SWP MIG 150 TURBO User manual

SWF
MM 51058-2010
2010-12
MIG-150
OPERATING INSTRUCTIONS
A
Caution
Please read and save these instructions. Read carefullybeforeattempting to
assemble, install, operates or maintains the productdescribed.Protectyourself and others
by observing all safetyinformation. Failure to complywithinstructionscouldresult in
personal injuryand/orproperty damage! Retain instructions for futurereference.

Responsibility
The usershall inspect the equipment, and faulty equipment shall be stopped. Allthe faulted,
missed,abrasive,distorted and pollutedparts shall be changedpromptly.Whenrepair or change,
the manufactureradvised the user to change the partforward the require in written or callingform
to the licenseddistributors.
The user cannot change any partswithout the manufacturesadvancedpermission,
Otherwise, the usershall be responsible foranthe accidents caused bythe inappropriate use.
Catalogue
Chapter/
Paragraph
Safety
Content
Safetywarning
Chapter 1 Productdescription
Chapter 2 Installing
Chapter 3 Operation
Chapter 4 Maintenance
Chapter 5 Troubleshooting
Chapter 6 Packinglist
Page
3
11
14
15
16

Safety Warning
GENERALSAFETY
A
A
A
Danger
Warning
Qaution
Dangermeans a hazardthatwill causedeath or seriousinjury if
the warning is ignored.
Warningmeans a hazardthatcould causedeath or seriousinjury
if the warning is ignored.
Cautionmeans a hazardthat may causeminor or moderateinjury
if the warning is ignored. It also may mean a hazardthatwillonly
causedamage to property.
JJuk BEJuSsffiS! Improper useof electric arc welders can
cause electric shock, injury, and death! Take all precautions
described in this manual to reduce the possibility of electric shock.
• Verifythat all components ofthearc welder are clean andin good condition prior to operating
the welder. Be surethat the insulation onall cables,electrodeholders, and power cords isnot
damaged.Alwaysrepair or replacedamagedcomponentsbeforeoperating the welder.Always
keepwelderpanels,shields,etc. in placewhenoperating the welder.
• Alwayswear dry protectiveclothing and weldinggloves, and insulatedfootwear.
• Alwaysoperate the welder ina clean, dry,well ventilated area. Donot operate the welder in
humid,wet, rainy, or poorlyventilatedareas.
•Be surethat the workpiece is properlysupported and groundedprior to beginning any electric
arc weldingoperation.
• Coiledweldingcableshould be spread out before useto avoidoverheating and damage to
insulation.
Electric arc welding operations produce
intense light and heat and ultraviolet (UV) rays. This intense light
and UV rays can cause injury to eyes and skin. Take all precautions
\d in thismanual to reduce the possibility of injury to eyes and skin.
•All personsoperatingthisequipment orinthe areawhileequipment isinuse mustwear
protective weldinggearincluding:weldinghelmet or shieldwithpropershade as specified inthe
followingchart,flameresistantclothing,leatherweldinggloves, and fullfootprotection.
• Neverlook atarc weldingoperationswithout eye protection as describedabove.Never usea
shadefilterlensthat is cracked,broken, or ratedbelownumber 10. Warnothers inthe area
notto look atthe arc.

Safety Warning
Electric arc welding operations causesparks
and heatmetal to temperaturesthat can causesevere burns! Use
protectivegloves and clothing whenperforming any metal working
operation.Take all precautionsdescribed in this manual to reduce the
possibility of skin and clothing burns.
• Makesurethat all persons inthe weldingarea are protectedfromheat,sparks, and ultraviolet
rays. Use additionalfaceshields and flameresistant barriers as needed.
• Never touch workpieces until completelycooled.
£jk 'l^SliEjtiiil^ j Heat and sparksproducedduringelectric arc
welding and othermetalworkingoperations can ignite flammable
and explosive materials! Take all precautions described in this
manual to reduce the possibility of flames and explosions.
• Remove all flammablematerialswithin 35 feet (10.7 meters) of weldingarc. If removal isnot
possible, tightlycoverflammablematerialswithfireproofcovers.
•Donot operate any electric arc welder in areaswhereflammable or explosivevapors maybe
present. Takeprecautions tobe surethatflying sparks and heat donot causeflames in hidden
areas, cracks,behindbulkheads,etc.
Do not breathe fumes that are produced by
the arc weldingoperation.Thesefumes are dangerous. Ifthe welding
area cannot be adequatelyventilated, be sure tousean air-supplied
respirator.
• Keep the head and face outofthe weldingfumes.
•Donot performelectric arc weldingoperations on metalsthat are galvanized or cadmium
plated, or containzinc,mercury, or berylliumwithoutcompleting the followingprecautions:
a. Remove the coatingfrom the basemetal.
b. Makesurethat the weldingarea is wellventilated.
c.Usean air-suppliedrespirator.
Extremely toxicfumes are createdwhenthesemetals are heated.
The electromagneticfieldthat is generated
during arc welding may interferewith the operation of various
electricai and electronicdevicessuch as cardiacpacemakers.
Persons usingsuchdevicesshouldconsult with theirphysician prior to
performing any electric arc welding operations.

