WELDCO MIG160D User manual

MIG160D
Inverter MIG/MMA/TIG Welder
OPERATORS MANUAL
IMPORTANT:
This manual contains important information regarding safety, operation, maintenance and storage of this product.
Before use read carefully and understand all cautions, warnings, instructions and product labels. Failure to do so
could result in serious personal injury and/or property damage.

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TABLE OF CONTENTS
Thank You For your Purchase..................................................................................................................................................... 3
Unpacking Your New Welder ......................................................................................................................................................... 3
Welding Hazards and Safety....................................................................................................................................................... 4
Work Area ...................................................................................................................................................................................... 4
Personal Protective Equipment and Clothing (PPE) ....................................................................................................................... 4
Electromagnetic and Radio Frequencies –“PACEMAKERS”........................................................................................................... 5
Pre-Checks...................................................................................................................................................................................... 5
Warning.......................................................................................................................................................................................... 5
Storage and Transportation ........................................................................................................................................................... 5
Technical Description ................................................................................................................................................................. 6
Compliance Plate............................................................................................................................................................................ 6
Duty Cycle....................................................................................................................................................................................... 6
Input Plug ....................................................................................................................................................................................... 6
Operating Environment.................................................................................................................................................................. 6
Machine Layout ......................................................................................................................................................................... 7
MIG Welding Setup .................................................................................................................................................................... 9
Fitting the Wire .............................................................................................................................................................................. 9
Gasless MIG Welding Setup ......................................................................................................................................................... 12
Gas MIG Welding Setup ............................................................................................................................................................... 15
MMA (Stick) Welding Setup ..................................................................................................................................................... 18
DC Lift TIG Welding Setup ........................................................................................................................................................ 20
Maintenance............................................................................................................................................................................ 22
Warranty.................................................................................................................................................................................. 22
Troubleshooting....................................................................................................................................................................... 23
Power Supply................................................................................................................................................................................ 23
Welding Torch .............................................................................................................................................................................. 23
Wire Feeder.................................................................................................................................................................................. 24
Cables ........................................................................................................................................................................................... 24

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Thank you for your Purchase.
Weldco would like to thank you for purchasing the MIG160D Inverter Welder.
This manual is designed to guide you through using your new machine.
Your Weldco inverter welder utilizes the latest in welding technology to ensure you receive professional results in a
variety of applications.
UNPACKING YOUR WELDER
Contents:
•MIG inverter power source.
•3m MB15 MIG torch
•Heavy duty earth clamp and lead.
•Heavy duty twist lock electrode holder and lead.
•0.8/0.9mm knurled roller = gasless (not shown)
•0.6/0.8mm V grooved roller = gas (not shown)
•0.9/1.0mm V grooved roller = gas (not shown)
•Gas tube (not shown)
•MIG accessory kit (not shown)
Please check all contents are correct and damage free before first use, if any issues please contact your local
dealer.

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WELDING HAZARDS AND SAFETY
Welding poses a variety of hazards to health and safety. Please ensure you have correct safety equipment for yourself and those
within the welding area. Your local distributor will be able to assist you with the correct Weldco protective helmet and gloves.
Detailed documents can be located on the Worksafe website, www.worksafe.govt.nz, topic welding.
WORK AREA
•Ensure your work area is clear, dry and free of trip hazards.
•That the area is well ventilated, and all flammable materials are removed to a safe distance.
•Never leave your welder powered up – unattended.
FIRE RISK
•Due to the welding process producing molten metal including sparks and fumes maximum fire safety must always
be obeyed. Ensure you have direct access to the correct fire extinguisher for your environment.
•Never weld tanks or containers that have or have held flammable liquid, gas or where the contents are under
pressure. This should only be carried out by trained specialists.
•Ensure that the area is checked for smoldering materials as material will remain hot well after welding.
ELECTRICITY CAN KILL
•Never weld or attempt to weld in a wet or raining environments. There is a serious risk of electrocution to the
operator or those within the area.
•it is recommended that the welder be connected to an RCD.
FUMES AND GASES
•Welding produces fumes and gases that can be harmful to the operator and those within the surrounding areas.
Always ensure that there is plenty of ventilation and fresh air.
•Do not weld material that has been coated or contaminated with paint, varnish or rubber as they may give off
harmful fumes or gas and increase the risk of fire and or explosion.
PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING
The user must comply with occupational health and safety rules and wear appropriate protective equipment.
BURNS
•The welding process causes the work piece and surrounding items to become hot.
•It is always recommended that flame resistant clothing be warn.
•Welding gloves must be worn to help prevent burns to hands and arms when handling hot objects.
•Avoid skin exposure to the Ultraviolet rays produced by the arc. It is recommended that skin be protected from
these harmful rays. Serious burns are possible when this recommendation is not followed.
•Approved welding helmets must be worn by the operator and any personnel with in 10m of the work area. It is also
recommended that welding safety screens are installed to protect.
•It is always recommended that enclosed footwear with rubber soles be worn to protect from sparks and molten
metal and to reduce the risk of electrocution.
•As welding produces gases and fumes many of these can be harmful it is recommended that the operator and
these in the direct area wear respirators with the relevant protection.
•Always where safety glasses when chipping the slag, scraping or preparing the work piece.

