SWS ALUMMIG 230 User manual

ALUMMIG
230
PLEASE DOWNLOAD AND READ THE
OPERATING MANUAL BEFORE OPERATION
FOR IMPORTANT SAFETY INFORMATION!
QUICK SETUP GUIDE

230 MACHINE OVERVIEW
FRONT LAYOUT
ALUMMIG
230
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7
MIG Trigger Mode / Welding Programs
Factory Reset NOTE: Saved data will be lost
Save & Load Programs
Back to main menu
Manual Wire Feed
GAS Check
Encoder Control Knob
Positive Output Terminal
Negative Output Terminal
EURO MIG Torch Connection
Push pull / Spool Gun / TIG Torch Connection
GAS Quick Connection NOTE: TIG Only
REAR LAYOUT
Inlet Gas Quick Connector
Power Switch
Mains Power Cable NOTE: 15 Amp Plug
Serial Number
Cooling Fan NOTE: Keep Unobstructed
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MACHINE OVERVIEW
SIDE LAYOUT
ALUMMIG
230
MIG Torch / Push pull / Spool Gun Selector Switch
Wire Spool Holder NOTE: 200mm Diameter Spools Only
Wire Feed Guide NOTE: DO NOT TRIM! The yellow Teflon guide is for soft
wires, and the wire wound guide is for hard wires.
MIG Torch Positive Terminal
MIG Torch Negative Terminal
Wire Feeder Pressure Adjustment NOTE: Do not over tighten when using soft
wires as this will distort the wire, causing feeding problems. Adjust so both
sides are the same tension. Only use as much tension as you need to eliminate
slippage.
Drive Roller Pin x 2 NOTE: To install line up the locator slot until fully inserted.
If the pin is not fully home the cage will not close.
Bottom Drive Roller x 2
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MIG TORCH OVERVIEW
ALUMMIG
230
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5.
TORCH LAYOUT
GAS Shroud
Swan Neck
Amps Up NOTE: The Amps can only be changed in
the MIG welding programs while not welding.
Amps Down
Trigger Switch
6.
7.
8.
EURO PLUG LAYOUT
LINERS
Torch Cable
Liner Retaining Nut
Torch Retaining Nut
The liner guides your wire inside the torch lead and
ensures the wire makes it out of the torch tip. You
may need to change your liner before you feed
your wire through, as these liners will only fit
specific sizes, the same as the drive rollers.
NOTE: The torch comes pre-installed with a Teflon
liner that is to be used with 1.0 - 1.2mm
Aluminium Wires only. If using steel wires change
to the other 0.8 - 1.0mm liner included in the box.
STEEL LINER
TEFLON LINER FOR ALUMINIUM

MIG TORCH
ALUMMIG
230
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8.
CHANGING THE LINER
Disassemble the MIG torch swan neck parts.
Remove the liner retaining nut.
Lay the torch out straight, then carefully pull out and remove the existing liner.
Carefully feed in the new liner down the torch lead until it exits the torch neck.
Teflon Liner - Remove the small rubber o-ring and install the retaining nut to tighten
down. Remove the retaining nut and reinstall the o-ring, then lightly tighten. For
steel liners, install the retaining nut.
Snip the excess liner off at the end of the Gas Diffuser.
Replace the swan neck parts.
Fully screw down the liner retaining nut and nip it uptight.
1. 2. 3. 4.
5. 6. 7. 8.

