WELDMARK WEM MP200 User manual

WEM MP200
Inver ter Powered Dual Voltage
Multi-Process Welder
OWNER’S MANUAL
04/2019
WARNING:
Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other
basic safety precautions may result in serious personal injury.

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WELDMARK WARRANTY
EFFECTIVE DECEMBER 1, 2017
LIMITED WARRANTY
This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for
new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from
the factory.
Limited to the warranty periods below, WELDMARK will repair or replace the item under warranty that fails due to defects in
material and workmanship. WELDMARK must be notified within 30 days of the failure, so as to provide instructions on how to
proceed with the repair of your welder and warranty claim processing. Warranty period begins at the time the welder is purchased
from andAuthorized Reseller of WELDMARK products. Keep your receipt as proof of purchase.
Warranty Periods
Limited Warranty is divided into three categories. No Warranty, 90 days and 3 year.
No Warranty
Normal wear items, MIG gun parts (contact tips, nozzle, contact tip adapter, MIG gun liner), drive roll, ground clamps.
90 days
All parts exterior of the main welder unit except normal wear items as described above. This warranty covers the absence of, or
defective parts. These parts include the regulator, gas hose, ground cable and clamp, and the MIG gun.
3 year
This 3 year warranty covers parts and Labor on items such as: transformer, reactor, rectifier, solenoid valve, PC Board, switches,
controls, gas valve, drive motor, drive system other than drive roll and any other component that requires the removal of the sheet
metal to access. Any shipping related to warranty repair is the responsibility of the customer.
Voiding Warranty
Warranty does not apply to: Shipping Damage, Misuse and abuse of the unit, alteration of the unit in any way.
Warranty Claim
This is a parts and labor warranty. Please contact the Authorized Weldmark Distributor that you purchased your unit from. Retain
your receipt in the case a warranty claim is needed. No warranty will be provided without the original receipt from an authorized
Weldmark Distributor.
Weldmark Distributor Warranty Process
The Weldmark Distributor Repair Center should contact Metal Man Work Gear at 888-762-4045 to get needed warranty parts and
to file a warranty claim. Please have available, the original sale date and unit serial number for warranty verification.

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GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed
below may result in serious injury.
CAUTION: Do not allow persons to operate or assemble this unit until they have read
this manual and have developed a thorough understanding of how the unit works.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors which cannot be built into
this product but must be supplied by the operator.
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY CONSIDERATIONS
1.1 Your Welding Environment
-Keep the environment you will be welding in free from flammable materials.
-Always keep a fire extinguisher accessible to your welding environment.
-Always have a qualified person install and operate this equipment.
-Make sure the area is clean, dry and ventilated. Do not operate the welder in humid, wet or poorly
ventilated areas.
-Always have your welder maintained by a qualified technician in accordance with local, state and
national codes.
-Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.
-Keep harmful arc rays shielded from the view of others.
-Mount the welder on a secure bench or cart that will keep the welder secure and prevent it from
tipping over or falling.
1.2 Your Welder’s Condition
-Check ground cable, power cord and welding cable to be sure the insulation is not damaged.
Always replace or repair damaged components before using the welder.
-Check all components to ensure they are clean and in good operating condition before use.
1.3 Use of Your Welder
Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do
not immerse them in water. These components and the welder must be completely dry before
attempting to use them.
-Follow the instructions in this manual.
-Keep welder in the off position when not in use.
-Connect ground lead as close to the area being welded as possible to ensure a good ground.
-Do not allow any body part to come in contact with the welding wire if you are in contact with the

