Top Gun MULTIMIG 160 User manual

INTRODUCTION
ISO9001:2000
2015.10
MULTIMIG
series inverter
INVERTER MIG Arc Welding Machine
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.
OPERATORS’MANUAL

CONTENT
- Ⅳ-
CONTENT
§
1 Safety ..........................................................................................1
§1.1 Signal Explanation....................................................................................................... 1
§1.2 Arc Welding Damage................................................................................................... 1
§1.3 The knowledge of Electric and Magnetic Fields....................................................... 5
§2 Overview.......................................................................................7
§2.1 Brief Introduction........................................................................................................ 7
§2.2 Working Principle........................................................................................................ 8
§2.3 Volt-Ampere Characteristic........................................................................................ 8
§3 Installation andAdjustment.....................................................10
§3.1 Parameters ................................................................................................................. 10
§3.2 Duty cycle and Over-heat...........................................................................................11
§3.3 Equipment Connection...............................................................................................11
§4 Operation....................................................................................15
§4.1 Layout for the front and rear panel......................................................................... 15
§4.2 Welding operation...................................................................................................... 17
§4.3 Welding parameters................................................................................................... 18
§4 .4Operation environment............................................................................................. 18
§4.5 Operation Notices...................................................................................................... 19
§5 Maintenance & Troubleshooting .............................................20
§5.1 Maintenance............................................................................................................... 20
§5.2 Troubleshooting ......................................................................................................... 21
§5.3Electrical schematic drawing..................................................................................... 22

SAFETY
- 1 -
§
1 Safety
§1.1 Signal Explanation
The above signals mean warning! Notice! Running parts and getting an electric
shock or thermal parts will take damage for your body or others. The corresponding
notices are as follows. It is quite a safe operation after taking several necessary
protection measures.
§1.2 Arc Welding Damage
The following signals and word explanations are to some damages for your body
or others happening on the welding operation. While seeing these, please remind of
yourself or others to be dangerous.
Only ones who are trained professionally can install, debug, operate, maintain and
repair the equipment.
During the operation, non-concerned people should be lift, especially for children.
After shut off the machine power, please maintain and examine the equipment
according to §5 because of the DC voltage existing in the electrolytic capacitors.
ELECTRIC SHOCK CAN KILL.
Never touch electrical parts.
Wear dry, hole-free gloves and clothes to insulate yourself.
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.
Take carefully when using the equipment in small place, falling-off and wet
circumstance.
Never close the machine power before installation and adjustment.

SAFETY
- 2 -
Ensure to install the equipment correctly and ground the work or metal to be welded
to a good electrical (earth) ground according the operation manual.
The electrode and work (or ground) circuits are electrically “hot” when the welder
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”.
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
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 a shock.
FUMES AND GASES CAN BE DANGEROUS.
Welding may produce fumes and gases hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume. 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 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

SAFETY
- 3 -
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.
ARC RAYS CAN BURN.
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 helpers 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 adds the 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.

SAFETY
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Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
WELDING SPARKS can cause fire or explosion.
Remove fire hazards 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 ear plugs 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
chains, crane cables or other alternate circuits. This can create fire hazards or
overheat lifting chains or cables until they fail.

SAFETY
- 5 -
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.
-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 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.
§1.3 The knowledge of 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 all the
world. Up to now, no material evidences show that EMF may have effects on health.
However, the research on damage 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.

SAFETY
- 6 -
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.
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.

