Yeswelder MIG-205DS User manual

MIG-205DS
IGBT INVERTER MULTI-PROCESS WELDER
(MIG, MAG, FLUX-CORED, STICK, LIFT TIG)
Aug., 2023
Copyright © YesWelder
OPERATOR’S MANUAL

TABLE OF CONTENTS
SAFETY············································································································································· 01
INSTALLATION··································································································································05
Technical Specifications····················································································································05
Safety Precautions···························································································································05
Location···········································································································································05
Stacking··········································································································································0 5
Tilting··············································································································································0 5
Included Components ······················································································································05
ACCESSORIES································································································································06
DESCRIPTION····································································································································07
Safety and Product Description·········································································································07
Controls and Settings·······················································································································08
Installing the MIG Gun Assembly·······································································································10
Gas Cylinder and Regulator Connection·····························································································10
Installing the Welding Wire················································································································10
OPERATION·······································································································································12
Performance Data Plate and Duty Cycle····························································································12
Internal Thermal Protection···············································································································13
Welding Preparation·························································································································13
Welding Wire Selection·····················································································································14
Gas Selection···································································································································14
Setup for MIG (GMAW) & Flux-Cored Wire Welding (FCAW)·······························································14
Setup for Aluminum Welding with Spool Gun······················································································15
Setup For Aluminum Welding With MIG Gun With Graphene Liner·······················································16
Setup for Stick Welding (SMAW)·······································································································18
Setup for TIG Welding (GTAW) with Lift Arc·······················································································18
MAINTENANCE & SERVICING···········································································································19
General Maintenance························································································································19
Consumable Maintenance·················································································································19
TROUBLESHOOTING·························································································································20
WIRING DIAGRAM·····························································································································23

- 01 -
SAFETY
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
YESWELDER.
When this equipment is shipped, the title passes to the pur-
chaser upon receipt by the carrier. Consequently, claims for ma-
terial damaged in shipment must be filed by the purchaser
against the transportation company when the shipment is re-
ceived.
PLEASE EXAMINE THE PACKING BOX AND
EQUIPMENT FOR DAMAGE IMMEDIATELY
SAFETY DEPENDS ON YOU
YESWELDER arc welding and cutting equipment are designed
and built with safety. However, your overall safety can be in-
creased by proper installation and thoughtful operation on your
part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIP-
MENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And
most importantly, think before you act and be careful.
WARNING
CAUTION
This statement appears where the information must be followed
precisely to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if neces-
sary to stay a reasonable dis-
tance from the arc.
READ and obey the Safety
Data Sheet (SDS) and the warn-
ing label on all welding materi-
als containers.
USE ENOUGH VENTILATION
or exhaust at the arc, or both, to
keep the fumes and gases from your breathing zone and the
general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may
be adequate if you keep your head out of the fumes (See be-
low).
USE NATURAL DRAFTS or fans to keep the fumes away from
your face.
If you develop unusual symptoms, see your supervisor. Per-
haps the welding atmosphere and ventilation system should be
checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding hel-
met properly fitted and with proper grade of filter
plate (See ANSI Z49.1).
PROTECT your body from welding spatter and
arc flash with protective clothing including
woolen clothing, flame-proof apron and gloves,
leather leggings, and high boots.
PROTECT others from spatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previ-
ously had been in contact with hazardous substances unless
they are properly cleaned.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures:
PROTECT compressed gas cylinders from excessive heat, me-
chanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical
circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
appropriate.
BE SURE protective equipment is in good condition. Also, wear
safety glasses in work area
AT ALL TIMES.

