheelectrodespecifi-
cations or consult the electrode manufacturer.
4.3 Connectthemachinetosuitablemainspowerus-
ing the mains input power lead. Switch the mains
power switch to ‘on’ to power up the machine.
SettheweldingmodetoMMA(3).
4.4 Select the required output current (1) and arc
force(2).Youarenowreadytoweld!
Accessories & Spare Parts
Binzel MT250 MIG Torch Range Parts
1. MSS2557 ShroudSpring
2. MSN2554 SwanNeckAssembly
5. UG8015 HandleCableSupportC/WBallJoint
9. B2514 ErgoHandleKitC/WLockNut
10. UG2516 Medium/LargeErgoTrigger
19. MOR1596 GunPlug‘O’Ring
20. MLN1597 LinerNut
AllproductsconformtoEN60974-7andareRoHS,REACHandWEEEcompliant

10 www.strata.co.nz
EZIMIG 200
EZIMIG 200 Consumables:
AAL3550 ArcLead16mm2Cable,35-70mmplug,4m
AEL3550 EarthLead16mm2Cable,35-70mmplug,3m
17512 15kg-5kgSpoolSpacer
17384 StrataCompactWeldingMachineTrolley
16895 15mH/D15AExtensionLead(3x2.5mm2wiring)
DW3000 AutoDarkeningHelmet,Shade9-13
DW4000 AutoDarkeningHelmet,Shade9-13
 withGrindingVisor
GR101AR ArgonTwinGaugeRegulator
GR101CO2 CO2TwinGaugeRegulator
GADAR ArgonCylindertoCO2RegulatorAdaptorM/M
GADCO2 CO2CylindertoArgonRegulatorAdaptor,
 F/MtoF/M,inc.NylonWasher
GR119 CO²GasRegulatorHeated220volt
MT250-4E MB25MigTorch4m(Euro)
MT250-3E MB25MigTorch3m(Euro)
MT250-5E MB25MigTorch5m(Euro)
MMT2406 MigTip0.6mm(5pk)
MMT2408 MigTip0.8mm(5pk)
MMT2409 MigTip0.9mm(5pk)
MMT2410 MigTip1.0/0.8mmAlum(5pk)
MMT2412 MigTip1.2/1.0mmAlum(5pk)
MTA2581 TipAdaptorM6tips(2pk)
MCN2570 NozzleConical(2pk)
MSS2557 ShroudSpring(2pk)
MSN2554 SwanNeck
MSL1539 SteelLiner0.6-0.9mm3m
MSL1549 SteelLiner0.6-0.9mm4m
MSL1559 SteelLiner0.6x0.9mmx5m
MTL1538T TeflonLiner0.6-0.8mmx3m
MSL2432 SteelLiner1.0-1.2mmx3m
MSL2442 SteelLiner1.0-1.2mmx4m
MSL2452 SteelLiner1.0-1.2mmx5m
MTL2432T TeflonLiner1.0-1.2mmx3m
MB25KIT MIGConsumablesStarterKit-MB25.
MW5KG06 MigWire5kgSpool-0.6mm
MW5KG08 MigWire5kgSpool-0.8mm
MW5KG09 MigWire5kg-0.9mm
MW15KG08 MigWire15kgSpool-0.8mm
MW15KG09 MigWire15kgSpool-0.9mm
MW15KG10 MigWire15kgSpool-1.0mm
MW5KG08FC FluxcoredMigWire-0.8mm,4.5kg
MW5KG09FC FluxcoredMigWire-0.9mm,4.5kg
MW2KG08AL 2.2kgSpool5356-0.8mmAluminium
MW2KG10AL 2.2kgSpool5356-1.0mmAluminium
ALS3550 MMALeadSet300A3+3m1/2”DinseConnectors
S400EH 400AScrewTypeElect.Holder
S500EC Strata500aEarthClamp
CP3550 CablePlug-35-50mm³-Male
ETCPH4825 OvercordR922.5mmElectrodes(350mm)
ETCPH4832 OvercordR923.2mmElectrodes(350mm)
ETCPH4840 OvercordR924.0mmElectrodes(350mm)
ETCPH6825 Overcord2.5mmElectrodes(350mm)
ETCPH6832 Overcord3.2mmElectrodes(350mm)
ETCPH6840 Overcord4.0mmElectrodes(350mm)
ETCPH6850 Overcord5.0mmElectrodes(350mm)
ETCPH7725 Supercito2.5mmElectrodes(350mm)
ETCPH7732 Supercito3.2mmElectrodes(450mm)
ETCPH7740 Supercito4.0mmElectrodes(450mm)
ETCPH56S25 Tenax56S2.5mmElectrodes(350mm)
ETCPH56S32 Tenax56S3.2mmElectrodes(350mm)
ETCPH56S40 Tenax56S4.0mmElectrodes(450mm)
PDL15 Plug,3Pin15A250Vstraight
17835 4RollWireFeederDriveRoller0.6/0.8mm‘v’groove
17836 4RollWireFeederDriveRoller0.9/1.0mm‘v’groove
17837 4RollWireFeederDriveRoller1.0/1.2mm‘v’groove
17838 4RollWireFeederDriveRoller0.8/0.9mmfluxcored
17839 4RollWireFeederDriveRoller1.0/1.2mmfluxcored
17841 4RollWireFeederDriveRoller0.8/1.0mm‘u’groove
17843 4RollWireFeederDriveRollerRetainer
17844 GasInletQC
TheseaccessorieslistedareavailablefromyourStrataSupplier.RefertotheStrataCatalogue,yourStrata
Supplier or look online at www.strata.co.nz for other accessories and consumables available.

