WeldCorp MIG 100 Operation manual

OWNERS OPERATING MANUAL
CONGRATULATIONS ON YOUR PURCHASE OF A QUALITY WELDCORP WELDER
MANUFACTURED IN ITALY, IT WILL PROVIDE YEARS OF RELIABLE OPERATION.

SAFETY INSTRUCTIONS Page 4
DESCRIPTION OF MACHINES Page 6
MIG 100 Page 6
MIG 120 Page 7
MIG 160 Page 8
ASSEMBLY INSTRUCTIONS Page 9
SET UP OF THE WELDER (GAS AND GASLESS) Page 10
OPERATION Page 11
MOUNTING OF THE REFILL WIRE SPOOL Page11
OPERATION—GAS OR NO GAS APPLICATION Page 11
KEY POINTS TO FEEDING THE WELDING WIRE Page 12
FEEDING THE WELDING WIRE Page 14
FITTING THE GAS BOTTLE Page 16
WELDING BASICS Page 17
THERMAL OVERLOAD Page 17
WELDING INFORMATION Page 18
WIRE EXTENSIONS (WIRE STICK OUT) Page 19
STARTING THE ARC Page 20
TECHNIQUES Page 20
WELDING EXAMPLES Page 21
TROUBLE SHOOTING GUIDE Page 22
SPARE PARTS
MIG 100 Page 24
MIG 120 / 160 Page 26
WARRANTY Page 30
WARRANTY FORM Page 31
CONTACT DETAILS Page 32
TABLE OF CONTENTS

Page 4
When using power equipment, basic safety precautions should
always be followed to reduce the risk of fire, electric shock and
personal injury, including the following. If used correctly, weld-
ers pose little risk to the operator; however, care should always
be taken to ensure safety and proper performance. Read all
owner’s operating instructions before attempting to operate any
product.
FOR SAFE OPERATION:
KEEP THE WORK AREA CLEAN: Cluttered
working areas (indoor and outdoor) invite injuries.
CONSIDER THE WORK ENVIRONMENT: Don’t expose power
equipment to rain. Don’t use welding equipment in damp or
wet locations. Keep the work area well lit. Don’t use welding
equipment in the presence of flammable liquids or gases.
GUARD AGAINST ELECTRIC SHOCK: Avoid body contact the
grounded surfaces (e.g. pipes, radiator, and electrical appli-
ances).
KEEP CHILDREN AND VISITORS AWAY: Keep children, in-
firmed persons and visitors away from the area of opera-
tion. Do not let children, infirmed persons or visitors touch
equipment or extension cables.
STORE IDLE TOOLS: When power equipment is not in use,
keep them in a dry, high or locked area, out of reach of
children.
WEAR SAFETY GLASSES: Always wear safety goggles or
other suitable eye protection when using welding equip-
ment.
SECURE WORK: Use clamps or a vice whenever possible to
secure work.
DON’T OVERREACH: Keep proper footing and balance at all
times.
SAFETY INSTRUCTIONS

Page 5
DRESS PROPERLY: DO NOT wear loose clothing or jewellery.
They can be caught in moving parts. Wear protective hair
covering to cover long hair, and gloves and non-slip foot-
wear is recommended when working outdoors.
TAKE CARE OF CABLES: Never carry welding equipment by
the cable and never pull the cable to disconnect it from a
socket. Keep cables away from heat, oil and sharp edges.
Replace damaged cables.
DISCONNECT TOOLS: Disconnect welding equipment when
not in use, before servicing, and when changing accessories
such as blades, bits and cutters.
AVOID UNINTENTIONAL OPERATION: Don’t carry plugged in
welding equipment with a finger on the switch. Be sure that
the switch is off when plugging in.
OUTDOOR USE EXTENSION CABLES: When electric power
equipment is used outdoors, only use extension cables
marked as suitable for outdoor use.
STAY ALERT: Watch what you are doing. Use common sense.
Do not operate welders when you are tired or under the in-
fluence of alcohol or drugs.
CHECK DAMAGED PARTS: Before using welding equipment,
parts that are damaged should be carefully checked to de-
termine that they will operate properly and perform their
intended function. Any part that is damaged should be prop-
erly repaired or replaced by an authorized service agent.
Have defect switches replaced by an authorized repair
agent. Do not operate power equipment if it cannot be
turned off and on by the switch.
REPAIR OF POWER EQUIPMENT BY EXPERTS: Power equip-
ment is built in accordance with relevant safety authority
requirements. The repair of power equipment must only be
carried out by experts; non-expert repairs may cause con-
siderable danger for the user and void warranty.

