Top Gun TGWMIG165MST User manual

USER MANUAL
TGWMIG165MST MIG /STICK/DC TIG

WARNING!
This operator’s Manual including the guides of equipment and installation descriptions, protect yourself and others
from possible serious injury or death, please read this manual carefully.
Symbol definition
This Manual contains symbols as blow, please refer to their means expressed
Symbol
Definition
Texts beginning with this symbol indicate potentially serious dangers
and, if not avoided, could result in serious accidents that could result
in death or serious injury to personnel.
The text beginning with this symbol indicates a potentially hazardous
situation that, if not avoided, could result in minor injury to persons or
property damage.
Texts beginning with this symbol indicate potential risks which, if not
avoided, may cause malfunction or damage to the equipment.
Version
Due to product version upgrades or other reasons, the contents of this document are not regularly
updated. Unless otherwise agreed, this document is intended as a guide only and all statements,
information and recommendations in this document do not constitute any guarantee, expressed or
implied.
The pictures in this document are for reference only. If the picture is different from the real one, then
prevail in kind.

Contents
1 Attention................................................................................................................... 1
2 Product brief introduction........................................................................................6
2.1 Summarize...........................................................................................................6
2.2 Technical parameters..........................................................................................7
3.Installation instructions............................................................................................... 8
4 operating instructions................................................................................................10
4.1 Operation panel interface................................................................................ 10
4.2 Welding operation instruction......................................................................... 11
4.3 Polarity conversion joint................................................................................... 12
4.4 Welding environment and safety..................................................................... 12
4.5 Welding problems and solution....................................................................... 13
5 Daily maintenance and checking............................................................................13
6 Trouble shooting and error checking..................................................................... 16
Initial problems diagnose..............................................................................................17
Initial problems diagnose..............................................................................................17
Appendix ⅠWelding parameter list............................................................................19

1
1 Attention
The precautions listed in this manual are intended to ensure the safe use of the machine and to
protect you and others from harm and injury.
The design and manufacture of the welding machine power take full account of the safety, be
sure to comply with the precautions in this manual, otherwise it will cause serious accidents.
Wrong use of welding machine power supply will cause the following kinds of different degrees
of harm and injury. Please read this manual carefully to avoid or minimize such harm.
Symbol
Description
Touching any live electrical part may cause fatal electric shock or burns.
Welding fumes and gases are hazardous to health.
Working in tight places can cause suffocation due to lack of oxygen.
Splashes and hot finished base metal can cause a fire.
Poor cable connection, steel and other parent metal side current loop is
not in full contact, it will cause heat conduction and cause a fire.
Do not weld on containers containing flammable substances as this may
cause an explosion.
Do not weld sealed containers, such as tanks (boxes), pipes and other
devices, otherwise it will rupture.
Arc light can cause eye irritation or skin burns and other body injuries.
Spatter and welding slag can burn eyes or burn the skin.
Dumping cylinders can cause injury.
Cylinders with high pressure gas, wrong use can cause high pressure
gas spouts, causing accident.
Do not place fingers, hair, clothing, etc. near rotating parts such as
cooling fans
The welding wire is shot from the torch and can stab eyes, face and
other exposed parts of the body
When lifting, staffs shall not be standing under the welder, or standing in
front of the movement, to prevent the welder falling injured.