11
www.strata.co.nz
EZIMIG 200
Wiring Diagram

12 www.strata.co.nz
EZIMIG 200
Care & Maintenance
Keep your Welding Machine
in Top Condition
TheEZIMIG200doesnotrequireanyspecialmain-
tenance, however the user should take care of the
machine as follows:
• Regularlycleantheventilationslots.
• Keepthecasingclean.
• Checkallcablesbeforeuse.
• Checkelectrodeholders,worklead/clampsand
welding torches before use.
• Replacewornelectrodeholdersandearth 
clamps, which do not provide a good
connection.
• Replacewornconsumablepartsinatimely 
manner.
• Useasoftclothorbrushtocleanelectrical 
components.
• Donotuseliquidcleaningproducts,wateror
especially solvents.
• Donotusecompressedairtocleanelectrical
components as this can force dirt and dust
further into components, causing electrical short
circuits.
• Checkfordamagedparts.Donotusethewelder
with damaged parts.
• Adamagedweldermustbecarefullycheckedby
a qualified person to determine that it will operate
properly. Check for breakage of parts, mountings
and other conditions that may affect its operation.
An authorised service centre should properly
repairadamagedpart.Haveyourwelderrepaired
by an expert.
This appliance is manufactured in accordance with
relevant safety standards. Only experts must carry
out repairing of electrical appliances, otherwise
considerable danger for the user may result. Use only
genuine replacement parts. Do not use modified or
non-genuineparts.
Storing the Welder
When not in use the welder should be stored in the
dryandfrost-freeenvironment.
WARNING! Beforeperformingcleaning/main-
tenance,replacingcables/connections,make
sure the welding machine is switched off and
disconnected from the power supply.