FEATURES
ANTI-SHOCK CLAMP
10 AMP SINGLE PHASE
ACCESSORIES INCLUDED
THERMOSTATIC CONTROL
ANTI-SCRATCH PAINT
ACCESSORIES ASSEMBLES
PORTABLE
EUROPEAN CONFORMITY
WIREFEEDER 2 REELS
SPEED INDICATOR
WIRE SPEED REGULATOR
DIRECT CONNECTION
FLUX CORED WIRE TORCH Page 6
DESCRIPTION OF MACHINES
These models are portable MIG Gas and Gasless Welders which are compact. The
robust format makes them a versatile and efficient for a variety of uses. The weld-
ers compliance to current regulations and the optimum quality of materials used will
ensure a long working life with complete safety.
MIG 100 GASLESS
SPECIFICATIONS
Mains Voltage 230V
Welding Current 35—100 Amps
Duty Cycle 20% 100 Amps
Wire 0.8—1.0 mm
Weight 13.8 Kg
ACCESSORIES
Electrode Holder
Work Clamp
Hand Held Face Mask
Combination Chipping Hammer with Wire Brush
Instructional DVD

Page 7
MIG 120 GAS / GASLESS
SPECIFICATIONS
Mains Voltage 230—400V
Welding Current 40—170 Amps
Minimum Electrode 1.6 mm
Maximum Electrode 4.0 mm
Weight 26.5 Kg
ACCESSORIES
Torch Cable
Work Clamp
Hand Held Face Mask
Combination Chipping
Hammer with Wire Brush
Instructional DVD
Gasless Welding Wire
FEATURES
ANTI-SHOCK CLAMP 10 AMP SINGLE PHASE
THERMOSTATIC CONTROL EUROPEAN CONFORMITY
ANTI-SCRATCH PAINT FLUX CORED WIRE
PORTABLE WIRE SPEED REGULATOR
FAN WIREFEEDER 2 REELS
DIRECT CONNECTION TORCH NO VOLTAGE ON TORCH
POWER GENERATOR SAFE
NOTE: This welder is a dual purpose gas / gasless machine. Refer to the table on
page 18 for the gas required.

Page 8
MIG 160 GAS / GASLESS
FEATURES
ANTI-SHOCK CLAMP 10 AMP SINGLE PHASE
THERMOSTATIC CONTROL EUROPEAN CONFORMITY
ANTI-SCRATCH PAINT FLUX CORED WIRE
PORTABLE WIRE SPEED REGULATOR
FAN WIREFEEDER 2 REELS
DIRECT CONNECTION TORCH NO VOLTAGE ON TORCH
POWER GENERATOR SAFE WHEEL KIT
NOTE: This welder is a dual purpose gas / gasless machine. Refer to the table on
page 19 for the gas required.
SPECIFICATIONS
Mains Voltage 230—400V
Welding Current 40—170 Amps
Minimum Electrode 1.6 mm
Maximum Electrode 4.0 mm
Weight 34.7 Kg
ACCESSORIES
Torch Cable
Work Clamp
Hand Held Face Mask
Combination Chipping
Hammer with Wire Brush
Instructional DVD
Gasless Welding Wire
Mini Regulator

ASSEMBLY INSTRUCTIONS
For the MIG 160
Slide the right wheel and axle into position. At-
tach the left wheel onto the axle and insert the R
Clips to retain wheels.
For the MIG 160
Fit the trolley base into position and secure with
screws.
For the MIG 120 and MIG 160
Slide the handle into the grooves on top of the
machine and secure with screws.
For the MIG 160
Slide the handle extension through the handle
and secure with screw.
Page 9
For the MIG 160
Attach gas bottle support and secure with screws.

Page 10
SET UP OF THE WELDER—GASLESS
WELDING
MACHINE
ARC
WORK
GROUND EARTH CABLE
MIG TORCH
WIRE FEED HOSE
SET UP OF THE WELDER—GAS
WELDING
MACHINE
ARC
WORK
GROUND EARTH CABLE
MIG TORCH
WIRE FEED HOSE
GAS
GAS HOSE

Page 11
OPERATION–Mounting of the Refill Wire
spool
For the MIG 100, MIG 120 and MIG 160
Remove empty spool and replace with refill spool as
pictured to the left.
Set the wire reel onto the spool and ensure that the
turns are not crossed on one another on the reel and
that they can easily unwind. Fit the washer, spring
and knob back into place as pictured to the left.
NOTE: Larger capacity gas bottles and regulators can be used with MIG 120 and
MIG 160 Welders. Contact your nearest Industrial Gas Dealer.
OPERATION–Gas or No Gas Application
NOTE: Ensure that the correct Gas or No Gas cable position is selected for the
MIG 120 or for the MIG 160 Welders. This is located inside the cabinet below the
wire feed.
ONLY FOR MIG 120 ONLY FOR MIG 160