MIG WIRE & DRIVE ROLLERS
MIG WIRE TYPES
DRIVE ROLLERS
ALUMINIUM WIRES
ALUMMIG
230
The drive roller size identification is the same side as the groove. When installing
the size being used the number faces away from you and towards the inside of
the machine.
V Groove
2 X 0.6~0.8
2 X 1.0~1.2
2 X Smooth
The MIG wire spool size used is 200mm in diameter and the machine
has programs for the following wire types. The MIG process selected
will determine which wire type can be used.
NOTE: Use the V drive rollers for hard wires and
fit the the smooth rollers on the bottom drives.
When using 0.9 hard wires use the 0.8 V Drive
NOTE: Use the U drive rollers for soft wires and
Fluxed core wires. Install the 4 rollers for the wire
size being used.
Steel Wires
0.6mm
0.8mm
0.9mm
1.0mm
1.2mm
Stainless Stee Wires
0.8mm
0.9mm
1.0mm
1.2mm
Aluminium Wires
5356 1.0mm
5356 1.2mm
4043 1.0mm
4043 1.2mm
Silicon Bronze
0.8mm
0.9mm
Flux Cored (Gas less)
0.8mm
0.9mm
U Groove
4 X 0.8~1.0
4 X 1.0~1.2
Use 1.0mm for 3mm and under and 1.2mm for 3mm and over materials.

WELDING MODES
ALUMMIG
230
MMA
LIFT TIG
MANUAL
DUAL
SETTINGS
SINGLE
SYNERGIC
WELDER
SETTINGS
ALUMMIG 200
MMA - Manual Metal Arc or Stick
Welding mode (MMA TORCH NOT
Included)
LIFT TIG - Tungsten Inert Gas welding
mode (TIG Torch NOT included)
MANUAL GMAW - MIG welding mode
with manual settings.
SYNERGIC GMAW - Gas Metal Arc
Welding synergic welding mode select
programs for ease of setup.
MAIN MENU
DUAL PULSE GMAW - Gas Metal
Arc Welding Dual Pulse synergic
welding mode select programs for
ease of setup.
SINGLE PULSE - Gas Metal Arc
Welding Single Pulse synergic
welding mode select programs for ease
of setup.

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2
1
GMAW SETUP
ALUMMIG
230
GMAW SETUP
1. Connect the MIG Torch to the EURO terminal and tighten it.
2. Connect the Ground Clamp to the Negative Terminal for DCEP MIG or to the
Positive terminal for Gas Less MIG only. To change the MIG torch to DCEN you
need to change the polarity inside the side door.
3. Connect the Gas Regulator to the GAS bottle and hose from the regulator to
the quick connect on the rear of the machine.
4. Install the rollers that match the wire size and install wire spool.
5. Release the wire feeder tensioner and thread the wire through the wire
feeder.
6. Hold the MIG torch in one hand and with the other hand press the wire feed
button on the front panel until the wire exits the MIG torch tip.
7. Press the Gas Check button on the front panel to set the correct Gas Flow
Rate.
3
6
72
4
5
5

GMAW SETUP
ALUMMIG
230
GMAW FUNCTIONS
1. Wire Speed / Weld Amps -
Adjusts the wire speed which is
relative to the amps used. The
voltage is adjusted synergically
relative to the arc length setting.
2. Voltage / Arc Length - Adjusts
the voltage and arc length.
higher voltage will produce a
longer arc length.
m/min V
(+ -15%)
4.8 21.0
3MM T Arc Length
Dual Pulse %
Dual Frequency Hz
Inductance
Wire Run in Speed %
0
25
1.0
0
0
3.1 mm
4S Dual Pulse5356 Aluminium ı 1.2mm ı Ar 100% ı EP
Weld A
First A
Arc L
Last A
Arc L
150
0
60
0
100
3. Torch Trigger Mode - Access from the P button on the front panel for 2T, 4T or
4T Special. 2T is regular torch mode, 4T allows to set the end amps and volts. 4T
Special allows to set the start amps and volts plus end amps and volts.
4. Material Thickness Guide - Provides a starting point for the thickness of metal
being welded.
5. Dual Pulse % - Sets the amount of dual pulse action that is used. Low settings
produce a low dual pulse effect high settings produce a high dual pulse effect.
6. Dual Frequency Hz - Sets the amount of time the dual pulse cycles from the low
part of the cycle to the high part of the cycle.
6. Inductance - Sets the amount of time the wire is short circuiting into the weld
puddle effecting the arc time and overall heat input.
7. Wire Run In Speed % - Sets the speed in which the wire is initially fed into the
metal. If the wire is stubbing is occurring use a lower setting. If the wire is
burning back into the tip use a higher setting.