13
www.strata.co.nz
EZIMIG 200
Welding
Settings

14 www.strata.co.nz
EZIMIG 200
Basic MIG Welding Guide
Two different welding processes are covered in this
section(GMAWandFCAW),withtheintentionofpro-
vidingtheverybasicconceptsinMIGwelding,where
aweldinggunishandheld,andtheelectrode(welding
wire)isfedintoaweldpuddle,andthearcisshielded
byagas(GMAW)orfluxcoredwire(FCAW).
Gas Metal ARC Welding (GMAW)
This process, also known as MIG welding, CO2
welding,MicroWireWelding,shortarcwelding,dip
transfer welding, wire welding etc., is an electric arc
welding process which fuses together the parts to be
welded by heating them with an arc between a solid
continuous, consumable electrode and the work.
Shielding is obtained from an externally supplied
welding grade shielding gas. The process is normally
applied semi automatically; however the process may
be operated automatically and can be machine oper-
ated. The process can be used to weld thin and fairly
thicksteels,andsomenon-ferrousmetalsinallposi-
tions.
GMAW Process
(Fig 1-1) Shielding Gas
MoltenWeldMetal
Nozzle
Electrode Arc
BaseMetal
SolidifiedWeldMetal
Flux Cored Arc Welding (FCAW)
This is an electric arc welding process which fuses
together the parts to be welded by heating them with
an arc between a continuous flux filled electrode wire
and the work. Shielding is obtained through decom-
position of the flux within the tubular wire. Additional
shielding may or may not be obtained from an ex-
ternally supplied gas or gas mixture. The process
is normally applied semi automatically; however the
process may be applied automatically or by machine.
FCAW Process
(Fig 1-2) Nozzle
(Optional)
FluxCored
Electrode
Arc
Base
Metal
Solidified
WeldMetal
Slag
Molten
Slag
MoltenMetal
Shielding Gas
(Optional)
Push Vertical Drag Pull
Position of MIG Torch
(Fig 1-3)
TheangleofMIGtorchtotheweldhasaneffecton
the width of the weld.
The welding gun should be held at an angle to the
weldjoint.(SeeSecondaryAdjustmentVariablesbe-
low).
Holdthegunsothattheweldingseamisviewedatall
times. Always wear the welding helmet with proper
filter lenses and use the proper safety equipment.
CAUTION!
Do not pull the welding gun back when the arc
is established. This will create excessive wire
extension (stick-out) and make a very poor
weld.
The electrode wire is not energized until the gun trig-
ger switch is depressed. The wire may therefore be
placed on the seam or joint prior to lowering the hel-
met.
It is commonly used to weld large diameter elec-
trodes in the flat and horizontal position and small
electrode diameters in all positions. The process is
used to a lesser degree for welding stainless steel and
for overlay work.

15
www.strata.co.nz
EZIMIG 200
(Fig 1-4) 5oto15o
LongitudinalAngle
Direction of Travel
90oTransverse
Angle
(Fig 1-5)
5oto15o
LongitudinalAngle 30oto60o
Transverse
Angle
Direction
of Travel
Vertical Fillet Welds (Fig 1-6)
10o
LongitudinalAngle
Direction of Travel
10oto20o
LongitudinalAngle
30oto60o
Transverse
Angle
30oto60o
Transverse
Angle
Direction of Travel
(Fig 1-7)
5oto15o
Longitudinal
Angle
30oto60o
Transverse
Angle
Distance from the MIG Torch Nozzle
to the Work Piece
TheelectrodewirestickoutfromtheMIGTorchnoz-
zleshouldbebetween10mmto20mm.Thisdistance
may vary depending on the type of joint that is being
welded.
Travel Speed
The speed at which the molten pool travels influences
the width of the weld and penetration of the welding
run.
MIG Welding (GMAW) Variables
Most of the welding done by all processes is on
carbon steel. The items below describe the welding
variables in short-arc welding of 24gauge (0.024”,
0.6mm)to¼”(6.4mm)mildsheetorplate.Theap-
pliedtechniquesandendresultsintheGMAWpro-
cess are controlled by these variables.
Preselected Variables
Preselected variables depend upon the type of mate-
rial being welded, the thickness of the material, the
welding position, the deposition rate and the mechan-
ical properties.
These variables are:
  • Typeofelectrodewire
  • Sizeofelectrodewire
  • Typeofgas
  • Gasflowrate
Primary Adjustable Variables
These control the process after preselected variables
have been found. They control the penetration, bead
width, bead height, arc stability, deposition rate
and weld soundness.
Theyare: • ArcVoltage
  • Weldingcurrent(wirefeedspeed)
  • Travelspeed
Secondary Adjustable Variables
These variables cause changes in primary adjustable
variables which in turn cause the desired change in
the bead formation. They are:
1. Stick-Out (distancebetweentheendofthecontact
tube(tip)andtheendoftheelectrodewire).Maintain
atabout10mmstick-out