2
To avoid accidents, please observe the following rules:
Do not use this machine for other works but welding.
The construction of the input power source, the setting of the installation site, the use of
high-pressure gas, storage and disposition, the storage of the workpiece after welding and the
disposal of waste shall be carried out in accordance with the relevant regulations.
Irrelevant staffs do not enter the welding work place.
Pacemaker wearers should consult with their doctor before operating.
Please let qualified people or persons which with relevant knowledge and skills to install,
operate, maintain and repair the welder.
To ensure safety, please understand the contents of this manual.
To avoid electric shock, please observe the rules
Do not touch live parts.
Let relevant technicians connect the welder and base metal grounding correctly.
It must switch off the power when installation, maintenance, and waiting 5 minutes before
operation. Capacitors can be charged, even if the power has been cut off, but also to ensure
that the capacitor is not charged voltage, and then operate.
Do not use cables that have insufficient cross-sectional area, damaged insulation sheath, or
exposed conductors
In the cable connection, please ensure the insulation.
Do not use the welder when the case opened or removed.
Do not use insulated gloves which is damaged or damped.
Please use safety net when working at height.
Regular maintenance and repair, and please repair the damaged parts before using.
When not in use, turn off all input power.
When using AC arc welder in narrow places or higher places, please observe the relevant
national and local standards and regulations.
To prevent fire and explosion, please observe the following rules：
Do not place flammable materials near the welding place.
Do not welding near flammable gas.
Do not place the hot finished base material close to flammable material.
When welding in the patio, on the ground and the wall, please remove the combustible
materials on the back.
The cable connected with the base metal as close as possible to the welding spot.

3
Do not welding gas-filled trachea, seal groove, etc.
Place a fire extinguisher near the welding work site to prevent the fire from happening.
To avoid breathing these fumes and gases hazardous to health, please use
the required protective equipment.
To prevent accidents such as gas poisoning and suffocation, please use the prescribed
exhaust facilities and use respiratory protection equipment.
To prevent welding fumes and other dust damage and poisoning, please use the prescribed
local exhaust equipment and respiratory protective equipment.
When working in cabinets, boilers, cabins, etc., CO2, which is heavier than air, stays at the
bottom. To prevent lack of oxygen, please fully ventilate and use an air respirator.
When working in a confined area, please accept the inspection of the supervisory staff, and
fully breathe and use respiratory protection equipment.
Do not weld in the degreasing, cleaning, and spray operation areas.
When welding plated or coated steel plates, harmful fumes and gases are generated. Please
use respiratory protection equipment.
To avoid harm to you and others caused by arc, splashing, welding slag,
noise, etc., please use the specified protective equipment.
When using welding or supervising welding, use protective equipment with sufficient shading.
Please wear protective glasses.
Wear protective equipment such as leather gloves for protection from welding, long-sleeved
clothes, feet, and aprons.
Set up a protective barrier around the welding site to prevent the arc from endangering others.
To prevent the dumping, cracking, etc. of gas cylinders, please observe the
following regulations:
Please use the cylinder correctly as specified.
Please use the gas regulator supplied with our company or recommended.
Please read the gas regulator instruction manual before use, please observe the precautions.
Use a dedicated cylinder holder and related parts to secure the cylinder.
Do not leave cylinders exposed to high temperatures or sunlight.
When opening the cylinder valve, do not approach the gas outlet on the face.
When the cylinder is not in use, attach the cylinder cap.
Do not place the welding torch on the cylinder. The electrode must not touch the cylinder.
Contact with rotating parts can cause injuries. Please observe the
following rules:

4
Do not use the welder with the case removed.
Persons with professional qualifications or relevant knowledge and skills can install, operate,
overhaul, and maintain the welder.
Do not put fingers, hair, clothing, etc. Close to the cooling fan and other rotating parts.
Wire ends can cause injuries. Please must observe the following rules:
When confirming whether to feed the wire, do not look into the hole of the contact tip.
Otherwise, the wire will shoot to hurt the eyes and face.
When manually feeding the wire or pressing the torch switch, do not place the end of the
torch close to the exposed part of the body such as eyes or face.
In order to work better and maintain the power of the welder, please must
observe the following regulations:
If the power source of the welder is placed on an inclined plane, attention should be paid to
preventing it from falling.
It is forbidden to use welding power for the thawing of pipes.
When the welding power source is lifted using a forklift, it should be mounted sideways to
prevent tipping.
When the welding power supply is lifted by a crane, the cable should be tied at the lifting ring.
The angle between the cable and the vertical should not exceed 15 degrees.
When the welder is equipped with gas cylinders and wire feeders, these two devices should be
taken from the power supply and the welder level should be kept as far as possible. When
moving the gas shielded welding machine on the ground, be sure to When the welding power
supply is lifted by lifting fork lift, to prevent dumping, please install from side.
When the welding power supply is hoisted, the cable shall be attached to the hanging ring, and
the Angle between the cable and the vertical direction shall not exceed 15 degrees.
When the welding machine is equipped with gas cylinder and wire feeder, the two devices
should be connected to the power supply and the welding machine level is maintained as far as
possible. When moving the gas shielded welding machine on the ground, be sure to fix the
cylinder with a belt or chain to prevent the dumping.
If the wire feeding machine is used for welding, make sure it is firm and insulated.。
If the device has a strap or handle, remember that it is only suitable for hand use. It is
prohibited to use crane, forklift or other mechanical hoisting.
Attention to electromagnetic interference
Additional precautions may be required when welding power is used in a local area.
Before installing the welding equipment, the user should assess the potential electromagnetic
problems in the installation environment area, as shown below:

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a) The upper, lower and adjacent power cables, control cables, signal cables and telephone
cables of the welding equipment;
b) Radio and television transmitting and receiving devices;
c) Computer and other control equipment;
d) Safety identification equipment, such as the monitoring of industrial equipment
e) People Health conditions such as cardiac pacemakers and hearing AIDS;
f) Equipment used for calibration and measurement;
g) Interference of other equipment in the environment; Users shall ensure that other
equipment in the environment is compatible with the environment; This may require
additional protection;
h) The actual situation of welding or other activities carried out.
Users should comply with the following items to reduce radiation interference:
a) According to the manufacturer's suggestion, the welding equipment should be connected
to the main supply line;
b) According to the manufacturer's suggestion, welding equipment should be maintained
routine;
c) The welding cables should be as short as possible so that they are close to each other and
close to the ground;
d) All the metal components of the welded assembly and its adjacent components shall be
subject to safety verification;
e) The workpiece should be kept well grounded;
f) Other cables and equipment in the environment can be selectively shielded and protected,
thus reducing the impact of interference. The welding equipment can be completely
shielded in special occasions.
The user should be responsible for the interference caused by welding.

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2 Product brief introduction
2.1 Summarize
The welding machine of our brand is manufactured by inverter technology.
The principle is to use the single tube IGBT (the inverter frequency can reach 25-50KHz) to
convert 50/60Hz to dc and then to high frequency and lower voltage rectification ，The pulse
width modulation (PWM) output can be used for welding high-power dc power supply，due to
switching power inverter technology is adopted, the weight of the welder has dropped
considerably, the conversion efficiency of the whole machine is increased by more than 30%.
The machine can meet the requirement of gas protection welding and increases the function of
manual arc welding and improving argon arc welding。Use full digital panel display，Wire feeding
speed and welding voltage centralized regulation can be achieved. so it is easier to adjust welding
parameters。Our carbon dioxide gas shielded welding machine is equipped with unique digital
electronic reactor circuit, The welding process of short circuit transition and mixed transition is
controlled very precisely, so It has excellent welding characteristics. Compared with silicon
controlled welder and tapped welder, it has the following advantages: stable wire feeding speed,
light energy, energy saving and no electromagnetic noise。It also has the characteristics of small
splash, good arc, deep pool and high load.
The equipment belongs to portable dual function machine, applicable to family customers. It has
the advantages of high efficiency and power saving, and it is suitable for welding of multi-metal
and multi-process requirements.
Thank you for choosing our products. Please feel free to give your precious suggestions; we will
make efforts to perfect our products and service.
This equipment is mainly used in industry. In the indoor environment, the equipment may
produce radio interference. Please take precautions before use.

