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

Chapter 3
Operation
A
Cautions
Donot operate the machinewhen the shell has beenopened,improper
cooling can damage the parts;makesure the sideboardhavebeenclosed.
Whenwelding, you mustwearhelmet,glove and otherguard.
3.1 Controls and component(diagram3-1)
7
Diagram 3-1
1. Welder
2. Torch
3. Overloadlamp
4. Powerswitch
5. Wirespeedcontrol
6. Amperageselectionswitch
7. Groundingcable
8. Powercord
3.2 Graphicsymbols and technical data
U0 .....V
X
\2 ...... A
U2 .....V
• -A
IP21
This symbolshows the secondaryno-loadvoltage (in volts).
Thissymbolshows the rateddutycycle.
Thissymbolshows the weldingcurrent in AMPS.
This symbolshows the weldingvoltage in VOLTS.
Thissymbolshows the ratedsupplyvoltage.
Thissymbolshows the weldingunit'smaximumabsorbedcurrent in AMP.
Thissymbolshows the weldingunit'smaximumeffectivesupplycurrent in AMP.
This symbolshows the weldingunit'sprotectionclass.
This symbolshowsthat the weldingunit is suitable forusein environments
wherethere isa highrisk of electricshocks.
Thissymbolshowsread the operatinginstructionscarefullybeforeoperation.
This symbolshows a singlephasetransformerrectifierwelder.
11

Chapter 3 Operation
^^•^ Thissymbolshows the supplypowerphase and linefrequency in Hertz.
1 "- oUMZ
This symbol shows the welder is metalinert and active gas welding
including theuseof fluxcoredwire.
3.3 Operationprocess
Before Welding
• Read and understand the safetyrulessection of this manual.
•Be sure all flammablematerials are removed the workarea.
• There is goodventilationaround the weldingunit andthe areathat you will be working.
•Be sure you havefire-extinguisherready in case ofan accident.
•Puton appropriateprotectiveclothing and insulatedleathergloves.
3.3.1 Use withcoredwire
The welder can usedwithspecialFluxwirethatdose not requireprotectivegas.Thiswire,
contrary tothe casewithelectrodes,does not leaveslag and givesbetterbreadpenetrationwith
substantially lowerlineabsorption.
Makesure youuse properweldingpolarity: as diagram3-2B.groundingcableconnects "+"
terminal, anothercable(weldingtorchcable) connect"-" terminal.
GAS I ffl NO GAS
A B
Diagram 3-2
Stepl: Connectworkclampontometal tobe welded, ortothe metal workbenchwhere the object
is mounted and electricallyconnected.
Step2: Before plugging in, adjustamperage and wirefeedspeedaccording to materialtype and
thickness, andthe wiresize.
StepS: Check the powerswitch isinOFF position, and thenplug the powercordinto its electrical
outlet.
Step4: Whileholding the Torchwith the wire andtip clearly outofthewayofany grounded objects,
turn the powerswitch toON position.
StepS: Orientyourself onthe area tobe welded, and thenplace the Face Shield overyour eyes.
Warning:Neverlook atthe ignited arc withoutANSIapproved, arc shaded, eye
protection ina full-faceshield.Permanent eye damage or blindness can occur. Skin
burns can occur. Never breathe arc fumes.
StepG: Press(andhold) the torchbutton and stroke the area tobe weldedwith the electrode
wire to ignite the arc.
Step7:Once thearcis ignited, tilt the electrodewireforward atan angle of approximately 35°(as
diagram3-3).
StepS: When the weld is complete,loose the torchbutton and lift the wire clearlyawayform any
groundobject, setthe FaceShielddown and turn the PowerSwitch tothe "OFF"position.
12

Chapter 3 Operation
Step9: Unplug the PowerCord fromthe electricaloutlet.
Diagram 3-3
3.3.2 Use mild steelwire
The welder canuse withmildsteelwire and shield gasfor weldingcarbonsteel. The
shielding gas should be eitherpure (100%) COa ora 75% argon-25% CO2 mixture.
Make sure youuse properweldingpolarity: as diagram3-2A.groundingcableconnect "-"
terminal, anothercable(weldingtorchcable) connect"+" terminal. The diameter ofthe wire you
select shouldcorrespond tothe thickness ofthe work piece.Makesurethat the contact tipis
matching the size ofthe wirediameter.
Stepl: Connectworkclampontometal tobe welded, ortothe metalworkbenchwhere the object
is mounted and electricallyconnected.
Step2:Before plugging in, adjustamperage and wirefeedspeedaccording to materialtype and
thickness, andthe wiresize.
StepS: Open thegas valve of regulator;press(and hold) the torchtrigger seta flow of5-7 L/Min
(depending onthe weldingpositionchosen).
Step4:Check the powerswitch isinOFF position, and thenplug the powercordinto its electrical
outlet.
Step5: Whileholding the Torchwith the wire andtip clearly outofthewayofany groundedobjects,
turn the powerswitch toON position.
StepG: Orientyourself onthe area tobe welded, and thenplace the FaceShieldoveryoureyes.
Warning: Never look atthe ignited arc without ANSIapproved, arc shaded, eye
protection ina full-face shield.Permanent eye damage or blindness can occur.Skin
burns can occur.Neverbreathe arc fumes,
Step7:Press(andhold) the torchtrigger and stroke the area tobe weldedwith the electrodewire
to ignite the arc.
StepS: Once thearcis ignited, tilt the electrodewireforward atan angle of approximately 35°(as
diagram 3-3).
Step9:When the weld is complete,loose the torchbutton and lift the wireclearlyawayform any
ground object, setthe Face Shield down and turn the Power Switch tothe "OFF"position.
Stepl 0: Unplug the PowerCordfrom the electricaloutlet.
Step 11: Close thegas cylindervalve.
Stepl 2: Depresstorchtrigger to release gasin regulator, gas pressure indicatorwillreturn to0.
A
Cautions
If welding with largecurrent fora longtime and exceed the dutycycle, the
overloadlampwii!light(yellow), andthe welderwill turn off until it coolsdown.
If thishappens, you must stop welding and wait about 5 minutes,then youcan
continue.
13