OVERVIEW
- 7 -
§2 Overview
§2.1 Brief Introduction
MIG SERIES arc welding machine adopts the latest pulse width modulation (PWM)
technology and insulated gate bipolar transistor (IGBT) power module, which can change work
frequency to medium frequency so as to replace the traditional hulking work frequency
transformer with the cabinet medium frequency transformer. Thus, it is characterized with
portable, small size, light weight, low consumption and etc.
MIG SERIES arc welding machine uses Mix gas as shielded gas to realize gas shielded
welding, active gas（Ar+O2、Ar+CO2）as shielded gas to realize MAG welding and inactive gas
（Ar）as shielded gas to realize MIG welding.
MIG SERIES arc welding machine has automatic protection functions with intelligent to
over-voltage, over-current and over-heat. If any one of the above problems happens, the alarm
lamp on the front panel will be lighted and output current will be shut off automatically to protect
itself and prolong the equipment using life.
MIG SERIES Features:
1. Digital control system, real-time display the welding parameters;
2. High performance multifunction power source (MMA/MIG/MAG);
3. Waveform control, stable welding arc;
4. IGBT technology, low power dissipation;
5. Rated duty circle is 40%(40℃).
MULTIMIG 160/200 has another feature: Synergic control of the welding current and voltage.
MIG SERIES arc welding machine is suitable for all positions welding for various plates made
of stainless steel, carbon steel, alloyed steel, copper, titanium, etc, which is also applied to pipe
installment, mould mend, petrochemical, architecture decoration, car repair, bicycle, handicraft
and common manufacture.
MAG--Metal Active Gas Welding
MIG--Metal Insert Gas Welding

OVERVIEW
- 8 -
§2.2 Working Principle
The working principle of MIG SERIES arc welding machine is shown as the following figure.
Single-phase 220V work frequencyAC is rectified into DC（350V）, then is converted to medium
frequency AC (about 40KHz) 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.
Rectifier Inverter Transformer Rectifier Hall
Current
Feedback
control
Single-phase AC DC AC DC
220V 50Hz
AC DC
Welding current
regulate
(Wire feed speed) Wire feeder
motor
PWM signal
CPU control
Voltage
Feedback
control
§2.3 Volt-Ampere Characteristic
MIG SERIES welding machine has an excellent volt-ampere characteristic, whose graph is shown as the
following figure. The relation between the rated loading voltage U2and welding current I2is as follows:
U2=14+0.05I2(V)
Current sensor

OVERVIEW
- 9 -
44
14
0600 Io（A）
Uo（V）
Working point
Volt-ampere characteristic The relation between the rated loading
voltage and welding current
§2.4Principles of welding

INSTALLATION AND ADJUSTMENT
- 10 -
§3 Installation and Adjustment
§3.1 Parameters
Parameters
Model MultiMIG200 PFC MV SYN
Input Voltage（V）1~110/120/130±10% 1~220/230/240±10%
Input Current（A）MIG 37.8 MMA 32 TIG 29 MIG 29 MMA 30 TIG 20
Input Power（KW）MIG 4.0 MMA 3.5 TIG 3.2 MIG 6.2 MMA6.2 TIG 4.2
Welding Current（A）40-200
No-load Voltage（V）65
Duty cycle（40℃）
35% 140A 30% 110A 40% 150A
60%
110A 60% 80A 60% 125A
100% 85A 100% 65A 100% 95A
30% 200A 25% 200A 35% 200A
60% 145A 60% 130A 60% 155A
100% 110A 100% 100A 100% 120A
Diameter(mm) Fe：0.6/0.9/1.0 Ss：0.8/0.9/ 1.0 Flux-Cored：0.6/0.8/0.9/1.0
Protection class IP23
Insulation class H
Dimensions（mm）511*213*400
Weight（Kg）15
Model
Parameters MultiMIG250 PFC MV SYN
Input Voltage（V）1~110/120/130±10% 1~220/230/240±10%
Input Current（A）MIG 42 MMA 40 TIG 26.5 MIG 37 MMA41 TIG 28.5
Input Power（KW）MIG 4.6 MMA 4.2 TIG 3.0 MIG 8.3 MMA 9.2 TIG 6.4
Welding Current（A）40-200
No-load Voltage（V）65
Duty cycle（40℃）
30% 160A 35% 130A 35% 140A
60% 115A 60% 100A 60% 110A
100% 90A 100% 80A 100% 85A
35% 250A 30% 250A 35%250A
60% 195A 60% 180A 60% 195A
100% 150A 100% 140A 100% 150A
Diameter(mm) Fe：0.6/0.9/1.0 Ss：0.8/0.9/ 1.0 Flux-Cored：0.6/0.8/0.9/1.0
Protection class IP23
Insulation class H
Dimensions（mm）618*240*445
Weight（Kg）23
Note: The above parameters are subject to change with the improvement of machines.