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material being welded, ground or electrode from another welder.
-Do not weld if you are in an awkward position. Always have a secure stance while welding to
prevent accidents. Wear a safety harness if working above ground.
-Do not drape cables over or around your body.
-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety
glasses while welding.
-Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals,
UV and IR rays.
-Do not overuse or overheat your welder. Allow proper cooling time between duty cycles.
-Keep hands and fingers away from moving parts and stay away from the drive rolls.
-Do not point MIG gun at any body part of yourself or anyone else.
-Always use this welder in the rated duty cycle to prevent excessive heat and failure.
1.4 Specific Areas of Danger, Caution or Warning
Electrical Shock
Electric arc welders can produce a shock that can cause injury or death. Touching
electrically live parts can cause fatal shocks and severe burns. While welding, all metal
components connected to the wire are electrically hot. Poor ground connections are a hazard, so
secure the ground lead before welding.
-Wear dry protective apparel: coat, shirt, gloves and insulated footwear.
-Insulate yourself from the work piece.Avoid contacting the work piece or ground.
- Do not attempt to repair or maintain the welder while the power is on.
-Inspect all cables and cords for any exposed wire and replace immediately if found.
-Use only recommended replacement cables and cords.
-Always attach ground clamp to the work piece or work table as close to the weld area as possible.
-Do not touch the welding wire and the ground or grounded work piece at the same time.
-Do not use a welder to thaw frozen pipes.
Fumes and Gases
-Fumes emitted from the welding process displace clean air and can result in injury or
death.
-Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and
safe.
-Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the
environment where you will be working.
-Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury or
barium). They will emit harmful fumes that are dangerous to breathe. If necessary, use a ventilator,
respirator with air supply or remove the coating from the material in the weld area.
-The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety
data sheet for the manufacturer’s instructions.
-Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners, sprays
and degreasers can be highly toxic when heated.
UV and IR Arc Rays
The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to
your eyes and skin. Do not look at the welding arc without proper eye protection.

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-Always use a helmet that covers your full face from the neck to top of head and to the back of each
ear.
-Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps output,
use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for
more information.
-Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant
cloth or leather shirts, coats, pants or coveralls are available for protection.
-Use screens or other barriers to protect other people from the arc rays emitted from your welding.
-Warn people in your welding area when you are going to strike an arc so they can protect
themselves.
Fire Hazards
Do not weld on containers or pipes that contain or have had flammable, gaseous or liquid
combustibles in them. Welding creates sparks and heat that can ignite flammable and
explosive materials.
-Do not operate any electric arc welder in areas where flammable or explosive materials are
present.
-Remove all flammable materials within 35 feet of the welding arc. If removal is not possible, tightly
cover them with fireproof covers.
-Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas,
cracks or areas you cannot see.
-Keep a fire extinguisher close in the case of fire.
-Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
-Do not have on your person any items that are combustible, such as lighters or matches.
-Keep work lead connected as close to the weld area as possible to prevent any unknown,
unintended paths of electrical current from causing electrical shock and fire hazards.
-To prevent any unintended arcs, cut wire back to ¼" stick out after welding.
Hot Materials
Welded materials are hot and can cause severe burns if handled improperly.
-Do not touch welded materials with bare hands.
-Do not touch MIG gun nozzle after welding until it has had time to cool down.
Sparks/Flying Debris
Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying
debris.
-Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear
plugs to keep sparks out of ears and hair.

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Electromagnetic Field
-Electromagnetic fields can interfere with various electrical and electronic devices such as
pacemakers.
-Consult your doctor before using any electric arc welder or cutting device
-Keep people with pacemakers away from your welding area when welding.
-Do not wrap cable around your body while welding.
-Wrap MIG gun and ground cable together whenever possible.
-Keep MIG gun and ground cables on the same side of your body.
Shielding Gas Cylinders Can Explode
High pressure cylinders can explode if damaged, so treat them carefully.
-Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
-Do not touch cylinder with MIG gun.
-Do not weld on the cylinder
-Always secure cylinder upright to a cart or stationary object.
-Keep cylinders away from welding or electrical circuits.
-Use the proper regulators, gas hose and fittings for the specific application.
-Do not look into the valve when opening it.
-Use protective cylinder cap whenever possible
1.5 Proper Care, Maintenance and Repair
-Always have power disconnected when working on internal components.
- Do not touch or handle PC board without being properly grounded with a wrist strap. Put PC board
in static proof bag to move or ship.
-Do not put hands or fingers near moving parts such as drive rolls or fan
USE AND CARE
•Do not modify this unit in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the equipment. There are specific applications for which this
unit was designed.
•Always check for damaged or worn out parts before using this unit. Broken parts will affect
the unit’s operation. Replace or repair damaged or worn parts immediately.
•Store idle. When this unit is not in use, store it in a secure place out of the reach of children.
Inspect it for good working condition prior to storage and before re-use.