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2.2 Technical parameters
Machine type
TGWMIG165MST
Supply voltage (V)
1 phase AC 240V±15%
Frequency (Hz)
50/60
Rated Max. input
current (A)
26.2 (MIG)
30.1 (MMA)
18.7 (TIG)
Output current
adjustment (A)
40-165 (MIG)
30-160 (MMA)
20-160 (TIG)
Output voltage (V)
16.0-22.3 (MIG)
21.2-26.4(MMA)
10.8-16.4 (TIG)
No load voltage (V)
62
Duty cycle (%)
15
Power factor
0.73
Efficiency (%)
80
Wire feeder type
All-in-one
Wire feed speed
(m / min)
2-15
Post flow time (S)
1.0
Wire diameter (mm)
0.8/1.0 (stainless steel/carbon steel)
1.0/1.2(flux cored)
Insulation grade
F
Enclosure protection
class
IP21
Suitable plate
thickness (mm)
0.5-5
Net Weight (kg)
7.8KG
Overall dimension
(mm)
410×165×300

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3.Installation instructions
Our welding machine is equipped with power supply voltage compensation device，The power
supply voltage can continue to work when the rated voltage is within 15% range.
When using longer cables, in order to reduce voltage drop, use a larger section of the cable is
recommended; If the connection cable is too long, It may have a great influence on the arc
performance of the welder as other performance of the system. So we recommend that you use
the recommended configuration length.
Confirm that the vent of the welding machine is not covered and blocked so as to avoid the
failure of the cooling system.
The yellow and green water line of the power supply must be effectively grounded.
gas shielded welding Installation.
The gas cylinder containing the carbon dioxide gas decompression flow meter is closely
connected with the carbon dioxide intake inlet of the machine.
insert the fast plug of the ground wire in the front panel on the fast socket.
The wire holder filled with wire installed on the wire feeder，The hole position of the wire plate
should be aligned with the fixed plug on the shaft.
According to the diameter of the wire, choose different wire feeder.
Loosen the pressure wheel nut, to pass through the guide wire tube into the wire feed wheel
groove, adjust the pressure wheel pressure welding wire, guarantee the welding wire is not
sliding, but cannot too much pressure, to prevent the welding deformation of wire so as to
influent the wire feeding.
The wire coil should be rotated and loosen the wire, to prevent the wire from loosening, the
new wire disk head is usually inserted into the fixed hole at the edge of the wire. In normal
use, to prevent the bending of the wire to be stuck, please cut this part of wire.
The welding gun is inserted into the output socket of the front panel and screwed tightly.
And put the wire into the gun.
Manual welding installation steps
There are two ways to connect the dc welder normally: Positive connection and negative
connection.
Positive connection：Welding pliers connected to the negative pole, workpiece connected to
positive pole. Suitable for acid electrode.
negative connection: workpiece connected to the negative pole, Welding pliers connected to
the positive pole. Suitable for basic electrode.
The welding is selected according to the process requirements of the workpiece, if selection
not well so that arc instability, spatter and adhesion occur, we can replace the fast plug to
change the polarity potable.
Make sure the cable is connected to the soldering pliers and the quick plug ，Connect the
quick plug to the corresponding fast socket ，And tighten it clockwise. The ground clamp

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clamps the workpiece.
This procedure must be operated by an electrician！
According to the input voltage and current of the welder（See the technical parameters table）
Connect proper power cable to the distribution box with corresponding capacity，Do not connect
the wrong voltage，make sure that the error of power supply is within permitted range.
Gas shielded welding installation instructions
Manual arc welding installation （For reference only, please choose the positive
connection or negative connection according to the actual choice.）

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4 operating instructions
4.1 Operation panel interface
TGWMIG165MST
1
Voltage display.
2
Current display.
3
Welding mode shift button:
1. Press the button can shift “Flux-cord 1.0” / “Flux-cord 1.2” / “Solid wire 0.8” / “Solid wire
1.0” / “MMA” / “LIFT TIG” functions.
2. Press & hold for 3 seconds, can shift to “Voltage-micro-adjustment” mode.
4
Multiple-function knob: set the welding data based on different mode.
5
Function mode selection MIG MMA LIFT TIG
Remark: Fast adjustment: Press and rotate the knob; Slow adjustment: Rotate the knob only
4
1
2
3
5