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ELECTROMAGNETIC AND RADIO FREQUENCIES – “PACEMAKERS”
•Avoid contact with the energized work piece.
•Always ensure you have adequate protection from electrocution and burns.
•Since the welder owns strong electromagnetic and radio frequencies. Persons fitted with “PACEMAKERS” or similar
devices MUST consult their doctor before turning on the welder. This relates to both the operator and those
nearby.
PRE-CHECKS
The following items must be checked by the operator each time before powering up the power source.
•Ensure that the welder is damage free and no exposed wires.
•Check all welding cables, insulation and accessories are free of damage.
•The work area is checked and free of hazards
•All personal protective clothing and equipment is defect free.
•Access to Fire extinguisher and welding blanket.
•All flammable material has been removed.
WARNING!
•Disconnect the power source before servicing and ensure the device has powered down.
•Contact your dealer or reseller immediately should your welder require servicing.
•It is not recommended that you remove the covers to carry out your own servicing – doing so will void the
warranty.
STORAGE, TRANSPORTATION AND MAINTENANCE
•Your welder contains sensitive electronics and needs to be stored in a dust and moisture free environment.
•Periodically your welder should be blown down using dry compressed air to remove any dust and metal fillings.
•Once your power source and welder have cooled down. Remove your accessories for storage – wipe both the welder
and accessories down with a clean cloth to remove any contaminates.
•Store your welder in a dry safe environment.
•When transporting ensure that the power source, accessories and wire are secure.
•Cylinders need to be stored and transported as per NZ regulations and safe operating procedures.

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TECHNICAL DESCRIPTION
COMPLIANCE PLATE
Duty Cycle
The welder’s duty cycle is the number of minutes in a 10-minute period the power source can safety produce the set
welding current (actual arc on). If this is exceeded the machine will enter thermal overload, turning the welding current off
protecting the welder. This is indicated by the light on the front panel.
For example:
•At 124 amps the welder will MIG continuously for 6 mins and needs to rest for 4 mins.
•At 62 amps the welder will MIG continuously or 100% of the time.
The duty cycle is tested at 40 degrees celsius, if the welder is operating in lower temperature e.g. 20 degrees celsius the
duty cycle will be higher.
INPUT PLUG
The MIG160D is fitted with a 10amp plug. This machine is designed to work with 10amp domestic wall sockets. It is important
that the machine is plugged directly into the mains plug. If an extension cord must be used a minimum 2.5mm wire thickness is
require and no more than 10m in length.
Using unsuitable extension cords will reduce the input voltage (known as voltage drop) and this will void the warranty of your
machine.
OPERATING ENVIRONMENT
•Operating temperature: -10℃~40℃.
•Transportation and storage: -25℃~55℃.
•Relative air humidity: 40℃ ≤ 50%; 20℃ ≤ 90%.
•The dust, acids, corrosive gases and substance in the ambient air must be not higher than normal level.
•Altitude must be less than 1km.
•Good ventilation around the machine, at a distance of at least 50cm around.
•Power source must be kept on a level surface to reduce the risk of the machine falling.

