TOP GUN WELDING MULTIMIG 355F User manual

INTRODUCTION
Ⅰ
I
IMPORTANT: Read this Owner’s Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
MULTIMIG 355F/MULTIMIG 515F
INVERTER Based Welding Machine
OPERATORS’ MANUAL

CONTENT
- II -
CONTENT
§1 Safety...............................................................................................
§1.1 Symbols Explanation ......................................................................................................
§1.2 Machine Operating warnings! .......................................................................................
§1.3 EMC device classification ..............................................................................................
§1.4 EMC measure..................................................................................................................
§1.5 Warning label ..................................................................................................................
§2 Overview .........................................................................................
§2.1 Features ...........................................................................................................................
§2.2 Technical Data .................................................................................................................
§2.3 Brief Introduction ...........................................................................................................
§2.4 Duty cycle and Over-heat ...............................................................................................
§2.5 Working Principle ...........................................................................................................
§2.6 Volt-Ampere Characteristic ...........................................................................................
§3 Panel Functions & Descriptions ...................................................
§3.1 Machine Layout Description .........................................................................................
§3.1.1 Front and rear panel layout of welding machine .....................................................................
§3.1.2 Front and rear panel layout of wire feeder ..............................................................................
§3.1.3 Internal panel layout of wire feeder ........................................................................................
§3.1.4 Front and rear panel layout of water cooling ...........................................................................
§3.2 Front Panel Functions and Descriptions ......................................................................
§3.2.1 Front Panel Functions of wire feeder ......................................................................................
§3.2.2 Operating process of wire feeder .............................................................................................
§3.2.3 Implicit parameter adjustment (Fn) .........................................................................................
§3.2.4 JOB mode ................................................................................................................................
§3.2.5 Synergic Function ...................................................................................................................
§3.2.6 MMA Function - Front Panel Description...............................................................................
§3.2.7 TIG Function - Front Panel Description ..................................................................................
§3.2.8 MIG Function - Front Panel Description.................................................................................
§4 Installation & Operation ..............................................................
§4.1 Installation & Operation for MMA Welding................................................................
§4.1.1 Set up installation for MMA Welding .....................................................................................

CONTENT
- II -
§4.1.2 MMA Welding .........................................................................................................................
§4.1.3 MMA Welding Fundamentals .................................................................................................
§4.2 Installation & Operation for TIG Welding ..................................................................
§4.2.1 Set up installation for TIG Welding ........................................................................................
§4.2.2 DC TIG Welding .....................................................................................................................
§4.2.3 TIG Welding Fusion Technique ...............................................................................................
§4.2.4 Tungsten Electrodes ................................................................................................................
§4.2.5 Tungsten Preparation ...............................................................................................................
§4.2.6 Gun switch control current ......................................................................................................
§4.2.7 Pedal switch control ................................................................................................................
§4.3 Installation & Operation for MIG Welding .................................................................
§4.3.1 Set up installation for MIG Welding .......................................................................................
§4.3.2 Wire Feed Roller Selection .....................................................................................................
§4.3.3 Wire Installation and Set Up Guide .........................................................................................
§4.3.4 MIG Torch Liner Installation ..................................................................................................
§4.3.5 MIG Torch Liner Types and Information ................................................................................
§4.3.6 Torch & Wire Feed Set Up for Aluminium Wire .....................................................................
§4.3.7 Set up installation for Spool Gun ............................................................................................
§4.3.8 MIG Welding ...........................................................................................................................
§4.3.9 MIG Torch /Spool Gun control ...............................................................................................
§4.4 Standard welding programs ..........................................................................................
§4.5 Welding parameters........................................................................................................
§4.6 Operation environment ..................................................................................................
§4.7 Operation Notices ...........................................................................................................
§5 Welding trouble shooting ..............................................................
§5.1 MIG welding trouble shooting .......................................................................................
§5.2 MIG wire feed trouble shooting ....................................................................................
§5.3 DC TIG welding trouble shooting .................................................................................
§5.4 MMA welding trouble shooting .....................................................................................
§6 Maintenance & Troubleshooting .................................................
§6.1 Maintenance ....................................................................................................................
§6.2 Troubleshooting ..............................................................................................................
§6.3 List of error code ............................................................................................................
§6.4 Electrical schematic drawing .........................................................................................