16 www.strata.co.nz
EZIMIG 200
Nozzle Angle, Right Handed Operator (Fig
1-10)
Direction of Travel
Leadingor“Pushing”
Angle(ForwardPointing) Trailingor“Pulling” Angle(BackwardPointing)
90o
Establishing the Arc
and Making Weld Beads
Before attempting to weld on a finished piece of work,
it is recommended that practice welds be made on
a sample metal of the same material as that of the
finished piece.
The easiest welding procedure for the beginner to ex-
perimentwithMIGweldingistheflat position. The
equipment is capable of flat, vertical and overhead
positions.
ForpracticingMIGwelding,securesomepiecesof16
or18gauge(1.5mmor2.0mm)mildsteelplate(150
x150mm).Use(0.8mm)fluxcoredgaslesswireora
solid wire with shielding gas.
Setting of the Power Source
PowersourceandCurrent(WireSpeed)settingre-
quires some practice by the operator, as the welding
plant has two control settings that have to balance.
ThesearetheCurrent(WireSpeed)controlandthe
weldingVoltageControl.
The welding current is determined by the Current
(WireSpeed)control,thecurrentwillincreasewith
increasedCurrent(WireSpeed),resultinginashorter
arc.LessCurrent(WireSpeed)willreducethecurrent
andlengthenthearc.Increasingtheweldingvoltage
hardly alters the current level, but lengthens the arc.
By decreasing the voltage, a shorter arc is obtained
with a little change in current level.
When changing to a different electrode wire dia eter,
different control settings are required. A thinner
electrodewireneedsmoreCurrent(WireSpeed)to
achieve the same current level.
A satisfactory weld cannot be obtained if the Current
(WireSpeed)andVoltagesettingsarenotadjustedto
suit the electrode wire diameter and the dimensions
of the work piece.
2. Wire Feed Speed. Increaseinwirefeedspeedin-
creases weld current. Decrease in wire feed speed de-
creases weld current.
Electrode Stick-Out
(Fig 1-8)
Gas Nozzle
Tip to
Work Distance
ContactTip(Tube)
Electrode Wire
Actual
Stick-Out
3. Nozzle Angle. This refers to the position of the
welding gun in relation to the joint. The transverse
angle is usually one half the included angle between
plates forming the joint. The longitudinal angle is the
angle between the centre line of the welding gun and
a line perpendicular to the axis of the weld.
Transverse & Longitudinal
Nozzle Axes (Fig 1-9)
LongitudinalAngle
Transverse Angle
Axis of Weld
The longitudinal angle is generally called the Nozzle
Angleandcanbeeithertrailing(pulling)orleading
(pushing).Whethertheoperatorislefthandedorright
handed has to be considered to realize the effects of
each angle in relation to the direction of travel.

17
www.strata.co.nz
EZIMIG 200
MIG Welding Troubleshooting
IftheCurrent(WireSpeed)istoohighforthewelding
voltage,“stubbing”willoccurasthewiredipsintothe
molten pool and does not melt.
Welding in these conditions normally produces a
poorweldduetolackoffusion.If,however,theweld-
ing voltage is too high, large drops will form on the
end of the wire, causing spatter. The correct setting
ofvoltageandCurrent(WireSpeed)canbeseenin
the shape of the weld deposit and heard by a smooth
regular arc sound.
ThegeneralapproachtofixGasMetalArcWelding
(GMAW)problemsistostartatthewirespoolthen
workthroughtotheMIGtorch.Therearetwomain
areas where problems occur with GMAW, Porosity
andInconsistentwirefeed.
When there is a gas problem the result is usually po-
rosity within the weld metal. Porosity always stems
from some contaminant within the molten weld pool
which is in the process of escaping during solidifica-
tion of the molten metal.
Contaminants range from no gas around the welding
arc to dirt on the workpiece surface. Porosity can be
reduced by checking the following points.
WARNING!
Disengage the feed roll when testing for gas flow by ear.
Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas
used depends on the following:
 •Thicknessofthemetaltobewelded
 •Typeofjoint
 •Capacityofthewirefeedunitandpowersource
 •Theamountofpenetrationrequired
 •Thedepositionraterequired
 •Thebeadprofiledesired
 •Thepositionofwelding
 •Costofthewire

18 www.strata.co.nz
EZIMIG 200
Wire feeding problems can be reduced by checking the following points.
Other weld problems can be reduced by checking the following points.