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TECHNICAL SPECIFICATIONS
Item
Specification
Power Supply
120V, 20A, 50/60 Hz, Single Phase
230V, 36A, 50/60 Hz, Single Phase
No-Load Voltage
69V DC
Output Range - MIG
30 to 90A DC with 120V Input Power
30 to 200A DC with 230V Input Power
Output Range - STICK
30 to 70A DC with 120V Input Power
30 to 170A DC with 230V Input Power
Duty Cycle-MIG
40% @ 90A with 120V Input Power
20% @ 200A with 230V Input Power
Duty Cycle-STICK
40% @ 70A with 120V Input Power
20% @ 170A with 230V Input Power
Suggested Wire
Steel, Stainless Steel, Aluminum
Suggested Wire Diameter
.023, .030; .035
Suggested Electrodes
E6013, E7014, E7018, Stainless Steel
Electrode Diameter
1/16 inch to 5/32 inch
Dimensions
19-1/8” x 9-1/2” x 14-3/4”
Weight
34-1/8 lb.
DESCRIPTION
The Weldmark MP200 is a dual voltage, portable DC inverter wire feed welder capable of welding
with solid wire (with shielding gas) or with flux core wire. It comes ready to accept part number
WEM-Spoolgun-MM optional Spool Gun for welding aluminum. This machine also has smooth DC
stick capabilities and the ability to perform lift start DC TIG welding on steel and stainless steel
materials with an optional two piece 17V style TIG torch. It can accept part number TIG torch
WEM 17V-25R and 25mm dinse TIG connector kit WEM SL2-25.
This Weldmark MP200 is capable of MIG welding 5/16ʺsteel in a single pass while using 230V input
power (3/16” steel when using 120V input power). It uses leading edge Inverter Technology to
provide high quality welds that are crisp, clean, and consistent with plenty of power that will impress
the most experienced of welders. Stick weld with electrodes up to 5/32ʺwith this exceptionally
smooth DC stick welding output. Stick weld on materials such as steel, stainless steel, cast iron,
hard facing and aluminum. This unit is an exceptional multi-process machine.
The Inverter Technology is evident from the moment you take this unit out of the box. One of the
many advantages of inverter technology is creating more welding power from a smaller transformer.
Typical applications for include home/hobbyist, construction, auto repair, farm and ranch and light
industrial applications.

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POWER INDICATOR LIGHT
In the “OFF” position no power is being supplied to the torch. In the “ON” position power is supplied to
the main transformer and control circuit.
PROTECTION INDICATOR LIGHT
If the duty cycle of the welder is exceeded, the internal temperature will exceed safe temperatures and
the machine will shut down. The thermal overload light will come on indicating this. Leave the unit on and
allow 15 minutes for cool down before the light will go off and the temperature to fall into an allowable
operating range.
WORK INDICATOR LIGHT
The work indicator will light when the torch trigger is pulled, indicating welding current is activated.
WELDING VOLTAGE
The voltage control is on the front panel of machine. Refer to the “set up” chart inside the wire feed
compartment for initial adjustment settings.
WIRE FEED SPEED / AMPERAGE CONTROL
Adjustment of the wire feed speed in the MIG Torch or SPOOL GUN mode. Adjustment of the amperage
in STICK welding mode. Refer to the "set up" chart inside the wire feed compartment for initial
adjustment settings.
SPOT TIMER ON/OFF SWITCH
This control turns the spot welder function ON or OFF.
Indicator
Lights
Voltage
Setting
Wire Speed
andAmperage
Control
Ground Cable
and Clamp
Spot Time
Adjustment
Gas
Hose
Regulator/
Flow gauge
Spool Gun
Stick/TIG
MIG Gun
Selector
Spot Timer
On/Off
MIG Gun
Digital
Meters
Electrode Holder
and Cable