SAFETY
-1-
§1 Safety
Welding and cutting equipment can be dangerous to both the operator and people in
or near the surrounding working area, if the equipment is not correctly operated.
Equipment must only be used under the strict and comprehensive observance of all
relevant safety regulations. Read and understand this instruction manual carefully
before the installation and operation of this equipment.
§1.1 Symbols Explanation
 The above symbols mean warning!
Notice! Running parts, getting an electric shock or making contacts with thermal
parts will cause damage to your body and others. The underline message is as
follows:
Welding is quite a safe operation after taking several necessary protection
measures!
§1.2 Machine Operating warnings!
 The following symbols and words explanations are for some damages to your body
or others, which could happen during the welding operation. While seeing these
symbols, please remind yourself and others to be careful.
 Only people who are trained professionally can install, debug, operate, maintain
and repair the welding equipment covered with this Operator’s Manual!
 During the welding operation, non-concerned people should NOT be around,
especially children!
 After shutting off the machine power, please maintain and examine the equipment
according to §7 because of the DC voltage existing in the electrolytic capacitors at
the output of the power supply!

SAFETY
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ELECTRIC SHOCK CAN KILL.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode
and work circuit is electrically live whenever the output is on. The input power
circuit and internal machine circuits are also live when power is on. In Mig/Mag
welding, the wire, drive rollers, wire feed housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly grounded
equipment is dangerous.
 Never touch live electrical parts.
 Wear dry, hole-free gloves and clothes to insulate your body.
 Be sure to install the equipment correctly and ground the work or metal to be
welded to a good electrical (earth) ground according to the operation manual.
The electrode and work (or ground) circuits are electrically “hot” when the
machine is ON. Do not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
 In semiautomatic or automatic wire welding, the electrode, electrode reel, welding
head, nozzle or semiautomatic welding gun are also electrically “hot”.
 Insulate yourself from work and ground using dry insulation. Make certain the
insulation is large enough to cover your full area of physical contact with work and
ground.
 Be Careful when using the equipment in small places, falling-off and wet
circumstance.
 Always be sure the work cable makes a good electrical connection with the metal
being welded. The connection should be as close as possible to the area being
welded.
Maintain the electrode holder, work clamp, welding cable and welding machine in
good, safe operating condition. Replace damaged insulation.
 Never dip the electrode in water for cooling.
 Never simultaneously touch electrically “hot” parts of electrode holders connected

SAFETY
-3-
to two welders because voltage between the two can be the total of the open
circuit voltage of both welders.
 When working above the floor level, use a safety belt to protect yourself from a
fall should you get an electric shock!
FUMES AND GASES CAN BE DANGEROUS.
Smoke and gas generated whilst welding or cutting can be harmful to people’s health.
Welding produces fumes and gases. Breathing these fumes and gases can be
hazardous to your health.
 Do not breathe the smoke and gas generated whilst welding or cutting, keep your
head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When welding with electrodes which
require special ventilation such as stainless or hard facing or on lead or cadmium
plated steel and other metals or coatings which produce highly toxic fumes, keep
exposure as low as possible and below the Threshold Limit Values using local
exhaust or mechanical ventilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional precautions are also required
when welding on galvanized steel.
 Do not weld in locations near chlorinated hydrocarbon vapors coming from
degreasing, cleaning or spraying operations. The heat and rays of the arc can react
with solvent vapors to form phosgene, a highly toxic gas, and other irritating
products.
 Shielded gases used for arc welding can displace air and cause injury or death.
Always use enough ventilation, especially in confined areas, to insure breathing air
is safe.
 Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used, including the material safety data sheet and follow your
employer’s safety practices.