19
www.strata.co.nz
EZIMIG 200
High Tensile and Alloy Steels
The two most prominent effects of welding these
steels are the formation of a hardened zone in the
weld area, and, if suitable precautions are not taken,
the occurrence in this zone of under-bead cracks.
Hardenedzoneandunderbeadcracksintheweldarea
may be reduced by using the correct electrodes, pre-
heating, using higher current settings, using larger
electrodes sizes, short runs for larger electrode de-
posits or tempering in a furnace.
Manganese Steels
The effect on manganese steel of slow cooling from
high temperatures causes embrittlement. For this
reason it is absolutely essential to keep manganese
steelcool during welding by quenching after each
weld or skip welding to distribute the heat.
Cast Iron
Mosttypesofcastiron,exceptwhiteiron,areweld-
able. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld it.
Trouble may also be experienced when welding
white-heartmalleable,duetotheporositycausedby
gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat
conductivityofcopper,makingpre-heatingofheavy
sections necessary to give proper fusion of weld and
base metal.
Types of Electrodes
ARCWeldingelectrodesareclassifiedintoanumber
of groups depending on their applications. There are
a great number of electrodes used for specialised in-
dustrial purposes which are not of particular interest
for everyday general work. These include some low
hydrogen types for high tensile steel, cellulose types
for welding large diameter pipes, etc. The range of
electrodes dealt with in this publication will cover the
vast majority of applications likely to be encountered;
are all easy to use.
MILD STEEL :
E6011-Thiselectrodeisusedforall-positionweldingor
forweldingonrusty,dirty,less-than-newmetal.Ithasa
deep, penetrating arc and is often the first choice for repair
or maintenance work.
E6013 -Thisall-positionelectrodeisusedforwelding
clean,newsheetmetal.Itssoftarchasminimalspatter,
moderatepenetrationandaneasy-to-cleanslag.
E7014 - All positional, ease to use electrode for use on
thickersteelthanE6013.Especiallysuitableforsheetmetal
lap joints, fillet welds and general purpose plate welding.
E7018-Alow-hydrogen,all-positionelectrodeusedwhen
qualityisanissueorforhard-to-weldmetals.Ithastheca-
pability of producing more uniform weld metal, which has
better impact properties at low temperatures.
CAST IRON:
ENI-CL -Suitableforjoiningallcastironsexceptwhite
cast iron.
STAINLESS STEEL:
E318L-16 -Highcorrosionresistances.Idealfordairy
work etc.
Electrodes for joining different metals
Effects of MMA Welding Various Materials

20 www.strata.co.nz
EZIMIG 200
Flat Position,
Down Hand Butt Weld
(Fig 1-11)
Flat Position,
Gravity Fillet Weld
(Fig 1-12)
Horizontal Position,
Butt Weld
(Fig 1-13)
Horizontal-Vertical
(HV) Position
(Fig 1-14)
Vertical Position,
Butt Weld
(Fig 1-15)
Vertical Position,
Fillet Weld
(Fig 1-16)
Overhead Position,
Butt Weld
(Fig 1-17)
Overhead Position,
Fillet Weld
(Fig 1-18)
Joint Preparations
Inmanycases,itwillbepossibletoweldsteelsec-
tions without any special preparation. For heavier
sections and for repair work on castings, etc., it will
be necessary to cut or grind an angle between the
pieces being joined to ensure proper penetration of
the weld metal and to produce sound joints.
In general, surfaces being welded should be clean
and free of rust, scale, dirt, grease, etc. Slag should
beremovedfromoxy-cutsurfaces.Typicaljointde-
signsareshowninFigure1-19.
Open Square Butt Joint (Fig
1-19a)
Gapvariesfrom1.6mm(1/16”)
to4.8mm(3/16”)dependingonplatethickness
Single Vee Butt Joint
(Fig 1-19b)
Notlessthan45°
Single Vee Butt Joint (Fig
1-19c)
Notlessthan70°
1.6mm(1/16”)max.
1.6mm(1/16”)
Double Vee Butt Joint (Fig
1-19d) Notlessthan70°
1.6mm(1/16”)max.
1.6mm(1/16”)
Basic MMA Welding Guide