Page 12
OPERATION–Key Points to Feeding the
Welding Wire
ENSURE THAT YOU CHOOSE THE CORRECT WIRE SIZE GROOVE ON THE
WIRE FEED ROLLER
It is critical that you choose the right size wire feed roller size. Using the incorrect
wire feed roller size will result in issues such as the wire not feeding correctly or
irregular welding due to incorrect wire speed. You can change this roller by remov-
ing the two screws on the wire feed roller bracket and followed by the wire feed
roller. You will see that on either side of the wire feed roller there is a 0.8 mm or
0.9 mm marking stamped into the roller. Always ensure that the welding wire size
matches the wire feed roller size.
ALWAYS ENSURE THAT YOU HAVE ENOUGH TENSION ON THE WIRE FEED
ROLLER
It is critical that you ensure that there is sufficient tension on the wire feed roller at
all times. If there is insufficient tension between the wire feed roller and the wire
tension bearing then you will experience issues such as the wire not feeding cor-
rectly or irregular welding due to incorrect wire speed. You can adjust the tension of
the wire by tightening or loosening the plastic tension screw as shown below.

Page 13
OPERATION–Key Points to Feeding the
Welding Wire
ALWAYS EXTEND THE MIG TOURCH LEAD FULLY WHEN FEEDING THE WIRE
THROUGH THE TORCH TIP
Always ensure that you always extend the welding torch lead to enable the MIG
wire to pass through the welding torch lead inner tube. The inner tube allows the
MIG wire to pass between the MIG welder and the welding torch without creating
drag. Ensure that the torch lead is not curled up or tightly wound as this can cause
the welding wire to pierce through the inner tube and protrude through the outer
protective layer of the torch lead.
ALWAYS CUT THE WELDING WIRE WITH A FLAT END
Welding
wire with a
sharp point
Welding
wire with
a flat end
Welding wire with a
sharp end protruding
Welding wire protrud-
ing through inner tube
due to a curved hose
ALWAYS REMOVE THE MIG TORCH TIP PRIOR TO FEEDING THE WIRE
THROUGH THE TORCH

Page 14
OPERATION–Feeding the Welding Wire
For the MIG 100, MIG 120 and MIG 160
Unwind the welding wire and feed it through the
plastic guide tube.
For the MIG 100, MIG 120 and MIG 160
Unscrew welding wire clamp nut.
For the MIG 100, MIG 120 and MIG 160
Align the welding wire to the feed rollers and
continue feeding the welding wire through the
intake tube.
For the MIG 100, MIG 120 and MIG 160
Tighten the welding wire clamp nut to fasten the
welding wire into position.
MIG 120 and MIG 160
Wire feed access from side panel.

Page 15
OPERATION–Feeding the Welding Wire
For the MIG 100, MIG 120 and MIG 160
Press the trigger switch to engage the MIG weld-
ing wire feed and wait until the wire is automati-
cally fed through the wire hose, ensuring the
feeding tube is straight and not coiled, as this
may cause a wire blockage.
If the welding wire fails to feed, recheck that the
correct procedure for Feeding the Welding Wire
has been followed.
For the MIG 100, MIG 120 and MIG 160
If the steps above have been followed and fails to
rectify the problem, remove the silver coloured
welding nozzle and copper contact tip as illus-
trated to the left, and check that the welding wire
is feeding without obstruction. Re-assemble the
contact tip and the nozzle.
For the MIG 100, MIG 120 and MIG 160
Checking the wire feed. Switch the welder on as
shown.

OPERATION—Fitting the Gas Bottle
For the MIG 120 and MIG 160
Clean dust and dirt from the gas bottle nipple.
Open the gas knob for a few seconds to release
some gas. This will avoid any remaining dust get-
ting into the regulator. Attached the appropriate
regulator as pictured.
For the MIG 120 and MIG 160
Insert the hose into the gas bottle as pictured,
secure as required.
For the MIG 120 and MIG 160
Secure the bas bottle in position as pictured onto
the welder, ensuring that the excess hose is inside
the welders casing.
For the MIG 120 and MIG 160
Insert the hose onto the welders gas valve as pic-
tured. This is located inside the casing of the weld-
ers.
Page 16
NOTE: WHEN THE WELDER IS NOT IN USE, ALWAYS CLOSE THE GAS BOTTLES
VALVE AND ZERO OUT THE REGULATOR.
NOTE: GAS BOTTLE IS NOT INCLUDED