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MACHINE LAYOUT
1. Female Euro Connector
2. Wire Feed Compartment door.
3. Negative Terminal
4. Positive Terminal
5. Polarity Cable
INSIDE – WIRE FEED COMPARTMENT
22. Spool Retainer Nut
23. Spool Brake Tensioner
24. Tensioner Adjuster
25. Tensioner Arm
26. Outer guide Tube
27. Roller Retainer Bolt
28. Drive Roller
29. Inner guide Tube
REAR PANEL
30. ON OFF Switch
31. 10amp 230-volt Power Cable and Plug
32. Gas Inlet
4.
3.
5.
1.
23.
22.
24.
29.
25.
26.
28.
27.
2.
REAR PANEL
INSIDE WIRE FEED COMPARTMENT
31.
32.
30.

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CONTROL PANEL LAYOUT
MIG Torch
MIG TORCH EXPLODED
Electrode Holder
Earth Clamp
Gas Nozzle
Tip Adapter Spring
Welding Tip
Tip Adapter
6. Voltage Display
7. Amperage Display
8. Wire Selector
9. Gas Test
10. Wire Feed
11. Main Adjustment
12. Step Selector
13. Welding Process
Selector
14. Torch Control & VRD
15. Gas selector
16. Voltage
17. Voltage Adjust
18. Alarm
19. Amperage
20. Inductance
21. Wire Feed
15.
16.
17.
18.
6.
7.
14.
11.
12.
13.
9.
10.
8.
7.
6.
21.
20.
19.

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SETUP FOR MIG WELDING
Smooth consistent wire feed is critical to achieve professional results.
FITTING THE WIRE 5KG/200MM DIAMETER WIRE SPOOL
1. Open the cover door (2) for the wire feed compartment. Remove the wire spool retaining nut (22) by threading the
retainer clockwise.
2. Fit the 5Kg/200mm diameter wire spool to the spool holder, lining up the locating pin with the locating plug on the
spool. Ensure the end of the wire feeds towards the drive rollers from the bottom of the spool.
3. Refit the wire spool retaining nut (22) and tighten anti clockwise hand tight.
4. Set the spool brake tensioner by rotating the adjustment nut (23).
To increase brake tension, turn clockwise. Turn anti-clockwise to decrease brake tension.
Set the spool brake tension so that the spool can rotate freely, without continuing to rotate once the wire feed stops.
Check performance from time to time to ensure that the wire is feeding correctly, especially as the wire spool empties.
Always reset when replacing with a new spool.

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FITTING THE WIRE 1KG/100MM DIAMETER WIRE SPOOL
1. Open the cover door (2) for the wire feed compartment. Remove the tensioning nut, washer’s and spring.
Slide off spool holder –keep in a safe place.
2. Fit the 1Kg/100mm diameter wire spool on the shaft. Ensure the end of the wire feeds towards the drive rollers
from the bottom of the spool.
3. Refit the washer’s, spring and tensioning nut. Set the spool brake tensioner by rotating the adjustment nut (23).
Ensure there is tension on the spool before fitting the wire into the wire feeder (spool will un-ravel).
To increase brake tension, turn clockwise. Turn anti-clockwise to decrease brake tension.
Set the spool brake tension so that the spool can rotate freely, without continuing to rotate once the wire feed stops.
Check performance from time to time to ensure that the wire is feeding correctly, especially as the wire spool empties.
Always reset when replacing with a new spool.

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WIRE FEEDER
4. Release the wire feeder tensioner arm (25) by pulling forward the tension adjustment knob (24).
Check the drive roller matches the wire type and wire diameter (size is stamped on the side of the roller).
“V”groove roller for solid hard gas shield wires –Mild steel and Stainless Steel.
“Knurled”roller for gasless/flux core.
“U” Groove roller for soft wire –Aluminium and silicon bronze.
To change the roller, undo the roller retainer bolt (27), slide off the roller, replace with the correct roller making sure
that the correct size groove is facing towards the machine. Tighten the retaining bolt anticlockwise, hand tight.
5. Whilst holding the wire spool (this will prevent the spool uncoiling) carefully snip the wire and feed through the
inlet guide tube (29), over the roller and into the outer guide tube (26), feeding the wire approximately 50mm out
of the female euro connect (1), fitting on the front of the machine.
6. Align the wire into the grove of the roller and close the wire tensioner arm (25) and adjust the wire feed tensioner
(24) making sure the wire remains in the groove.
7. Adjust the wire feed tension (24) by turning clockwise to increase the tension and anti-clockwise to reduce. Do not
over tighten the tension, the wire will be crushed –especially soft and flux cored wires.