Chapter 4 Maintenance
A
Warning
Before performing any maintenance onthe Welder,unplug the Power
Cord from the electrical outletand allow all parts ofthe welder to cool
thoroughly.
1. Periodicallyopen the AccessPanelfrom the unit and, usingcompressed air, blow outall dust
and debris from the interior.Inspect allair vents and cooling slots to ensure that they are clean
and unobstructed.
2. Alwaysstore the Welder ina clean, dry, safelocation outof reach of children and other
unauthorizedpeople.
3. For optimalweldquality,clean and inspect the Contact Tipand Nozzlebeforeeach use, as
follows:
NOZZLEINSPECTION, CLEANING, AND REPLACEMENT
1. Turn the Nozzlecounterclockwisewhilepulling to remove.
2. Scrub the interior ofthe Nozzle cleanwith a wirebrush.
3. Examine theendofthe Nozzle. Theend should be flat and even. Iftheendis uneven,
chipped, melted,cracked, or otherwisedamaged, the Nozzlewilladverselyeffect the weld
and should be replaced.
4. Reinstall the Nozzleafterinspecting and cleaning the Contact Tip.
CONTACT TIP INSPECTION,CLEANING, AND REPLACEMENT
1. Makesure the entireWeldingTorch is completelycoolbeforeproceeding.
2. Remove the Nozzle as explainedabove.Thenremove the Contact Tip.
3. Scrub the exterior ofthe Contact Tip cleanwith a wirebrush.Checkthat the Contact Tipisthe
proper type forthe wire size used.
4. Examine the hole attheendofthe Contact Tipforthe followingproblems: The holeshould be
an evencircle, and should notbe oblong or have any bulges init;The Contact Tip will
decrease in efficiency asthe centerholeenlarges.
5. Ifany problems are notedwith a ContactTip, itis recommended to have it replaced.
6. Wheninspection and maintenance is completed,reinstall the Contact Tipand Nozzle.
14

Chapter 5
Troubleshooting
Warning
Be CERTAIN to shut offthe welder, disconnect it frompower, and discharge
the torch to groundbeforeadjusting,cleansing, or repairing the unit.
Electricalrepairsshouldonly be made by trainedtechnician.
TROUBLESHOOTING
SymptomPossibleCauseCorrectiveAction
No output
1. Dutycycleexceeded
2. Poor work clamp connection
3. Blownbreaker or fuse
1. Allowwelder to cooluntillampgoes out
2.Be sure ail connections are secure, and
attachingsurface is clean
3. Reducecircuit load, resetbreaker or
replacefuse
Wiretangles at
drive roller
1. Wrongsizecontact tip
2. Torch liner clogged or
damaged
3. Contact tip clogged or
damaged
4. Driverollerworn
5. Not enough tension
1. Use propersizecontact tip
2. Clean or replace wire liner
3. Clean or replacecontact tip
4. Replacedrive roller
5. Tighten tension knob
Gun nozzle
arcs to work
surface
1. Slaginside gun nozzle
2. Insulation ring melted
expired
or
1. Cleanslagfrom gun nozzle
2. Replace nozzle
Work clamp
and/or cable
gets hot
1. Poorcontact
2. Using an extensioncordwith
excessive length
1. Be sure all connections are secure, and
attachingsurface is clean
2. Never usean extensioncordlongerthan
20ft
Wiredoes not
feed
1. Wirejammed
2. Out of wire
3. Not enoughtension
4. Wirelinerworn
5. Contact tip clogged
1. Reloadwire
2. Replacewirespool
3. Tightentensionknob if wire is slipping
4. Replaceliner
5. Replacecontact tip
Weldpopsand
sputters
1. Wirespeedsetting
2. Contact tip size too large
3. Polarity set incorrectly
4. Driverollerslipping
5. Gas bottleempty
1. Tune in correctsetting
2. Replacecontact tip
3. Reversepolarity
4. Increasetension
5. Replace gas bottle
15

Chapter 6
Packing list
Packing list
No.
1
2
3
4
5
6
7
Name
Weldingpower
Operating manual
Weldwire
Handle
Screw
Gas hose
Hoseclamp
Specification
MIG-150
GB9074.4 M5X16
Qty
1
1
1
1
2
1
2
Remark
~ " 1
16