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4.2 Welding operation instruction
On display
After open the power supply，front panel display state Sq-type，and【Multifunctional data display
window】Flash 3 seconds (Or any buttons and knobs on the front panel). Enter the welding mode
saved last time.
Manual welding operation procedures
At the welding stop, operation [manual welding and gas protection welding switch key], Manual
welding indicator light, into manual welding mode.
In Manual welding mode, operation【VRD/ 2T/ 4T Function switch key】, VRD Indicates that the
VRD function is turned on, meanwhile【Multifunctional data display window】display, VRD The
indicator light is not on, indicating that the VRD function is not turned on.
during welding process adjust【Multifunctional data adjusting knob】The welding current can be
changed, in【Multifunctional data display window】display. The welding current range is 30A to
maximum current adjustment.
Operating procedures for gas protection welding
Check wire operation：press gun switch，within 5S If not enter welding state, it will enter the wire
check state，Wire feeder fast wire feeder，It is convenient to send wire from wire feeder to gun
head.
2T/4T operation: 【VRD/ 2T/ 4T Function switch key】, select welding mode. 2T indicator light on,
Represents two-step control: press the welding gun switch, gas flow in advanced, normal weld;
Loosen the welding gun switch，burn-back & remove the ball, lag 3 seconds stop gas flow. 4T
indicator light on, represents four-step control: press the gun switch for the first time, gas flow in
advance, pilot arc welding; First release the welding gun switch, normal weld; Press the gun
switch for the second time. The welding current is attenuated to the arc current and maintained;
Release the welding gun switch for the second time, burn-back/ remove the ball, Time delay 3
seconds off gas.
Fault display：
Failure display of wire feeder
wire feeder fault display Err 003, at【Multifunctional data display window】display continuously
flashing, the welder does not work properly this moment. Turn off the welder and restart it.
Overcurrent, overheating fault display
The welding machine over flow failure display Err 001, at【Multifunctional data display window】
display continuously flashing, The welder does not work properly this moment. Turn off the welder
and restart it, the front panel normally shows the welding parameters set before the failure, the
welder's overheating fault will be automatically relieved, and the front panel shows normal, the
welder can work normally, then no need to reset the welder.

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4.3 Polarity conversion joint
This machine has the polarity conversion; There are positive output terminal and negative output
terminal between wire feeder and wire spool; When use solid wire with gas protection, torch
socket should be connected to the positive output terminal, ground cable should be connected to
the negative output terminal; When use flux-cored wire, the two connected cable should be
exchanged.
4.4 Welding environment and safety
Working surrounding
a) Welding should be carried out in dry surroundings. The air humidity level should not be higher
than 90%.
b) The temperature should be between -10C to 40C.
c) Don’t use the welding machines in sunshine or rain. Keep it off water.
d) Don't use the machines in the places of dust or corrosive air.
e) MIG welding should not be carried out in places with quick air flow.
Safety norms
Protection circuit of over-voltage, over-current and over-heat circuits are designed in the
welding machines. It will stop working automatically when the input voltage, output current or
internal temperature exceed the rated value. But if the machines are excessively used, such
as with input voltage higher than the rated, the machine might be damage. Please pay close
attention to the following matters.
a) Keep good ventilation!
The welding machines work with high welding current. Nature air flow can’t reach the
requirement of heat dissipation. So the fans are installed as cooling system to ensure stable
performance.
Make sure the ventilation windows are not covered or blocked. The distance between the
machines and things around should not be less than 0.3m. Good ventilation is good for
welding performance and operational life.
b) Never over load!
Check the maximum rated current (according to the Duty Cycle chosen). Make sure the
welding current is never higher than the rated value. Over current running will obviously
shorten the operation life, even damage the machine.
c) Never over voltage!
The Input Voltage could be found in Technical data diagram. The auto-compensation