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SPOOL GUN-TIG/STICK-MIG GUN WELDING SELECTOR
When performing normal MIG welding, this switch should be turned on “MIG” position. When using the
spool gun, the switch should be in “spool gun” position. When DC stick welding, the switch will be in the
"stick" position.
SPOT TIME ADJUSTMENT
The Spot Time Adjustment allows you to set a time from 0.1 to 9.9 seconds for consistent spot welds.
MIG GUN
The welding wire is driven through the welding cable and gun to the work piece. It is attached to the drive
system. The trigger activates the drive motor.
OPTIONAL SPOOL GUN (WEM-Spoolgun-MM)
The Spool Gun is typically used for welding aluminum. The soft aluminum wire has a hard time feeding
consistently in the standard MIG Gun. Load 4-inch spools of aluminum wire in the spool gun for easy and
consistent feeding of aluminum wire.
ELECTRODE HOLDER AND CABLE
The Electrode Holder holds the stick welding electrode. The cable most often connects to the Positive (+)
weld output connection for stick welding.
GROUND CABLE AND CLAMP
The ground cable and clamp are attached to the work piece to complete the circuit allowing the flow of
current needed to weld.
GAS HOSE
The gas hose connects to the regulator/flowgauge and delivers the shielding gas from the shielding gas
bottle to the welder.
GAS REGULATOR/FLOWGAUGE
The Gas Regulator/Flow gauge installs on the shielding gas cylinder for MIG welding with solid wires.
The regulator controls the compressed gas and allows you to adjust the flow rate of the gas.
DIGITAL METERS
Digital meters display welding amperage and voltage while welding.
ASSEMBLY
1. MIG GUN ASSEMBLY
1.1 Locate the wing nut retaining bolt inside the front panel on the drive system. Loosen the
retaining bolt.
1.2 Make note of the retaining groove location on the back end of the MIG gun.
1.3 Insert the back end of the MIG gun into the MIG socket on the front of your machine. Make
certain to completely slide the gun all the way in. Slightly twist to assist with pushing the gun to the
back of the receptacle. The retaining bolt can then be tightened, making certain the bolt sets down
into the retaining groove on the back of the MIG gun.
1.4 Connect the 5-Pin trigger connection on the MIG gun to the 5-Pin trigger receptacle on the front
Retaining
Bolt
Retaining
Groove

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panel.
1.5 Connect the ground cable to the Negative (-) weld output connection and move the Weld
Power Cable to the Positive (+) weld output connection for MIG welding. If welding with
self-shielded flux core, connect the ground cable to the Positive (+) weld output connection and
move the Weld Power Cable to the Negative (-) weld output connection.
1.6 Make certain the SPOOL GUN/MIG GUN SELECTOR on the front panel is switched into the
MIG GUN position.
2. OPTIONAL SPOOL GUN ASSEMBLY
2.1 This unit is set-up to accept the Optional Spool Gun.
2.2 The Spool Gun has three connection points at the back of the Spool Gun. (1) The gas
connection is a slide on quick connector. (2) The weld power connection has a round ring
connection. (3) The snap-on trigger connection is 5-Pin.
2.3 We recommend removing the MIG gun when the Spool Gun is connected to avoid accidental
MIG
Socket
5-Pin Trigger
Receptacle
Positive (+)
Weld Output
Connection
Negative (-)
Weld Output
Connection
Weld Power
Cable

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arcing. Loosen the wing nut retaining bolt and slide the MIG gun out of the front of the machine.
Disconnect the 5-Pin trigger connection on the front of the machine.
2.4 Carefully slide the gas connector (1) and the weld power connection (2) through the weld cable
access opening in the front of the machine.
2.5 Open the wire compartment door.
2.6 Connect the gas connection quick connector to the gas connector (1) on the back panel of the
wire compartment.
2.7 Connect the weld power connection to the bolt on the top of the MIG connector (2).
2.8 Connect the 5-Pin trigger connector to the 5-Pin receptacle on the front of the machine (3).
2.9 Make certain the SPOOL GUN-TIG/STICK-MIG GUN SELECTOR on the front panel is switched
into the SPOOL GUN position.
Weld Cable
Access Opening
(2)
(1)
(3)