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SETUP FOR GASLESS MIG WELDING
Please ensure you have all relevant safety equipment and PPE ready.
1. Connect the MIG torch male Euro Connector to the female Euro Connector (1) on the front of the power source. Secure
hand tight.
2. Check that the correct flux gasless (Flux cored) wire, drive roller (28) and welding tip (34) are fitted.
3. Connect Polarity cable (5) to the Negative Terminal (3).
4. Connect Earth Lead to the Positive Welding Terminal (4).
5. Connect Earth Clamp to the work piece.
6. Ensure the main power switch is in the OFF position. Plug the 10amp plug into the 10amp wall socket. Turn power to
the ON position on both the wall socket and the power source. The front panel will illuminate, and the cooling fan will
start.
7. Select MIG on the welding process selector (13)
5. Polarity Cable
4. Positive Earth

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8. Select torch function (14)
•2T for standard torch operation. Press and hold the trigger to start the weld, continue to
hold trigger whilst welding. Releasing the trigger stop welding.
•4T is used for long welding runs or for out of position welding where holding the trigger on
is difficult. Each press of the trigger starts and stops welding. Press once and release to start
the weld press again to stop.
9. Select FLUX on the gas selector (15)
10. Select wire size on the wire size selector (8) that matches your wire. If SP is selected, then
both the voltage (heat) and wire speed (m/min) are adjusted.
11. With the nozzle and tip from the welding torch removed, press the wire check (10) to run
the wire feed motor to push the wire through the torch. Once the wire comes out of the torch
press wire check (10) again or press the torch trigger to stop the wire feeder.
12. Your MIG160D is synergic, removing the guess work out of selecting the right combination
of VOLTAGE and WIRE SPEED. Once you have selected your FLUX and WIRE DIAMETER,
increasing or decreasing the main adjustment knob (11) will adjust both the voltage (heat) and
wire speed (m/min). The voltage will be displayed on voltage display screen (6) and your wire
speed (m/min) on the amperage display screen (7).
12. By pressing the Main adjustment dial (11) you can adjust the synergic curve up or down to fine tune your welder’s
performance. After pressing the main control dial - turn the dial (11) clockwise this will increase VOLTAGE only
(increasing heat to the weld pool but not wire speed), turning the dial anti-clockwise will reduce the VOLTAGE only
cooling the weld pool (effectively increasing wire speed). Push the button (11) again to lock in your setting.
As your MIG160D has an MCU (computer chip) your setting will be saved until next time.
13. To adjust your voltage and wire speed individually, select SP on the wire size selector (8).
The voltage will be displayed on the voltage display screen (6) and your wire speed (m/min) on
the amperage display screen (7).

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14. To increase or decrease wire speed, adjust the main adjustment dial (11). To switch to voltage
adjustment, press the main adjustment dial (11). Adjust the main adjustment dial to increase or
decrease voltage as required. Press the main adjustment dial again to switch back to wire speed
adjustment.
Note: In SP mode best practice suggests setting the voltage first and then matching your wire
speed.
15. To adjust inductance, Press the step selector (12) the inductance indicator light illuminates
and by turning the Main adjustment dial (11) clockwise increases inductance.
Turn the knob anti-clockwise reduces inductance.
A high inductance setting increases the frequency of each short circuit/arc cycle which increasing
the wetting of the world pool. Lower inductance will assist in narrowing the world bead, freezing the world pool faster
for thinner materials.
16. With your PPE on, hold your welding torch and begin welding

