WeldCorp MULTI PULSE PRO 240 Operation manual

OWNER’S OPERATING
MANUAL
MIG/TIG/ARC 240
ELECTRONIC INVERTER
INVERTER MULTI PULSE PRO

TABLE OF CONTENTS
Safety instructions 3-4
Page
Multi Pulse Pro 240 Welder 5
Installation 6
Welder Information 6-9
• Control panel
• MIG/MMA/TIG Welding
• Parameters
• Thermal protection
Machine set up (MMA / TIG / MIG / MIG Aluminium / MOG) 10-11
Maintenance 12
Troubleshooting 12
Multi Pulse Pro 240 Welder overview 13
Spare parts list 14-16
Welding machine technical data 17
Wiring Diagram 18
Warranty 19-20
Declaration of conformity 21

SAFETY INSTRUCTIONS
When using power equipment, basic safety precautions should always be followed to reduce
the risk of re, electric shock and personal
injury, including the following. If used correctly, welders 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.
WARNING: PERSONS FITTED WITH ELECTRONIC
DEVICES INCLUDING BUT NOT LIMITED TO
PACEMAKERS AND HEARING AIDS SHOULD NOT
OPERATE ELECTRONIC INVERTER WELDERS
WARNING: CONTACT LENS SHOULD BE REMOVED
BEFORE USE
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 ammable liquids or gases.
• GUARD AGAINST ELECTRIC SHOCK: Avoid body contact the grounded surfaces (e.g.
pipes, radiator, and electrical appliances).
• KEEP CHILDREN AND VISITORS AWAY: Keep children, inrmed persons and visitors
away from the area of operation. Do not let children, inrmed 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.
• SECURE WORK: Use clamps or a vice whenever possible to secure work.
• WEAR SAFETY GLASSES: Always wear safety goggles or other suitable eye protection
when using welding equipment .
!
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• DON’T OVERREACH: Keep proper footing and balance at all times.
• 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
footwear 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: Do not carry plugged in welding equipment with
a nger on the switch. Be sure that the switch is o 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uence of alcohol or drugs.
• CHECK DAMAGED PARTS: Before using welding equipment, parts that are damaged
should be carefully checked to determine that they will operate properly and perform
their intended function. Any part that is damaged should be properly repaired
or replaced by an authorized service agent. Have defect switches replaced by an
authorised repair agent. Do not operate power equipment if it cannot be turned o and
on by the switch.
• REPAIR OF POWER EQUIPMENT BY EXPERTS: Power equipment 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 considerable danger for the
user and void warranty.
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INV / MIG / TIG / ARC 240 MULTI PULSE PRO WELDERS
This product is an inverter welding machine, multi-function MMA/TIG LIFT/MIG/MAG/MOG,
which can be supplied with single-phase voltage 220V to 240V, 50/60Hz.
It allows the welder to weld:
MMA: rutile, basic, nickel-based (cast iron), special steel, cellulosic electrodes and aluminium.
TIG LIFT: steel and its alloys, copper bronze etc.
MIG: aluminium and its alloys, copper, special and nickel-based and high strength steels.
MAG: low carbon steels, stainless steels.
MOG: ux cored wires, weldable without the aid of the gas.
The machine is equipped with a control function of the power absorbed from the main
supply, simply activating a selector key switch on its control panel. The machine has an
important design feature due to its modular structure of the power units, which makes it
easy to repair.
It has a cylinder trolley which is retractable, a feature that allows you to reduce the space
during transport. The user interface consists of two knobs with built-in switch and two
displays.
This model is equipped with the pulsed MIG function. For the feeding of the wire during
charging of a new spool, a button (positioned near the wire feeder) provides to the
advancement of the wire, thus avoiding to press the button of the torch and waste gas until
the wire reaches the end of the torch.
This welding machine is for professional use only and is reserved for the industry.
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WARNING: This equipment does not comply with IEG 61000-3-12. If it is connected
to a public low voltage system, it is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment may be connected
DESCRIPTION OF THE MACHINE
FRONT PANEL
On the front side of the machine are:
1. Control Panel
2. Power selector key, maximum - limited
3. TIG torch connector
4. Euro connector
5. Socket positive ‘+’
6. Cable GAS / NO GAS
7. Socket negative ‘-’
REAR PANEL
On the back panel of the machine are:
1. TIG Gas attack
2. MIG Gas attack
3. Power Switch ON / OFF
4. Power supply cable