Page 17
WELDING BASICS
When you weld external influences play a large part in what type of result you are
going to get. These external influences are sometimes mistaken for machine faults.
Below is a list of effects that you may come across and their possible causes.
POROSITY This is when small holes appear in the weld. This is caused by the gas
during the welding process coming into contact with other gases within the metal
being welded. This can be rectified by grinding the weld back and cleaning the work
piece, ensuring that the gas flux is set to 8 litres per minute and incline the torch
while welding.
SPATTER This is when small balls of molten metal come out of the arc. A little
amount is unavoidable but by selecting the correct settings including gas glow and
ensuring the welding torch is clean it should be kept to a minimum.
NARROW HEAP WELDING This can caused by moving the torch to fast.
VERY THICK OR WIDE WELDING This can be caused by moving the torch too
slowly.
WIRE BURNS BACK This can be cause by the wire feed slipping, being loose, hav-
ing a damaged welding tip, wire quality, the voltage being to high or the nozzle
being held to close to the work piece.
POOR PENETRATION This can be caused by moving the torch over the work piece
to fast, low voltage or incorrect wire speed. To rectify this adjust the settings and
clean the work piece.
WORK PIECES PIERCING This can be caused by moving the torch too slowly, the
voltage being to high or by incorrect wire speed.
WELDING ARC INSTABILITY This may be caused by incorrect voltage, wire
speed or gas speed.
THERMAL OVERLOAD
This welder is fitted with a thermal overload cut out which operates automatically to
stop the transformer overheating which may cause damage to the welder.
The welder will become operational again automatically once the temperature has
reduced itself to an acceptable working temperature.

TABLE FOR SELECTION OF THE WELDING CURRENT ACCORDING TO THE
WIRE SIZE, WIRE SPEED, METAL PROFILE AND METAL THICKNESS
Metal Profile Weldable
Metal
Thickness
Wire Size Wire Speed
(Metres Per
Minute)
AMP / Power
Setting
Sheet Steel
Steel Tube 2.0—2.5 mm 0.8—.09 mm 4.0—6.0 m Position 1
Sheet Steel
Steel Tube
Steel Plate
2.5—5.0 mm 0.8—.09 mm 6.0— 10.0 m Position 2
NOTE: This welder is not recommended for metal thinner than 2.0 mm
WELDING INFORMATION
MIG 100 GASLESS
MIG 120 GAS / GASLESS
TABLE FOR SELECTION OF THE WELDING CURRENT ACCORDING TO THE
WIRE SIZE, WIRE SPEED, METAL PROFILE AND METAL THICKNESS
Metal Profile Weldable
Metal
Thickness
Wire Size Wire Speed
(Metres Per
Minute)
AMP /
Power
Setting
Sheet Steel
Steel Tube 0.8—2.0 mm 0.6—.09 mm 4.0—6.0 m Position 1
Sheet Steel
Steel Tube
Steel Plate
2.0—3.0 mm 0.8 mm 4.0— 8.0 m Position
2—3
Shielding
Gas
Argon /
CO2 Mix
Argon /
CO2 Mix
or No Gas
Sheet Steel
Steel Tube
Steel Plate
3.0—5.0 mm 0.8—0.9 mm 6.0—10.0 m Argon /
CO2 Mix
or No Gas
Position
3—4
Aluminium Tube
Aluminium Plate 0.1—5.0 mm 0.9 mm 5.0—10.0 m Argon Position 3—4

MIG 160 GAS / GASLESS
TABLE FOR SELECTION OF THE WELDING CURRENT ACCORDING TO THE
WIRE SIZE, WIRE SPEED, METAL PROFILE AND METAL THICKNESS
Metal Profile Weldable
Metal
Thickness
Wire Size Wire
Speed
(Metres Per
Minute)
AMP /
Power
Setting
Sheet Steel
Steel Tube 0.8—2.0 mm 0.6—.09 mm 4.0—6.0 m Position 1
Sheet Steel
Steel Tube
Steel Plate
2.0—3.0 mm 0.8 mm 4.0— 8.0 m Position
2—3
Shielding
Gas
Argon /
CO2 Mix
Argon /
CO2 Mix
or No Gas
Sheet Steel
Steel Tube
Steel Plate
3.0—5.0 mm 0.8—0.9 mm 6.0—10.0 m Argon /
CO2 Mix
or No Gas
Position
3—4
Aluminium Tube
Aluminium Plate 0.1—5.0 mm 0.9 mm 5.0—10.0 m Argon Position 3—4
WIRE EXTENSIONS (WIRE STICK OUT)
TOO SHORT
NORMAL
TOO LONG

STARTING THE ARC
Hold the torch with the wire approximately 2 mm
from the work piece. Press the torch trigger to
begin welding.
STARTING THE ARC
TECHNIQUES
Effect of Electrode Wire Position and Welding Technique
PUSH PERPENDICULAR DRAG / PULL
10 10
DIRECTION OF WELDING
Electrode
wire
directed
ahead of
bead
Electrode
wire
pointed
back into
bead
Push
Technique Gun Perpendicular Technique Drag / Pull Technique