SAFETY
-4-
ARC RAYS: Harmful to people’s eyes and skin.
Arc rays from the welding process produce intense visible and invisible ultraviolet
and infrared rays that can burn eyes and skin.
 Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing open arc welding.
 Use suitable clothing made from durable flame-resistant material to protect your
skin and that of your coworkers from the arc rays.
 Protect other nearby personnel with suitable, non-flammable screening and /or
warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter
or metal.
SELF-PROTECTION
 Keep all equipment safety guards, covers and devices in position and in good
repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all
other moving parts when starting, operating or repairing equipment.
 Do not put your hands near the engine fan. Do not attempt to override the governor
or idler by pushing on the throttle control rods while the engine is running.
DO NOT add any fuel near an open-flame welding arc or
when the engine is running. Stop the engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact with hot engine parts and igniting.
Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

SAFETY
-5-
WELDING SPARKS can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to
explode. Flying sparks from the welding arc, hot work piece, and hot equipment can
cause fires and burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is safe before
doing any welding
 Remove fire hazards material from the welding area. If this is not possible, cover
them to prevent the welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire
extinguisher readily available.
 Where compressed gases are to be used at the job site, special precautions should
be used to prevent hazardous situation.
 When not welding, make certain no part of the electrode circuit is touching the
work or ground. Accidental contact can cause overheating and create a fire hazard.
 Do not heat, cut or weld tanks, drums or containers until the proper steps have
been taken to insure that such procedures will not cause flammable or toxic vapors
from substances inside. They can cause an explosion even though they have been
“cleaned”.
 Vent hollow castings or containers before heating, cutting or welding. They may
explode.
 Sparks and spatter are thrown from the welding arc. Wear oil free protective
garments such as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap
over your hair. Wear earplugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
 Connect the work cable to the work as close to the welding area as practical. Work
cables connected to the building framework or other locations away from the
welding area increase the possibility of the welding current passing through lifting

SAFETY
-6-
chains, crane cables or other alternate circuits. This can create fire hazards or
overheat lifting chains or cables until they fail.
Rotating parts may be dangerous.
 Use only compressed gas cylinders containing the correct shielding gas for the
process used and properly operating regulators designed for the gas and pressure
used. All hoses, fittings, etc. should be suitable for the application and maintained in
good condition.
 Always keep cylinders in an upright position securely chained to an undercarriage
or fixed support.
 Cylinders should be located:
-Away from areas where they may be struck or subjected to physical damage.
-At a safe distance from arc welding or cutting operations and any other source
of heat, sparks, or flame.
 Never allow the electrode, electrode holder or any other electrically “hot” parts to
touch a gas cylinder.
 Keep your head and face away from the cylinder valve outlet when opening the
cylinder valve.
 Valve protection caps should always be in place and hand tight except when the
cylinder is in use or connected for use.
Gas Cylinders.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Because gas cylinders are normally part of the welding process, be sure to
treat them carefully. CYLINDERS can explode if damaged.
 Protect gas cylinders from excessive heat, mechanical shocks, physical damage,
slag, open flames sparks, and arcs.

SAFETY
-7-
 Insure cylinders are held secure and upright to prevent tipping or falling over.
 Never allow the welding electrode or earth clamp to touch the gas cylinder, do not
drape welding cables over the cylinder.
 Never weld on a pressurised gas cylinder, it will explode and kill you.
Open the cylinder valve slowly and turn your face away from the cylinder outlet
valve and gas regulator.
Gas build up.
The build up of gas can causes a toxic environment, deplete the oxygen content in
the air resulting in death or injury. Many gases use in welding are invisible and
odourless.
 Shut off shielding gas supply when not in use.
 Always ventilate confine spaces or use approved air-supplied respirator.
Electric and Magnetic Fields.
Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). The discussion on the effect of EMF is ongoing in the entire
world. Up to now, no material evidences show that EMF may have effects on health.
However, the research on the effect of EMF is still ongoing. Before any conclusion,
we should minimize exposure to EMF as few as possible.
In order to minimize EMF, we should use the following procedures:
 Route the electrode and work cables together – Secure them with tape when
possible.
 All cables should be put away and far from the operator.
 Never coil the power cable around your body.
 Make sure welding machine and power cable to be far away from the operator as
far as possible according to the actual circumstance.