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SETUP FOR GAS MIG WELDING
Please ensure you have all relevant safety equipment and PPE ready.
1. Connect the optional Weldco Argon Regulator (WDC0812) to the argon cylinder or CO2 cylinder and connect the
gas line to the regulator.
2. Connect the gas line from the regulator to the gas inlet (31)
3. Open the valve on the cylinder and set your gas flow rate between 5-10L/min. It is good practice to test for leaks.
Close the cylinder valve. If there are no leaks the regulator will maintain the set L/min and cylinder pressure values.
Always turn off your cylinder valve when not in use.
4. Connect the MIG torch male euro connector (32) to the female euro connector (2) on the front of the power source.
Secure hand tight.
5. Check that the correct gas shield wire, drive roller (28) and welding tip (34) are fitted.
6. Connect Polarity cable (5) to the positive welding output terminal (4).
7. Connect Earth Lead to the negative output welding terminal (3).
8. Connect Earth Clamp to the work piece.
9. Ensure the main power switch (30) is in the OFF position. Plug the 10amp plug into the 10amp wall socket. Turn
power to the ON position on both the wall socket and the power source. The front panel will illuminate, and the
cooling fan will start.
5. Polarity Cable
3. Negative Earth

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10. Select MIG on the welding process selector (13)
11. Select torch function (14)
•2T for standard torch operation. Press and hold the trigger to start the weld, continue to
hold trigger whilst welding. Releasing the trigger stop welding.
•4T is used for long welding runs or for out of position welding where holding the trigger on
is difficult. Each press of the trigger starts and stops welding. Press once and release to start the
weld, press again to stop.
12. Select either CO2 or Mix on the gas selector (15) to match your shielding gas.
13. Open the cylinder valve and press and hold the gas check button (9) the gas solenoid will click,
and gas will flow through the torch. Check the flow rate of the regulator and ensure it is set to your
preferred level.
14. Select wire size on the wire size selector (8) that matches your wire. If SP is selected, then
both the voltage (heat) and wire speed (m/min) are adjusted.
15. With the nozzle and tip from the welding torch removed, press the wire check (10) to run
the wire feed motor to push the wire through the torch. Once the wire comes out of the torch,
press wire check (10) again or press the torch trigger to stop the wire feeder. Replace your
welding tip, tighten and reinstall nozzle to the torch.
16. 16. Your MIG200D is synergic, removing the guess work out of selecting the right combination
of VOLTAGE and WIRE SPEED. Once you have selected your GAS and WIRE DIAMETER,
increasing or decreasing the main adjustment knob will adjust both the voltage (Heat) and wire
speed (m/min). The voltage will be displayed on the Voltage display screen (6) and the wire
speed (m/min) on the Amperage display screen (7).
17. By pressing the main adjustment dial (11) you can adjust the synergic curve up or down to fine tune your welder’s
performance. After pressing the main control dial - turn the knob (11) clockwise, this will increase VOLTAGE only
(increasing heat to the weld pool but not wire speed), turn the dial anti-clockwise will reduce the VOLTAGE only

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slightly cooling the weld pool (effectively increasing wire speed). Push the button (11) again to lock in your setting.
As your MIG160D has an MCU (computer chip) your setting will be saved until next time.
18. To adjust your voltage and wire speed individually, select SP on the wire size selector (8).
The voltage will be displayed on the voltage display screen (6) and your wire speed (m/min) on
the amperage display screen (7).
19. To increase or decrease wire speed, adjust the main adjustment dial (11). To switch to
voltage adjustment, press the main adjustment dial (11). Adjust the main adjustment dial to
increase or decrease voltage as required. Press the main adjustment dial again to switch back to
wire speed adjustment.
Note: In SP mode best practice suggests setting the voltage first and then matching your wire
speed.
20. To adjust inductance, press the step selector (12) the inductance indicator light illuminates
and by turning the main adjustment dial (11) clockwise, increases inductance. Turn the knob anti-
clockwise reduces inductance.
A high inductance setting increases the frequency of each short circuit/arc cycle which increasing
the wetting of the world pool. Lower inductance will assist in narrowing the world bead, freezing
the world pool faster for thinner materials.
21. With your PPE on, hold your MIG torch and start welding.
22. When you have finished welding CLOSE the cylinder valve and turn OFF your machine.
Warning!
Please check your argon cylinder valve is closed after every use.
Never leave your machine running unattended.