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INSTALLATION
Electrical Shock
• High voltage danger from power source! Consult a qualified electrician for proper
installation of receptacle. This unit must be grounded while in use to protect the operator
from electrical shock.
• Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter
between the unit’s power cord and the power source receptacle. Make sure the POWER
switch is OFF when connecting this unit’s power cord directly to a properly grounded 230 or
120 VAC, 60 Hz, single phase, 50 or 20 amp input power supply.
1. POWER REQUIREMENT 230V - AC single phase 230V (200-240V) 50/60 Hz fused with a 50
amp time delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if the
ACTUAL power source voltage is less than 215 volts AC or greater than 240 volts AC.
2. POWER REQUIREMENT 120V - AC single phase 120V (110-130V) 50/60 Hz fused with a 20
amp time delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if the
ACTUAL power source voltage is less than 110 volts AC or greater than 130 volts AC.
3. EXTENSION CORD - We do not recommend an extension cord because of the voltage drop
they produce. This drop in voltage can affect the performance of the welder. If you need to use
an extension cord, it must be size #12 or larger. Check with a qualified electrician and your local
electrical codes for your specific area. Do not use an extension cord over 25 ft. in length.
4. INSTALL THE WIRE ROLLER - The wire roller has been factory installed. However, check to
make certain the correct wire groove is in place to accommodate the size of wire you are using.
Open the wire feed compartment. Adjust the drive roller according to the following steps; see
following picture about the wire feeder structure:
a.Open the door to the welder drive compartment.
b.Remove the drive tension by loosening the Drive Tension Adjuster (1) and moving the
Drive TensionAdjustor away from the Drive TensionArm (2). Lift the Drive Tension
Arm away from the Drive Roller (3).
c.If there is wire already installed in the welder, roll it back onto the wire spool by
hand-turning the spool clockwise. Be careful not to allow the wire to come out of the
(1)
(2)
(3)

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rear end of the inlet guide tube without holding onto it or the wire spool will unspool
itself. Put the end of the wire into the hole on the outside edge of the wire spool and
bend it over to hold the wire in place. Remove the spool of wire from the drive
compartment of the welder.
d.Remove the drive roller by turning the drive roll knob (3) counter-clockwise. Carefully
slide the drive roll assembly off of the drive shaft. This drive roll assembly consists of
three pieces. The outer drive roll, inner drive roll and a key. Be careful not to
misplace the key.
e.Based on the wire diameter select the correct groove. When installing the drive roller,
the number stamped on the drive roller for the wire size you are using should be
facing you. Push the Drive Roller onto the Drive Roller Shaft.
f. Reinstall the Drive Roller knob and tighten clockwise.
g.Close the door to the welder drive compartment.
5. INSTALL THE WIRE - We recommend the use of 0.023, 0.030, or 0.035 MIG or flux cored
wire on this unit.
a. Select welding wire - Both four-inch or eight-inch wire spools of 0.023, 0.030, or
0.035 wire can be used on this welder.
NOTE: - Burn through can occur if you attempt to weld mild or stainless steel thinner than 24 gauge.
- Remove all rusted wire from your wire spool. If the whole spool is rusty, discard it.
b. Installing the wire:
Electrical Shock
•Electric shock can cause injury or death! Always turn the POWER switch OFF and
unplug the power cord from the AC power source before installing wire.
NOTE:
- Before installing, make sure that you have removed any old wire from the gun assembly. This will
help prevent the possibility of the wire jamming inside the gun liner.
- Be very careful when removing the welding nozzle. The contact tip on this welder is live whenever
the gun trigger is pulled. Make certain POWER is turned OFF.
c. Remove the nozzle and contact tip from the end of the gun assembly.
d. Make sure the proper groove on the drive roller is in place for the wire installed. If not,
change the drive roller as described in Section 3.
e. Remove the packaging from the spool of wire and then identify the leading end of the
wire secured on the edge of the spool. DO NOT UNHOOK ITAT THIS TIME.
MIG
Nozzle
Flux Core
Nozzle
Contact
Tip