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INSTALLATION
Warning: Use all precautions required in the safety general manual before
operating the welder, reading carefully the risks associated with the welding
process.
The installation must be made by the trained personnel in compliance to the
standard IEC 60974-9 and the current and local legislation. All connections must be
made in accordance with the reference standard. To lift the machine, the lifting hole
must be applied on the top of the machine. Do not use it to lift the machine at more
than 1 meter from the oor.
The input voltage must match the voltage indicated on the technical plate located
on the product. The equipment should only be used on a supply system that is
a single-phase, three-wire system with an earthed neutral. Use the machine on
electric system having supply features and power protection that are compatible
with the current required for its use. For more details see the information on the
plate placed on the machine. The machine has an IP 21S protection level.
Mounting and adjusting the gas cylinder: must be placed in the back of the
machine and secured with a chain (supplied as accessory). Assemble the pressure
reducer and adjust the output pressure of the gas between 5 & 25 litres per minute.
WELDER INFORMATION
The machine functions are controlled by the control panel on the front panel. The panel is
composed of two displays, “DISP-1”and“DISP-2” and two knobs, “ENC-1” and “ENC-2”, which
allow the rotation and the pressure.
To select the type of welding,
press “ENC-1” on “DISP-1” will
show the type of welding and
by turning it you can choose
between MMA, TIG and
MIG. Stopping the rotation
of the knob, the on-board
microcontroller automatically
selects the type of welding
displayed.

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WELDER INFORMATION (cont.)
Once you have chosen the “MMA” welding, you
can adjust the welding current by turning the
knob “ENC-2”, the value displayed in DISP-2.
Once you have chosen the “TIG” welding, you can
adjust the welding current by turning the knob
“ENC-2”, the value displayed in DISP-2.
Once you have chosen the “MIG” welding, you
can set the following parameters:
Wire speed: the parameter is displayed on the
“DISP-1”after selecting the “MIG” welding. The
value is expressed as a percentage and can be
changed by rotating “ENC-1”.
Power: automatically appears on the“DISP-2”
when choosing “MIG” welding. You can change
the value turning “ENC-2”. The power value is
expressed as a percentage.
During MIG welding,“DISP-1” displays the voltage
and “DISP-2”shows the set welding current.
MMA WELDING
TIG WELDING
MIG WELDING

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WELDER INFORMATION (cont.)
The machine allows you to set parameters: Ramp-Up, Burn-Back, Pulse and Frequency.
Ramp-Up: allows you to set how many seconds you want to
reach the set speed of the wire. During this time, there will be a
gradual increase of the wire speed. To set this parameter, press
the knob “ENC-2” until ‘r’ appear on display “DISP-2”, to change
the value turn “ENC-2”.
Burn-back: adjusts the remaining length of the wire from the
end of the welding torch. To set this parameter, press the knob
“ENC-2” until ‘b’ appears on display “DISP-2”. Changing the
length increases or descreases the time by turning “ENC-2”.
Pre-gas: adjusts the opening time of the gas (in seconds)
before the arc is striking. To set this parameter, press the knob
“ENC-2” until ‘g’appears on display“DISP-2”, to change the value
of the opening time of the gas turn “ENC-2”.
Frequency: is used to set the frequency at which the pulses are
repeated over time. To set this parameter, press “ENC-2” until
you see ‘f’ on “DISP-2”. You must choose the “PULSE” for this
parameter to be displayed. During set up, if you do not make
any changes within 3 seconds, the display“DISP-2” will show
the value of the power set “PXX”
Pulse: allows to carry out the welding with lower power in order to avoid the
heating of the workpiece, allows a speed of execution of the welding considerably
higher than in non-pulsed MIG. Furthermore, these is a drastic reduction of
sparks and fumes in welding with a considerable reduction in the time of rework
of welded pieces that have, in fact less deformation and an excellent degree of
nish. The pulse parameter is adjusted by the knob “ENC-2” (press the knob until
you see ‘o’on “DISP-2”). The rotation of “ENC-2” allows you to choose between the
following values:
0 = no pulse, 5 = 50% power pulse and 10 = 100% power pulse