INSTALLATION AND ADJUSTMENT
- 11 -
§3.2 Duty cycle and Over-heat
The letter “X” stands for the duty cycle, which is defined as the proportion of the time that a
machine can work continuously within a certain time (10 minutes). The rated duty cycle means
the proportion of the time that a machine can work continuously within 10 minutes when it
outputs the rated welding current.
The relation between the duty cycle “X” and the output welding current “I” is shown as the
right figure.
I（A）
0
100％
60％
90
X
The relation between duty cycle and welding
current for MIG160
115 160
If transformer is over-heat, the heat relay inside it will open and will output an instruction to
circuit board, cut AC relay and the output welding current, and brighten the over-heat pilot lamp
in the front panel. At this time, the machine should be relaxed for 15 minutes to cool the fan.
When operating the machine again, the welding output current or the duty cycle should be
reduced.
§3.3 Equipment Connection
Operation Steps：
1、Connect the power source input cable of welding machine with the output port of air switch in
electric box on the spot.
2、Connect the cable plug of wire feeder to the positive output of welding machine.
3、Connect the control cable plug of wire feeder to the aero socket on the front board of welding
machine.

INSTALLATION AND ADJUSTMENT
- 12 -
4、Connect the negative pole of welding machine to the work piece (base metal).
.
5、Connect the output pipe of gas cylinder to the input joint of gas valve on the wire feeder and
clamp it.
6、Insert the torch joint into the output of wire feeder unit and keep the wire aim at the wire
feeder mouth.
Note: The plane of the joint should be aimed at screw, plugged tightly and rotated 90º, then
screw the bolt tightly to ensure the gun contacting closely.
7、Connect the shielded gas pipe of torch with the output of front panel on wire feeder.
8、Connect the control cable pin of torch with the two-lead aero socket of front panel on wire
feeder.
9、Notice that the wire diameter should be accordant with the wire wheel and torch tip and press
the wire properly with the handle.
§3.4 Maintenance of MIG Gun mechanism
§3.4.1 Dissection graphics for the MIG GUN
12
34
7
11
1213
14
15
1617
18
19
10
95 6
8
3.1
§3.4.2 The parts list for the MIG GUN
NO. Description QTY. Remark
1
Tip D.12 14-15AK
1

OPERATION
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2
Electric nozzle 0.8/M6*25
1
3
15AK Goose gun neck
（
Hexangular adapter and Plastic adapter
）
1
3.1 15AK Goose gun 1
4 Hexangular adapter 1
5 Plastic adapter 1
6 MIG blue handle 1
7 Torch Switch 21.8mm 1
8 Screw D.3*10 3
9
Handle locking ring
1
10 Cable fixing joint 15AK 1
11
Coaxial cable team /16mmq/3m
1
12
Cable thimble 12-16-25 MMQ
1
13 CO2Euro-rear thimble 1
14 Screw M4*6 UNI 6107 1
15 Torch locknut /plastic screw thread 1
16 Euro-main socket/flexibility pin 1
17 Feeding pipe locknut 1
18 Insulating feed pipe 0.6-0.8 3m, Blue 1
19 Spanner for the electric nozzle 1
§3.4.3 The operation for the MIG GUN
1. Service the wire feed mechanism at least every time the reel is changed.
·Check the wear of the feed roll groove and change the feed roll when necessary.
·Clean the welding gun wire guide with compressed air.
2. Cleaning the wire guide
Pressure of the feed rolls remove metal dust from the filler wire’s surface which then finds its
way to the wire guide. If the wire guide is not cleaned, it gradually clogs up and causes wire feed
malfunctions. Clean the wire guide in the following manner：
Remove the welding gun’s gas nozzle, contact tip and contact tip’s adapter.
With a pneumatic pistol, below compressed air through the wire guide.
Blow the wire feed mechanism and reel housing clean with compressed air.
Reattach the welding gun’s parts. Tighten the contact tip and contact tip’s adapter to spanner
tightness.

OPERATION
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3. Changing the wire guide
If the wire guide is too worn or totally clogged, change it to a new one according to the
following instructions.
Open the mounting nut of the wire guide which exposes the end of the wire guide.
Straighten the welding gun’s cable and withdraw the wire guide from the gun.
Push a new wire guide in to the gun. Make sure that the wire guide enters all the way into the
contact tip’s adapter and that there is an O-ring at the machine-end of the guide.
Tighten the wire guide in place with the mounting nut.
Cut the wire guide 2mm from the mounting nut and file the sharp edges of the cut round.
Reattach the gun in place and tighten the parts to spanner tightness.