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f. Place the spool on the spool hub so the wire will pull off the bottom of the spool. The
welding wire should always come off the bottom of the spool into the drive
mechanism. See following figure.
g. The welder can use either 4-inch or 8-inch spools. See the following figure for
additional reference. The wing nut controls the tension on the spool.
h. Setting the wire spool tension. a) Turn the spool of wire with one hand. b) Increase
the spool tension by tightening (turn clockwise) the wing nut while turning the spool.
Turn the spool while tightening the wing nut until the spool slows down and you feel
a slight drag. Stop tightening the wing nut; you may need to repeat these steps until
proper spool tension is achieved.
NOTE:
- If TOO MUCH tension is applied to the wire spool, the wire will slip on the drive roller or will not be
able to feed at all. If TOO LITTLE tension is applied, the spool of wire will want to unspool itself
when the trigger is released. Readjust the spool tension using the wing nut as necessary to correct
for either problem.
i. With the welder disconnected from the power source, remove the leading end of the
wire from the spool. Hold on to it securely, so as not to allow unspooling or
tangling of the wire as it will result in tangled wire and feeding problems.
j. Cut off any bent portion of the wire using a wire cutter.
k. Loosen the tension adjusting knob by holding the drive tension arm in place and lift
the tension arm up off the drive roller.
8-Inch
4-Inch

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l. Insert the wire into the inlet guide tube and feed it across the drive roller and into the
gun assembly about six inches.
-Make certain that the welding wire is actually going into the gun liner. If not, the wire will jam up in
the mechanism.
m. Line the wire up with the correct groove in the drive roller. Place the drive tension
arm back above the drive roller.
n. Place the drive tension adjustment arm back in place.
o. Tighten (turn clockwise) the drive tension adjusting knob until the tension roller is
applying enough force on the wire to prevent it from slipping in the drive rollers. DO
NOT OVER TIGHTEN.
p. NOW YOU CAN LETGO OF THE WIRE.
q. Plug in the welder power cord and turn the welder ON. Set the voltage switch to the
voltage setting recommended for the gauge metal that is to be welded. Refer to the
set-up chart on the back side of the drive compartment door.
-The welding wire is electrically hot when the power is on and the gun trigger is activated.
r. Set the WIRE SPEED control to the middle of the wire speed range.
s. Straighten the MIG gun cable and pull the trigger in the gun handle to feed the wire
through the gun assembly. When at least one inch of the wire sticks out past the end
of the gun, release the trigger.
t. Turn the Power Switch to the OFF position.
u. Select a contact tip stamped with the same diameter as the wire being used.
NOTE:
- Due to inherent variances in flux cored welding wire, it may be necessary to use a contact tip one
size larger than your flux core wire if wire jams occur.
v. Slide the contact tip over the wire (protruding from the end of the gun). Thread the
contact tip into the end of the gun and hand-tighten securely.
w. Install the nozzle on the gun assembly.
x. Cut off excess wire that extends past the end of the nozzle more than 1/4 inch.
y. Turn the welder ON.
6. SETTING THE DRIVE ROLLTENSION
•Arc flash can injure eyes! To reduce the risk of arc flash, make certain that the wire
coming out of the end of the gun does not come in contact with the work piece, ground
clamp, or any grounded material during the drive tension setting process or arcing will
occur. a. Press the trigger on the gun.
b. Turn the drive tension adjustment knob clockwise until the wire seems to feed
smoothly without slipping.

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7. GAS INSTALLATION
Shielding gas cylinders and high pressure cylinders can explode if damaged, so treat them
carefully.
•Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
•Do not weld on the cylinder.
•Always secure cylinder upright to a cart or stationary object.
•Keep cylinders away from welding or electrical circuits.
•Use the proper regulators, gas hose and fittings for the specific application.
a. Polarity Changing - When MIG wire is used, shielding gas is required and the polarity on this
unit needs to be electrode positive.
b. Electrode Positive for MIG Welding - The Weld Power Cable should be connected to the
positive (+) weld output connection on the front of the machine. The ground cable would
then be connected to the negative (-) weld output connection.
c. Electrode Negative for Flux Core Welding - The Weld Power Cable should be connected to
the negative (-) weld output connection on the front of the machine. The ground cable would
then be connected to the positive (+) weld output connection. Refer to the polarity setting
label inside the wire compartment.
d. Connect one end of the gas hose to the gas hose connection on the back of the welder. Use
a wrench to snug up the connection.
e. Connect the other end of the gas hose to the gas hose connection on the supplied rear
mount regulator/flow gauge. Use a wrench to snug up the connection.
f. Before installing the regulator, it is good practice to make certain no debris is in the gas
bottle connection. Rotate the bottle so the gas connection is not pointing toward you or any
other person. Turn the valve on the gas bottle clockwise and quickly close. This quick thrust
of gas will clear any debris in the connection. Connect the regulator to the gas bottle
connection. Use a wrench to snug up the connection.
(1) Gas Bottle Valve
(2) Gas Flow Gauge (Set at 20 CFH)
(3) Gas Pressure Gauge
(4) Regulator
(5) Gas Flow Adjuster
(6) Gas Hose Connection
(7) Gas Cylinder
1
7
4
3
2
6
5