SAFETY
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 Connect the work cable to the workpiece as close as possible to the area being
welded.
 The people with heart-pacemaker should be away from the welding area.
Noise can damage hearing.
Noise from some processes or equipment can damage hearing. You must protect
your ears from loud noise to prevent permanent loss of hearing.
 To protect your hearing from loud noise, wear protective ear plugs and/or ear
muffs. Protect others in the workplace.
 Noise levels should be measured to be sure the decibels (sound) do not exceed safe
levels.
Hot parts.
Items being welded generate and hold high heat and can cause severe burns. Do not
touch hot parts with bare hands. Allow a cooling period before working on the
welding gun. Use insulated welding gloves and clothing to handle hot parts and
prevent burns.
§1.3 EMC device classification
Radiation Class A Device.
 Only can be used in the industrial area
 If it is used in other area, it may cause connection and
radiation problems of circuit.
Radiation Class B device.
 It can meet the radiation requirements of residential area and industrial area. It also
can be used in residential area which power is supplied by public low voltage circuit.
EMC device can be classified by power nameplate or technical data.

SAFETY
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hanker welding machines belong to Class A.
§1.4 EMC measure
In the special situation, The specified area may be affected, the
standard of radiation limit value has been complied with (eg: The
device, which is easy effected by electromagnetism, is used at the
installation location, or there is radio or TV near the installation location). In this
condition, the operator should adopt some appropriate measures to remove
interference.
Accoring to the domestic and international standards, the ambient devices’
electromagnetism situation and anti-interference ability must be checked：
 Safety device
 Power line, Signal transmission line and Date transmission line
 Date processing equipment and telecommunication equipment
 Inspection and calibration device
The effective measures avoid the problem of EMC：
a) Power source
Even though the power source connection meet rules, we still need to take
additional measure to remove the electromagnetic interference. (eg: Use the right
power filter. )
b) The welding line
 Try to shorten the length of cable
 Put the cable together
 Be Far away from other cable
c) Equipotential connection
d) Ground connection of work-piece
 When necessary, use appropriate capacitance to connect the ground.
e) Shielding, when necessary
 Shield the ambient devices

SAFETY
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 Shield the whole welding machine
§1.5 Warning label
The device with a warning label. Do not remove、destroy or cover this label. These
warnings are intended to avoid incorrect device operations that could result in
serious personal injury or property damage.

OVERVIEW
-11-
§2 Overview
§2.1 Features
New PWM technology and IGBT inverter technology.
MIG/MAG with Pulse SYN/Dual pulse SYN/Manual
and SYN function
-Synergic programs for aluminum,
mill steel, stainless steel and CuSi
-JOB mode (Save and call 100 different job
records)
- 2T /4T/S4T/Spot Weld welding mode
- function parameter adjustment
MMA function (Stick electrode)
- VRD (Voltage Reduction Device)
- Hot start (improves electrode starting)
- Adjustable Arc Force
DC TIG
- Lift Arc ignition (prevents tungsten sticking
during arc ignition)
- 2T /4T Trigger Control
- Adjustable Down slope
-Gas/air cooling mode
Internal wire feeder, gear driven for up to
300mm Ø spool
Euro style MIG torch connection
IP23 rating for environmental/safety
protection
Tolerant to variable power supply
Spool Gun Connection