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WELDER INFORMATION (cont.)
FUNCTION RESET
Turn o the machine, the microprocessor on board stores the last welding settings
used. It also possible to reset the welding parameters restoring it to factory settings.
To reset:
1) Turn o the welding machine
2) Hold onto “ENC-1” until the welding machine is on; reset is successful if the
display shows “ooo ooo”, or retry steps 1-2
3) Release ENC-1
PROTECTION FROM OVERHEATING
The duty cycle is the fraction or percentage of a ten-minute cycle that a power
source may be used without overheating. For example, a welding machine with
150 amp - 30% duty cycle can weld continuously at 150 amps for 3 minutes and
then must cool down during the remaining 7 minutes to prevent overheating, with
the ambient temperature of 40 degrees celcius.
Using the machine with proper duty cycle according to the selected welding
current prevents overheating. If the machine stops due to overheating, both
displays will ash showing “H00” and cannot be possible to weld. You can restart
welding as soon as the “H00” signs disappear from the displays.
Turning the key on the front panel, you can choose low-power
(key position on the word“10A”) or the maximum power (key
position on the word“MAX”)

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MACHINE SET UP - MMA / TIG / MIG / MIG ALUMINIUM
AND MOG WELDING
Below are shown guidelines to set up the machine for a MMA/TIG/MIG/MIG Aluminium
and MOG welding.
ELECTRODE (MMA)
1) Turn o the welding machine
2) Connect the plug of the work clamp to the negative socket “-” and the plug of the
electrode holder to the positive socket“+” of the welding machine. Insert the electrode in
the electrode holder; the diameter and the type must be chosen in function of the welding
current and the thickness and type of workpiece to be welded.
To use the basic or any other special electrode weldable in DC, please always refer to what is
stated on the packaging of the electrodes (in Ex. DC+ or DC- or AC/DC +-).
3) Connect the power supply to the power outlet and turn on the welding machine.
4) Select the MMA welding
5) Select the welding current
7) To use various types of electrodes follow the polarity markings on the package containing
electrodes.
TIG LIFT
1) Turn o the welding machine.
2) Connect the plug of the work clamp to the power positive socket”+” and the plug of the
TIG torch to the negative socket“-” of the welding machine.
3) Connect the work clamp to the work piece.
4) Put the gas cylinder on the rear panel of the welder and x it with the chain; connect the
gas tube cylinder on the rear panel of the machine
5) Connect the torch gas tube on the front panel
6) Connect the power supply plug to the power outlet and turn on the welding machine.
7) Select the TIG welding.
8) Select the welding current.
9) To stop welding, turn o the machine and close the gas valve.
MIG / MAG
1) Turn o the welding machine.
2) Connect the plug of the work clamp to the Negative socket “-” and the plug of the cable
GAS I NO GAS (Figure 1.A.4) to the Positive socket “+” on the machine.
3) Insert the plug of the MIG torch in the EURO connector on the front panel
(continue over the next page)