g. Open the Gas Bottle Valve on the cylinder of gas.
h. Turn the Gas Flow Adjuster on the regulator so that the gas flow rate is set at approximately
20 CFH. Make certain you are reading the correct scale on the gauge.
NOTE: Slowly open the cylinder valve by turning it counterclockwise until the cylinder pressure
gauge registers on the first gauge of the regulator. Turn the adjustment knob clockwise (right) slowly
to increase gas flow to 20 CFH. To reduce the gas flow, turn the adjustment counterclockwise (left).
The gas valve is located on the back panel of the welder and activated by the trigger. Gas flow
should be heard when the trigger is activated. No gas flow will result in a harsh arc with excessive
spatter, a smooth weld bead will be difficult to obtain. Avoid unnecessary gas loss by closing the
tank valve when finished welding.
i. Gas selection:
Different materials require different shielding gas when MIG welding, refer to the set up chart inside
the wire feed compartment.
Mild steel: Use 75% Argon and 25% CO2 for reduced spatter and reduced penetration for thinner
materials. Do NOT USE Argon gas concentrations higher than 75% on steel. The result will be
extremely poor penetration, porosity, and brittleness of weld.
Mild steel: Use CO2 for deeper penetration but increased spatter. (A CO2 regulator adapter will be
needed.)
Stainless steel: Use a mixed gas consisting of Helium, Argon and CO2.
Aluminum or bronze: Use 100% Argon.
MIG OPERATION
Electrical Shock
•High voltage danger from power source! Consult a qualified electrician for proper
installation of receptacle. This welder must be grounded while in use to protect the
operator from electrical shock.
•Do not remove grounding prong or alter the plug in any way. Use only the supplied
adapter between the welder's power cord and the power source receptacle. Make sure the
POWER switch is OFF then connect your welder's power cord to a properly grounded 230
VAC (230V - 240V), 60 HZ, single phase, 50 amp power source. If operating on 120V, attach
the 120V Adapter cord to the unit power cord and then connect the assembly to a properly
grounded 120 VAC (110V-130V), 60 Hz, single phase, 20 amp power source.
1. POWER SWITCH
The power switch supplies electrical current to the welder. Whenever the power switch is in the ON
position, the welding circuit is activated. ALWAYS turn the power switch to the OFF position and
unplug the welder before performing any maintenance.
2. VOLTAGE SELECTOR
The voltage selector controls the welding voltage/heat. This unit has a voltage control that is
infinitely adjustable within its range. Refer to the label inside the welder side door for recommended
voltage selector settings for your welding job.