Safety Warning
• Neverwrap arc weldercablesaround the body.
• Alwaysposition the electrode and groundleads so thatthey areonthe sameside ofthe body.
• Exposure to electromagneticfieldsduringwelding may haveotherhealtheffectswhich arenot
known.
A
Warning
Equipment maintenance—The wrong or
inappropriate equipment maintenance can cause injury or death.
•The licensedpeople cando assembly,maintenance and someotheroperation.
•The powersourceshall be turned off when any maintenancework inthe powersourceneeded.
• Endure that the cable,earthwire,connector,mainlead and power supply areinthe normal
work.
•Donot abuseequipments and firing.
• Keep the safeequipment and cabinetshall in peace and goodcondition.
•Donot change any equipment.

Chapter 1
Product Description
1.1 Produceapplication
MIG seriesweldingmachineadoptspecialtappedtransformeradjustingstyle. Itisthe
economical and practicalmechanicalproducts, ithas wire-feedsystem,smallvolume,easy to
shift and simpleoperation, it applies to weldingmildsteel,low-alloysteel andsoon.
1.2 Modelunit
~~ -----. ^JVSpdel
Item ^~~~ — -—•—__
Rated input voltage
Frequency
Phase
Max. Inputcurrent
No-loadvoltage(peakvalue)
HeatSetting
Ratedoutputcurrent
Ratedoutputvoltage
*Duty cycle
Insulationgrade
Usable wire
Weight
Dimension(LxWXH)
MIG-150
230V
50Hz
Single
20A
25-45VDC
MIN, 1 MAX, 1
30A 75A
15.5V 17.8V
100% 25%
MAX, 2
105A
19.2V
15%
H
0.8mm or 0.9mmfluxcorewire;
0.6mm to 0.8mmsteelwire
26.2Kg
43cm X 27cm X 34. 5cm
*Duty cycle isthe ratio ofthe uninterruptedon-loadduration tothe totaltime (10 minutes
here). It liesbetween 0 and 1, andcanbe expressed asa percentage. For example, inthe case of
a 60% dutycycle, a load is applied continuously for6 min followed bya no-loadperiod of4 min.
Note; 1.The heatingtest ofthe weldingpowersource is carried outat ambient
temperature. Dutycycle at40'C has beendetermined by simulation.
2. The weldingpower sourcebelongs to Group 2 and Class B ISM equipment
according to CISPR 11:2003.
1.3 Environmentalcondition
a) Range ofthe temperature ofthe ambient air:
Duringwelding: —10°C to +4CTC
After transport and storage at: —251; to +55"C
b) Relative humidity ofthe air:
Upto50%at 40°C
Upto90%at 20"C
c) Ambient air, freefromabnormalamounts of dust,acids,corrosivegases or substances etc.
other thanthosegenerated bythe weldingprocess.
d) Altitudeabove sea level upto 1000m.
6

Chapter 1
Product Description
e) Base ofthe weldingpowersourceinclude upto 15"
1.4 Voltagecharacteristic and currentcharacteristic of welding power
The curve (as diagram 1-1) means "V-A" externalstaticcharacteristic of weldingpower,
gradient of curenamedslope,normalmeans "drop off voltage per 100A". The curvesshow the
outputvoltage wecangetinany presetoutputcurrentbecause the "V-A"slope is fixed.
50 100150200
MIG-150 externalstaticcharacteristic
I2(A)
250
Diagram 1-1 staticexternalcharacteristiccurve
1.5 Safety
Before operating the equipment, you mustread the safetydirections to avoid the hurt duetothe
inaccurate and improprietyinstalling.