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function will keep the welding current in the rated range. If the input voltage exceed the
permissible value, the machine would be damaged. Users should take protective measures
in advance to avoid it.
d) Make sure earth connected before operation.
On the rear panel of welding machine, a screw for earth connecting would be found. It must
be ground connected with cable whose section is bigger than 6mm2before operation, to
avoid accidents caused by static or electricity leak.
4.5 Welding problems and solution
The phenomenon listed below may happen due to relevant accessories used, welding
material, surroundings and power supply. Pleas improve surroundings and avoid these
problems..
Arc starting difficulty. Arc interruption happens easily:
a) Examine whether grounding wire clamp contacts with the work pieces well.
b) Examine whether each joint has improper contact.
The output current fails to reach rated value:
The deviation of power voltage from rated value may cause that the output current does no
accord with adjusted value. When the power voltage is lower than rated value, the maximum
output current may be lower than rated value.
The current can not keep stable during operation:
This situation may relate to the following factors:
a) The voltage of electric power network changes;
b) Serious interference from electric power network or other electric facilities.
Gas vent in welds:
a) Examine whether the gas supply circuit has leakage.
b) Examine whether there is sundries such as oil, dirt, rust, paint etc. on the surface.
5 Daily maintenance and checking
Daily maintenance

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a) Remove dust regularly with dry compressed air. If the welding machine is used in
surroundings with heavy smoke and polluted air, it is necessary to remove dust at least one
time one month.
b) The pressure of compressed air shall fall to required level to prevent damage to small
components in the machine.
c) Examine inside electric joints and ensure perfect contact (Especially plugs and sockets).
Fasten the loosing joints. In case of oxidation, remove oxide film with sand paper and connect
again.
d) Prevent water from entering into the machine and prevent the machine from getting moist. If
any, blow and dry. Measure the insulation with megohmmeter to make sure it is qualified to
use.
e) If the welding machine is not used for a long time, pack the machine in original package and
store in dry surroundings.
f) Every time the wire feeder operates for 300hours, grind the electrical carbon brush and clear
up the armature commutator. Rinse speed reducer, apply 2# Molybdenum Disulfide lubricant
to the turbine, whirlpool rod and bearing.
All the maintenance and testing must be carried out when the power supply is totally cut
off. Please make sure the power is off before opening the closure.
Daily checking
WELDING POWER SUPPLY
Position
Checking keys
Remarks
Control panel
Operation, conversion and installation of the switch
Check the state of the power indicator light
Lead to unstable arc and
wire sending
Cooling fan
Check if the fan state and the sound is normal or not
Clean the residue and
check the reason and
solve it
Power part
Check if there is abnormal liberation and sound
when the power is on
Check if there is smell when the power is on
Whether the outside color change or get warm
Outer parts
Whether the wire feeder pipe is broken, and the
connector is loosen
Whether the outer shell or other connect parts are
loosen

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WELDING TORCH
Position
Checking keys
Remarks
Loophole
If installment fixed, the front distorted
Reason for air hole.
Attach splash or not.
Reason for burning the torch.
（can use splash-proof material ）
Electric hole
If installment fixed
Reason of torch screw thread damage
Damage of its head and hole blocked
or not
Reason of unstable arc and broken arc
Wire sending
tube
Check the extended size of the pipe
Have to be changed when less than 6mm,
when the extended part too small, the arc
will be unstable.
Wire diameter and the tube inner
diameter match or not
Reason of unstable arc, please use the
suitable tube.
Partial winding and extended
Reason of poor wires sending and unstable
arc, please change.
Block caused by dirt in the tube, and
the remains of the wire plating lay.
Reason of poor wire sending and unstable
arc, (use kerosene to wipe or change new
one.)
Wire sending tube broken O circle wear
out
Pyrocondensation tube broken, change
new tube. Change new O circle
Gas bypass
Forget to insert or the hole blocked, or
different factory component.
May lead to vice (splash) because of poor
gas shield, torch body get burned (arc in the
torch), please handle.
CABLE
Position
Checking keys
Remarks
Output
cable
Wearing-out of the cable insulated material
Cable connecting head naked (insulation damage),
or loosen (the end of power supply, and cable of
main material connecting point)
For life security and stable
welding, adopt suitable
method to check according
to working place
Simple check daily
Careful and in-depth
check on fixed period
Input cable
If the connection between the plug and the power
socket is firm
If the power input end cable fixed
If the input cable is worn out and bares the
conductor
In case of leakage and to
ensure safety, please do
perform daily checking