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3. WIRE SPEED CONTROL
The wire speed control adjusts the speed at which the wire is fed out of the welding torch. The wire
speed needs to be closely matched (tuned-in) to the rate at which it is being melted off. Some things
that affect wire speed selection are the type and diameter of the wire being used, the heat setting
selected, and the welding position being used. Refer to the label inside the welder side door for
recommended wire speed settings for your welding job.
NOTE: The wire will feed faster without an arc. When an arc is being drawn, the wire speed will
slow down.
4. HOLDING THE TORCH
The best way to hold the welding torch is the way it feels most comfortable to you. While practicing
with your new welder, experiment holding the torch in different positions until you find the one that
seems to work best for you.
5. POSITION OF THE TORCH TO THE WORK PIECE
There are two angles of the torch nozzle in relation to the work piece that must be considered when
welding.
5.1. Angle can vary, but in most cases the optimum angle will be 60 degrees, the point at which the
torch angle is parallel to the work piece. If angle A is increased, penetration will increase. If angle A
is decreased, penetration will decrease also.
5.2. Angle B can be varied for two reasons: to improve the availability to see the arc in relation to
the weld puddle and to direct the force of the arc.
6. DISTANCE FROM THE WORK PIECE - If the nozzle is held off the work piece, the distance
between the nozzle and the work piece should be kept constant and should not exceed 1/4 inch or
the arc may begin sputtering, signaling a loss in welding performance.
7. TUNING IN THE WIRE SPEED - This is one of the most important parts of wire welder operation
and must be done before starting each welding job or whenever the voltage setting, or wire diameter
is changed.
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!
Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc
or begin welding until you are adequately protected. Wear flame-proof welding gloves, a
heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved
welding helmet.
7.1 Connect the Ground Clamp to a scrap piece of the same type of material which you will be
welding. It should be equal to or greater than the thickness of the actual work piece, and free of oil,
paint, rust, etc.
7.2 Select a heat setting.

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7.3 Hold the torch in one hand. Hold the wire just off the work piece. (See HOLDING THE TORCH
section if you are uncertain of the angle at which you will be welding.)
7.4 Set the wire feed speed based on the thickness of material and the set-up chart on the back
side of the wire feeder door.
7.5 Lower your welding helmet. Pull the trigger on the torch and let the wire feed into the work
piece to start an arc. Then begin to drag the torch toward you.
7.6 LISTEN! If the arc is sputtering, increase the wire speed slightly and try again. Continue
increasing the wire speed adjustment until you achieve a smooth buzzing sound. If the wire seems
to "pound" into the work piece, decrease wire speed slightly and try again. Use the wire speed
control to slightly increase or decrease the heat and penetration for a given voltage setting by
increasing or decreasing the wire speed slightly. Repeat this tune-in procedure if you select a new
voltage setting, a different wire diameter, or a different roll of wire.
8. WELDING TECHNIQUES
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!
Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc
or begin welding until you are adequately protected. Wear flame-proof welding gloves, a
heavy long sleeved shirt, trousers with out cuffs, high topped shoes, and an ANSI approved
welding helmet.
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH! To prevent ELECTRIC SHOCK, do not
perform any welding while standing, kneeling, or lying directly on the grounded work piece.
8.1 Moving the torch
Torch travel refers to the movement of the torch along the weld joint and is broken into two elements:
Direction and Speed. A solid weld bead requires that the welding torch be moved steadily and at the
right speed along the weld joint. Moving the torch too fast, too slow, or erratically will prevent proper
fusion or create a lumpy, uneven bead.
Travel direction is the direction the torch is moved along the weld joint in relation to the weld
puddle. The torch is either PUSHED into the weld puddle or PULLED away from the weld puddle.
For most welding jobs you will pull the torch along the weld joint to take advantage of the greater
weld puddle visibility.
Travel speed is the rate at which the torch is being pushed or pulled along the weld joint. For a
fixed heat setting, the faster the travel speed, the lower the penetration and the lower and narrower
the finished weld bead. Likewise, the slower the travel speed, the deeper the penetration and the
higher and wider the finished weld bead. As a good rule of thumb, the thickness of a cross-section

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of the weld bead should be approximately the same thickness as the thinnest material you are
welding.
8.2 Types of welding beads
As you become more familiar with your new welder and better at laying some simple weld beads,
you can begin to try some different weld bead types.
The STRINGER BEAD is formed by traveling with the torch in a straight line while keeping the wire
and nozzle centered over the weld joint. See following figure.
The WEAVE BEAD used when you want to deposit metal over a wider space than would be
possible with a stringer bead. It is made by weaving from side to side while moving with the torch. It
is best to hesitate momentarily at each side before weaving back the other way.
8.3 Welding position
FLAT POSITION is easiest of the welding positions and is most commonly used. It is best if you can
weld in the flat position if at all possible, as good results are easier to achieve.
HORIZONTAL POSITION is performed very similarly to the flat weld except that angle B (see
HOLDING THE TORCH) is such that the wire, directed more toward the metal above the weld joint