SAVE PROGRAM
1. Select a MIG welding mode eg double pulse GMAW
2. Press the M button once in the chosen MIG welding mode screen.
3. Use the encoder dial to select and press on SAVE
4. Name the program up to 5 characters and select ENTER
5. Settings are now saved into the program when the parameters are adjusted.
6. To create a new program repeat the steps outlined above.
LOAD PROGRAM
1. Press the M button on the front panel.
2. Select LOAD and press.
3. Select the saved program.
DELETE PROGRAM
1. Press the M button on the front panel.
2. Select the TRASH icon.
3. Select the program to be deleted press to delete.
GMAW SETUP
ALUMMIG
230
GMAW FUNCTIONS
SAVE & LOAD PROGRAMS
9. Hot Start - Applies extra voltage to
the first few seconds of the weld
that helps reduce weld build up.
Use a higher setting for a hotter
start.
10. Burn Back % - Sets the amount of
wire that burns back to the tip
when finishing welding. A higher
setting will produce a longer stick
out.
11. Gas Preflow - Sets the amount of time the gas flows before the arc starts.
12. Gas Postflow - Sets the amount of time the gas flows after the arc stops.
m/min V
(+ -15%)
4.8 21.0
3MM T Arc Length
Hot Start %
Burn Back %
Gas Preflow s
Gas Postflow s
0
50
20
0.5
1
3.1 mm
4S Dual Pulse5356 Aluminium ı 1.2mm ı Ar 100% ı EP
Weld A
First A
Arc L
Last A
Arc L
150
0
60
0
100

GMAW SETUP
ALUMMIG
230
The synergic welding modes for no pulse, single pulse and dual pulse allow ease of
setup with this machine by selecting the welding consumable type then setting the
thickness on the main welding screen. The program then can be fine-tuned for the
joint type and welding position using the trim and other functions. The synergic mode
makes setting up fast by it must be stressed that it is only a guide and some
fine-tuning may or may not be needed depending on the job type.
1. From the main welding, menu select synergic, single pulse or dual pulse.
NOTE: Aluminium can only be welded in single or dual pulse GMAW modes.
2. Select the torch trigger mode and welding program using the P button on the
front panel.
SYNERGIC WELDING MODES
To use the machine in Synergic mode first you need to select the correct program for
the wire being used. On this screen, the machine will also show the gas needed and
polarity needed. EP is electrode positive EN is electrode negative.
1. Select the Synergic welding mode from the main screen.
2. Press the P button to select the trigger mode used such as 2T
3. Press the P button again to select the correct program for the wire being used.
PROGRAM SETTINGS
The welding parameters for each synergic program has been set in the factory to be as
accurate as possible and is a good starting point. In saying this the material thickness
selector is only to be used as a guide as different joint types, welding positions, welding
techniques and machine settings will require different heat inputs.
ADJUSTING THE TRIM
The wire feed speed/welding amps setting relates to the thickness selector in the
bottom left of the screen. Increasing the wire feed speed will also increase welding
amperage allowing thicker sections to be welded.
WIRE FEED SPEED & WELDING AMPERAGE

GMAW SETUP
ALUMMIG
230
This setting adjusts the voltage which relates to the arc length and overall heat input of
the weld. Higher voltage settings eg +6 arc length will produce a longer hotter arc
making the wire burn back closer to the torch tip. Lower voltage settings will produce a
colder shorter arc eg -5 arc length with the arc burning closer to the weld pool.
Joint type and welding technique will determine what voltage and arc length is used for
the best result. When decreasing voltage/arc length you can compensate by increasing
the wire feed speed/amperage and vice versa. Other factors that will change the heat
inputs needed is the dual pulse, pulse frequency and inducatnce settings. It is always
recommened to test the machine settings on scrap material before commencing
welding on the job at hand.
VOLTAGE & ARC LENGTH