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SETUP FOR MMA (STICK) WELDING
Please ensure you have all relevant safety equipment and PPE ready.
This setup is for the most common electrode positive setting for General purpose rods. Please check your electrode packaging
to confirm.
1. Connect the earth clamp cable into the NEGATIVE (3) terminal on the front of the machine. Connect the Earth clamp to
the work piece. It is important the earth clamp makes strong contact with bare metal – remove paint, rust or other
contaminates to ensure strong contact. Failure to do so will reduce your welding performance.
2. Connect the electrode holder cable into the POSITIVE (4) terminal on the front of the machine.
Ensure that the plug is secure in the socket to reduce any chance of arcing from loose connection
3. Ensure the main power switch (30) is in the OFF position. Plug the 10amp plug into the 10amp wall socket. Turn power
to the ON position on both the wall socket and the power source. The front panel will illuminate, and the cooling fan
will start.
1. Negative Earth
2. Positive Electrode Holder

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4. Once the machine has powered up press the welding process selector (13) to select MMA.
5. Your Weldco Inverter welder is fitted with a “Voltage Reduction Device” (VRD).
The VRD reduces the open circuit voltage to safer levels. The VRD default is OFF.
To activate this feature press VRD/Torch control button (14) until the VRD light is activated. Press
the button again to turn OFF VRD.
6. Adjust the welding current to the relevant level for the welding electrode type and size, as
per the electrode manufacturer by adjusting the main adjustment dial (11).
7. Your machine has adjustable “Hot Start” for that assists striking and prevents sticking when
the electrodes are cold. The “Arc Force” increases the welder’s ability to weld with a very short ARC
even when touching the work piece. To adjust “Hot start” press the step selector button (12)
“HOT” will appear in the voltage display, turn the main adjustment knob (11). To adjust the “Arc
Force” press the step selector button again until “FOR” is displayed in the voltage display, turn the
main adjustment dial to adjust.
8. Insert the electrode into the twistlock electrode holder and tighten firmly. Once the electrode contacts the work piece
(also any metal connected to the work piece) the electrode will strike an arc, for this reason do not rest the fitted
electrode on the work area.
9. With your PPE on, strike the work piece with the electrode (like striking a match) hold the electrode slightly off the work
piece to maintain a constant arc.
10. To stop the weld, quickly lift the electrode from the work piece (stopping the electrical circuit).
11. It is important to chip away the “SLAG” before continuing to weld and for weld inspection, Allowing the weld to cool
slightly will make “SLAG” removal easier.
18 19 20

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SETUP FOR DC LIFT TIG WELDING
(Optional accessories required. See your Weldco Dealer)
This machine is designed to weld Mild steel and Stainless steel only.
To weld Aluminium AC current is required.
Please ensure you have all relevant safety equipment and PPE ready.
1Connect the earth clamp cable into the POSITIVE (4) terminal on the front of the machine. Connect the Earth clamp to
the work piece. It is important the earth clamp makes strong contact with bare metal – remove paint, rust or other
contaminates to ensure strong contact. Failure to do so will reduce your welding performance.
2Connect the optional Weldco VALVE TIG torch (WDC0818) into the NEGATIVE (3) terminal on the front of the machine.
Ensure that the plug is secure in the socket to reduce any chance of arcing from loose connection
3Connect the optional Weldco Argon Regulator (WDC0812) to the argon cylinder and connect the gas line from the TIG
torch to the regulator. With the valve of the TIG torch open turn on the argon cylinder and set the regulator to
between 6-10 L/min. Close the valve on the TIG torch. It is good practice to test for leaks. Close the cylinder valve. If
there are no leaks the regulator will maintain the set L/min. Always turn off your cylinder valve when not in use.
4Ensure the main power switch (30) is in the OFF position. Plug the 10amp plug into the 10amp wall socket. Turn power
to the ON position on both the wall socket and the power source. The front panel will illuminate, and the cooling fan
will start.
4. Positive Earth
3. Torch Negative