OPERATION
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§4 Operation
§4.1 Layout for the front and rear panel

OPERATION
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1. Welding current knob: Set the welding current.
2. Alarm Led: When the welder is over voltage, less voltage, over current or over heated,
the alarm pilot lamp will be on.
3. Power Led: Power led is lighted when open the machine.
4. Current display: Welding Current display when machine is working, Set current
display before welding. Unit：A.
5. Wire speed LED：You can use current setting knob to set the wire speed when the wire speed LED
is on(MIG).
6. Current LED：When the current LED is on, it display the actual output welding current(MIG).
7.Welding voltage/Down slope/Arc force knob: On MIG, When the program voltage
can’t perfectly match the welding current, the knob can adjust voltage On TIG, the
knob can adjust the current down time. On MMA, the knob can adjust the force
current.
8.Voltage display: Welding voltage display when machine is working, Set voltage display
when MIG mode before welding. Unit：V.
9. Wave control knob: Controls arc characteristics, Determines the rate at which the
amperage rises when a short circuit is produced.
10.Spool Gun Switch: You can control the spool gun function active(ON) or not(OFF), at
the same time ,you must make the Switch 14 in “ON” mode;
11.Romote Switch
12. Manual wire switch & air check switch: up for manual wire and down for air check.
13. Polarity conversion: connect to”+”,the MIG gun connecter will be “+”,connect to
“-”,the MIG gun connecter will be “-”;
14.TIG GAS Connect.
15.Output anode: When TIG mode, this polarity must connect the work piece
16. MIG GUN Connect.

OPERATION
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17. TIG gun control connecter.
18.Output cathode：When MIG mode, this polarity must connect the work piece
19.Burnback knob
20.Slow feed knob
21.Post flow knob
22.Pre-flow knob
§4.2 Welding operation
For example MULTIMIG 200
§4.2.1 MIG mode operation:
1. Shielding Gas choice
1) When the wire material is Fe, the shielding gas is 80%Ar + 20%CO2 ；
2) When the wire material is Ss, the shielding gas is 98%Ar + 2%O2 ；
3) When the wire material is Al, the shielding gas is 100%Ar.
2. Welding state choice
1)Press the weld manner key, choose MIG manner and the MIG LED is lighted；
2) Spool Gun Switch turn off(down).
3) Manual wire switch & air check switch，Burnback adjust，Slow feed adjust,Post flow
adjust, Pre-flow knob adjust；
3)Press the welding mode key, choose 2T or 4T；
4)Spool Gun Switch turn on(up):
3. Adjust Welding parameter
1) Different wire diameter ,the minimum welding current is different；
2) Adjust the current knob , the corresponding welding voltage is changed automatically；
3) When the programmable welding voltage isn’t the perfect for the operator, the voltage

OPERATION
- 18 -
can be changed tinily by adjusted the knob；
4) If the operator adjust the wave control knob, the arc characteristics can be controlled；
§4.2.2 TIG mode operation:
1. Press the weld manner key, choose TIG manner and the TIG LED is lighted；
2. Press the welding mode key, choose 2T or 4T；
3. Adjust the current knob to control the welding current；
4. Adjust the down slope knob to control the welding current descend time.
§4.2.3 MMA mode operation:
1. Press the weld manner key, choose MMA manner and the MMA LED is lighted；
2. Adjust the current knob to control the welding current；
3. Adjust the welding arc force knob to control the arc force current.
Note
：
The current display is preset current before welding and is welding current when
welding. The voltage display is real voltage.
§4.3 Welding parameters
Wire diameter (mm)
Welding current (A)
Plate thickness (mm)
0.6
25-110
1.0-1.6
0.8
35-160(200)
1.0-2.3
0.9
45-160(200)
1.0-2.3
1.0
45-160(200)
1.2-6
§4 .4Operation environment
▲Height above sea level ≤1000 M
▲Operation temperature range -10～+40℃.
▲ Air relative humidity is below 90 %( 20℃).