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MACHINE SET UP - MMA / TIG / MIG / MIG ALUMINIUM
AND MOG WELDING (cont.)
MIG / MAG (continued from previous page)
4) Connect the tube of the gas cylinder on the rear panel of the machine. The gas used is
generally a mixture of Argon and C02 (MIX), otherwise only C02. It is recommended to use
the Argon for the welding of the aluminum.
5) Open the side mantle, place the wire spool on the paddle wheel (if it there isn’t) and insert
the wire in the wire feeder.
WARNING: The roller has two grooves: changing the roller, you can choose the appropriate
groove according to the diameter of the wire that you want to use. When changing the
diameter of the wire is necessary to change both the roller and the contact tip (end part of
the torch from which one you can see the wire coming out). Unscrew the gas nozzle and the
contact tip to facilitate the passage of the wire.
6) Unroll the torch cable so as to prevent the thread from curling.
7) Stop the roller.
8) Connect the power supply plug to the power outlet and turn on the welding machine.
9) Select MIG welding, press the wire feed button (Figure 3, the button is near the wire
feeder) until the wire comes out of the torch, close the side mantle.
MIG WITHOUT GAS (MOG)
1) Turn o the welding machine.
2) Open the side mantle, mount the ux cored wire coil (see “MIG/MAG” use), choose the
roller for the ux cored wire.
3) Connect the plug of the work clamp to the Positive socket, “+”, and the plug of the cable
GAS I NO GAS to the Negative socket, “-”.
4) Connect the power supply plug to the power outlet and turn on the welding machine.
5) Select the MIG welding, press the wire feed button until the wire comes out of the torch,
close the side mantle.
MIG ALUMINIUM
For MIG welding with aluminum wire it is necessary to set the machine with the KIT FOR
ALUMINIUM WELDING. The kit (not included with the machine) includes: Teon sheath,
nipple, o-ring. Proceed as presented in section “MIG/MAG” use. In this case, use pure argon.

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TROUBLESHOOTING
MAINTENANCE
All maintenance and repairs must be carried out by an authorised repair agent. Any non-
authorised repairs will void warranty. Personnel in compliance to the norm (IEC 60974-4).
If you are still having diculty with your welder, do not hesitate to contact our service team on:
1800 011 812

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MULTI PULSE PRO 240 WELDER

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SPARE PARTS LIST - INVERTER MULTI PULSE PRO 240
Product Code: WCM0007

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SPARE PARTS LIST - INVERTER MULTI PULSE PRO 240
Product Code: WCM0007

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SPARE PARTS LIST - INVERTER MULTI PULSE PRO 240
Product Code: WCM0007

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WELDING MACHINE TECHNICAL DATA

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ELECTRICAL DIAGRAM

1YEAR WARRANTY
Subject to the warranty conditions below, this Weldcorp product (“the Product”) is warranted by
ITW Group, a division of ITW Australia Pty Ltd (“the Company”) to be free from defects in material or
workmanship for a period of 12 months from the date of original purchase (“the Warranty Period”).
Under this warranty, the Company will, subject to the conditions below and at the Company’s option,
repair or replace the Product, or refund the purchase price of the Product, if such a defect becomes
apparent during the Warranty Period.
In the event of such a defect, the Product must be returned to the place of purchase, together with proof
of purchase. Any handling and transportation (and other expenses) incurred in claiming under this
warranty are not covered by this warranty and will not be borne by the Company.
The Company’s dealers or agents are not permitted to oer any warranty or guarantee on the Company’s
behalf in relation to the Product, except as expressly stated in this warranty.
The Company’s obligations under this warranty are subject to: (a) the Product having been used in
accordance with the Company’s directions, instructions and recommendations; (b) the Product having
been used under normal conditions and with reasonable care (including in relation to the maintenance
of the Product); (c) the Product not having been altered, tampered with or otherwise dealt with by any
person in a manner other than as intended in respect of the Product. For the avoidance of doubt, this
warranty does not cover damage, malfunction or failure resulting from misuse, neglect, abuse, or where
the Product has been used for a purpose for which it was not designed or is not suited, or if repairs,
alterations or modications have been attempted by a person who is not an Authorised Service Agent of
the Company. This warranty also does not apply to accidental damage or normal wear and tear.
In addition to other rights and remedies that may be available under law, our goods come with
guarantees that cannot be excluded under Australian Consumer Law (for consumers in Australia) and the
Consumer Guarantees Act (for consumers in NZ). If you are a consumer in Australia, you are entitled to a
replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or
damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable
quality and the failure does not amount to a major failure. If you are consumer in New Zealand, we will
comply with our obligations to you under the Consumer Guarantees Act.
ITW Group, a division of ITW Australia Pty Ltd (ACN 004 235 063)
73C Elizabeth Street
Wetherill Park, New South Wales, 2164
Australia
Ph: 1800 011 812
Email: [e-mail]
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