OVERVIEW
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§2.2 Technical Data
Models
Parameters
MULTIMIG 355F
MULTIMIG 515F
Input Voltage（V）
3~415±10%
3~415±10%
Frequency (HZ)
50/60
50/60
Input Current（A）
MIG 19 TIG 15 MMA 21
MIG 33 TIG 27.5 MMA 35
Input Power（KW）
MIG 12.8 TIG 10 MMA 14
MIG 21.5 TIG 18 MMA 23
Welding Current（A）
40-350(MIG)
40-500(MIG)
Welding Voltage（V）
10-35(MIG)
10-50(MIG)
No-load Voltage（V）
67
66
Duty cycle（40℃）
60%350A
100%275A
60%500A
100%400A
Diameter(mm)
Fe:0.6/0.9/1.0/1.2
Ss:0.8/0.9/1.0/1.2
Flux-Cored:0.6/0.8/0.9/1.0/1.
2
Fe:0.6/0.9/1.0/1.2/1.6
Ss:0.8/0.9/1.0/1.2/1.6
Flux-Cored:0.6/0.8/0.9/1.0/1.
2/1.6
Protection class
IP23
IP23
Insulation class
H
H
Dimensions（mm）
690*260*470
644*253*423
Weight（Kg）
21.5
30
Power Factor
0.7
0.7
Note: The above parameters are subject to change with future machine improvement!
§2.3 Brief Introduction
MULTI-GMAW series of welding machines is a new inverter-based MIG/MMA/TIG Welding
machine with Synergic Programs and Dual pulse functions. The MIG function allows you to weld
with Gas Shielded wire applications giving excellent, professional welding results. Easy step-less
adjustment of voltage and wire feed coupled with integrated digital meters allows easy setting of
welding parameters. MULTI-GMAW series of welding machines features MIG welding with
Synergic welding programs designed for ease of use with your selected gas mixture. The operator
selects the gas mixture and wire diameter they are using then simply start welding. Once this is
done the operator can make fine adjustments to the voltage for even greater control of the weld
pool. The added Lift-Arc DC TIG capability delivers perfect arc ignition every time and a
remarkably smooth stable arc produces high quality TIG welds. TIG functionality includes
adjustable Down Slope & Post Gas as well as being gas solenoid-valve equipped. The stick
welding (MMA) capability delivers easy electrode welding with high quality results, including

OVERVIEW
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cast Iron, stainless and low hydrogen. An additional feature is the Spool gun ready function that
allows the simple connection of Spool Gun for the use of thin or softer wires that don’t have the
column strength to feed through MIG torches, such as aluminum wire. In the JOB mode, 100
different JOB records can be stored and called , improve the quality of welding process .
MULTI-GMAW series of arc welding machine is an industrial quality machine that is suitable
for all positions welding for various plates made of stainless steel, carbon steel, alloyed steel etc.
Applications applied to pipe installment, petrochemical, architecture equipment, car repair,
bicycle repair, handicraft and common steel fabrication.
MULTI-GMAW series of welding machines has built-in automatic protection functions to
protect the machines from over-voltage, over-current and over-heat. If any one of the above
problems happens, the alarm lamp on the front panel will be lit and output current will be shut off
automatically for the machine to protect itself and prolong the equipment using life.
§2.4 Duty cycle and Over-heat
The letter “X” stands for Duty Cycle,
which is defined as the portion of the time
a welding machine can weld continuously
with it’s rated output current within a
certain time cycle (10 minutes).
The relation between the duty cycle “X”
and the output welding current “I” is
shown as the right figure.
If the welding machine is overheating,
the IGBT over-heat protection sensing will
send a signal to the welding machine
control unit to cut the output welding current OFF and light the over-heat pilot lamp on the front
panel. In that case, the machine should not be welding for 10-15 minutes to cool down with the
fanrunning. When operating the machine again, the welding output current or the duty cycle
should be reduced.
Relation of welding current and duty cycle for
MULTIMIG 355F