Chapter 2 Installing
2.1 The requirement of installingground
Equal ground is necessary tothe machine, the groundmust be havegoodventilation
system, and can't be exposed in dust,dirt, wetand activesteam, the minimum distancebetween
side board and it'snearest bar must 5546cm andthe minimumdistance between backboard and
it's nearest bar must 5-46cm.
2.2 Check,discharged and placed
(1) Afterreceiving the equipment, you shouldcheck ifthe equipment has beendamaged
during traffic; if damaged, you shouldnotify the conveyances, if lackspareparts,please notify the
dealer at once.
(2) Take the spareparts out frompackingbox,remove the packingmaterial, and check ifany
cast in packingbox.
(3) Checkeveryairway inthe shell, and makesurepacking box can'tblock air circulating.
(4) Chooseroomyground to placedspareparts, in order to installingconveniently.
2.3 Installing the handle(Following the diagram 2-1)
1. Place the handle (1) ontopofthe cover.
2. Secure the handle,using the screws(2).
Diagram 2-1
2.4 Wirespool loading
NOTE:Thiswelder can weldusing 0.8rr,m or 0.9mmFlux-Coredwire (E71T-GS), 0.6mm or
0.8mmsteelwire(E70S-6),wirespoolsize: 4"(102mm) diameter.
1. Verify unit isoffand opendoorpanel to exposewirefeedmechanism.
2. Unscrew and remove the wing nut (1) andthe spool locking knob (2) (see diagram2-2).
3. Installwirespool (3) over the spool axle (4)and onto the spring(5). The wire onthe spool
shouldunwindclockwise, so wire can come off spool ontheend closest tothe wirefeed
guidetube.
4. Turn the spool (3)by hand whileslowlytightening the spool locking knob (2) until a light
drag is felt, and thentighten the wing nut (1) up against the spoollockingknob(2).
8

Chapter 2
Installing
.©
Diagram 2-2
2.5 Wirethreading
1. Loose and lower the tensionadjustingknob(7),rotate the swing arm(8) awayfrom the wire
feeddriveroll(9).
Diagram 2-3
2. Carefullydetach theendofthe wirefrom the spool(3). To prevent the spoolfrom
unwinding,maintaintension onthe wireuntilafterstep 5.
3. Cutthe wire end fromspool and straighten the first 4" (100mm). Donot allow wire to
unravel. Makesure thecutendhasno burrs or sharpedges(cutagain, if needed).
4. Thread the wire through wirefeedguidetube(6),over the groove in drive roll (9)and into
torch tube.
5. Close the swing arm(8)and latch the tensionadjustingknob (7)in place.Makesure the
wire is positioned inthe groove ofthe driveroll.
6. The milled nut (10) onthe tensionadjustingknob (7) adjusts the pressure onthe wire.
Adjust pressure by turning the milled nut (10) until smooth and easywire feeding. Start
with the pressure settoan intermediatevalue.Readjust, if necessary.Slightlyless
pressure mayberequired. Ifthe driverollslipswhilefeedingwire, the pressureshould be
increased until the wirefeedsproperly.
7. Removenozzle (11) by turningclockwise,thenunscrewcontact tip (12) from endof
welding torch(Seediagram2-4).Plugwelderinto a properpower supplyreceptacle.
8. Turn on welder andset wirespeedrate to6.Laythe torchcable outina straightline and
presstorchtriggeruntilwirefeeds out past the torchend. Turn welderoff.
9. Carefullyslipcontact tip (12) overwire and screw tip intotorchend. Cut wire off
approximately 1/4 inchfromcontact tip end. Install nozzle by turningclockwise.
12
Diagram 2-4
9

Chapter 2
Installing
2.6 Connection welder togas cylinder
Clean the threads ofthegas cylindervalve.Alsoopen thegas valve fora few seconds to blow
out any dirt of particulates that may havegotteninto the richer in order to preventthemfrom
entering the regulator.Checkyourregulator(outletflowmeter:0-25L/Min,inletgauge:0-25Mpa,
pressure range for safeoutpouring: 0-0.35Mpa) to makesurethat itwas suppliedwith a gasket.
Tighten the regulatorcoupling tothe cylinder gas valve. Now connect the welder gas line tothe
hosebarboutlet on yourregulator; a stainlesssteelhose clamp canbe used to insure a leak-proof
connection.(Seediagram2-5)
Check all connections for leaks by opening the regulator and cylinder gas valves.
Always shut offthe regulator and cylinder gas valves when the machine isnotin use.
REGULATOR
HOSE BARB
Diagram 2-5
10