OVERVIEW
-14-
§2.5 Working Principle
The working principle of MULTI-GMAW series welding machine is shown as the following
figure. Three-phase 380V work frequency AC is rectified into DC（530V）, then is converted to
medium frequency AC (about 20KHz) by inverter device (IGBT), after reducing voltage by
medium transformer (the main transformer) and rectifying by medium frequency rectifier (fast
recovery diodes), and is outputted by inductance filtering. The circuit adopts current feedback
control technology to insure current output stably when MMA or TIG. And adopts voltage
feedback control technology to insure voltage output stably when MIG. Meanwhile, the welding
current parameter can be adjusted continuously and infinitely to meet with the requirements of
welding craft.
§2.6 Volt-Ampere Characteristic
MULTI-GMAW series of welding machines has an excellent volt-ampere characteristic, whose
graph is shown as the following figure. The relation between the rated loading voltage U2 and
welding current I2 is as follows: U2=14+0.05I2(V)
44
14
0600 Io（A）
Uo（V）
Working point
Volt-ampere characteristic The relation between the rated loading
voltage and welding current

OPERATION
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§3 Panel Functions & Descriptions
§3.1 Machine Layout Description
§3.1.1 Front and rear panel layout of welding machine
1. “-” Output terminal
2. Gas outlet
3. TIG gun control connector
4. “+” Output terminal
5. Gas Inlet
6. “+” Output terminal
7. The wire feeder control connector
8. The water cooling control connector
9. Input power cable
10. Power switch
11. Adjustment Knob
12. No water LED
13. Alarm Led
14. Power Led
15. The digital meter
16. 2T/4T Selector Switch
17.Gas/Air cooling mode Selector Switch
18. MIG/TIG/MMA/VRD MMA Selector
Switch
19. Fan
§3.1.2 Front and rear panel layout of
wire feeder
1. Mig Torch/Spool Gun Connector
2. Spool Gun Power Supply
Connection
3. Water Inlet connector (blue)
4. Water outlet connector (red)
5. Gas Inlet
6. The wire feeder control connector
7. “+” input terminal
8. Water Inlet connector (blue)

OPERATION
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9. Water outlet connector (red)
§3.1.3 Internal panel layout of wire feeder
1. Spool holder assembly
2. Wire feed assembly
§3.1.4 Front and rear panel layout of water cooling
1.Water inlet
2. Water Inlet connector (blue)
3. Water outlet connector (red)
4. The water cooling control connector
5. Water Inlet connector (blue)
6. Water outlet connector (red)
§3.2 Front Panel Functions and Descriptions
§3.2.1 Front Panel Functions of wire feeder
1. Adjustment Knob
2. Adjustment Knob
3. MIG-MAG Manual / MIG-MAG
SYN selector switch
4. Manual wire key
5. 2T/4T /Spot Weld selector Switch
6. JOB key (Call save JOB parameters)
7. Gas/Air cooling mode Selector Switch
8. Save/Delete key (Press and hold the key to
delete the job parameters that have been
save)
9. Function key 17. Wire feed LED

OPERATION
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10.Air check key 18. Material thickness
11. No water LED 19. Inductance LED
12. Spool Gun LED 20. voltage feedback LED
13. Alarm Led 21. The digital meter
14. JOB LED 22. Welding voltage LED
15. Welding current LED 23. Current feedback LED
16. The digital meter 24. Power LED
25.Second Light
§3.2.2 Operating process of wire feeder
1) Welding method selection (press the selector
switch(1) to select, the corresponding indicator
light)
MIG-MAG Pulse SYN
MIG-MAG dual pulse SYN
MIG-MAG Manual
MIG-MAG SYN
2) Welding mode selection (press the selector
switch(2) to select, the corresponding indicator
light)
2T mode
Burn back Time
Pre Gas Time
Slow Feed Time
Post Gas Time
Welding conditions
Gun Switch
Gas Supply
Wire Feed
Output Voltage
Output Current