SAFETY
Read and understand the following safety highlights. For addi-
tional safety information, it is strongly recommended you down-
load free PDF of Standard ANSI Z49.1 from the American Weld-
ing Society.
https://www.aws.org/library/doclib/AWS-Z49-2021.pdf
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust ex-
poses you to chemicals known to the State of Cal-
ifornia to cause cancer and birth defects, or
other reproductive harm.
ŸAlways start and operate the engine in a well-ventilated
area.
ŸIf in an exposed area, vent the exhaust to the outside.
ŸDo not modify or tamper with the exhaust system.
ŸDo not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or cutting,
produces fumes or gases which contain chemicals known
to the State of California to cause birth defects and, in
some cases, cancer. (California Health & Safety Code §
25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
1.a. Turn the engine off before troubleshoot-
ing and maintenance work unless the
maintenance work requires it to be run-
ning.
1.b. Operate engines in open, well-
ventilated areas or vent the engine ex-
haust fumes outdoors.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is run-
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
ning. Stop the engine and allow it to cool before refueling
to prevent spilled fuel from vaporizing on contact with hot
engine parts and igniting. Do not spill fuel when filling tank.
If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair. Keep hands,
hair, clothing and tools away from V-
belts, gears, fans and all other moving
parts when starting, operating or repair-
ing equipment.
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove guards
only when necessary and replace them when the mainte-
nance requiring their removal is complete. Always use the
greatest care when working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt
to override the governor or idler by pushing on the throttle
control rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turn-
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor causes lo-
calized Electric and Magnetic Fields (EMF). Welding cur-
rent creates EMF fields around welding cables and welding
machines
2.b. EMF fields may interfere with some pacemakers, and weld-
ers having a pacemaker should consult their physician be-
fore welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Se-
cure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
workcables. If the electrode cable is on your right
side, the work cable should also be on your right
side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
ing the engine or welding generator dur-
ing maintenance work, disconnect the
spark plug wires, distributor cap or mag-
neto wire as appropriate.
1.h. To avoid scalding, do not remove the radi-
ator pressure cap when the engine is
hot.
- 02 -

SAFETY
- 03 -
ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) cir-
cuits are electrically “hot” when the
welder is on. Do not touch these “hot”
parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insula-
tion. Make certain the insulation is large enough to cover
your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous con-
ditions (in damp locations or while wearing wet cloth-
ing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable
or accidental contact with the workpiece or ground)
use the following equipment:
ŸSemiautomatic DC Constant Voltage (Wire) Welder.
ŸDC Manual (Stick) Welder.
ŸAC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode stinger, work clamp, welding cable
and welding machine in good, safe operating condition. Re-
place damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of elec-
trode stingers connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
4.a. Use a shield with the proper filter and cover plates to pro-
tect your eyes from sparks and the rays of the arc when
welding or observing open arc welding. Head shield and fil-
ter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-
flammable screening and/or warn them not to watch the
arc nor expose themselves to the arc rays or to hot spatter
or metal.
ARC RAYS CAN BURN.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing
these fumes and gases. When welding,
keep your head out of the fume. Use enough ventilation
and/or exhaust at the arc to keep fumes and gases away
from the breathing zone. When welding hardfacing (see
instructions on container or SDS) or on lead or cad-
mium plated steel and other metals or coatings which
produce highly toxic fumes, keep exposure as low as
possible and within applicable OSHA PEL and ACGIH
TLV limits using local exhaust or mechanical ventila-
tion unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances, out-
doors, a respirator may also be required. Additional
precautions are also required when welding on galva-
nized steel.
5.b. The operation of welding fume control equipment is af-
fected by various factors including proper use and position-
ing of the equipment, maintenance of the equipment and
the specific welding procedure and application involved.
Worker exposure level should be checked upon installation
and periodically thereafter to be certain it is within applica-
ble OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon va-
pors coming from degreasing, cleaning or spraying opera-
tions. The heat and rays of the arc can react with solvent
vapors to form phosgene, a highly toxic gas, and other irri-
tating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation, espe-
cially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for
this equipment and the consumables to be used, including
the Safety Data Sheet (SDS) and follow your employer’s
safety practices. SDS forms are available from your weld-
ing distributor or from the manufacturer.
5.f. Also see item 1.b.

SAFETY
- 04 -
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If this is not
possible, cover them to prevent the welding sparks from
starting a fire. Remember that welding sparks and hot ma-
terials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near hy-
draulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode cir-
cuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until
the proper steps have been taken to insure that such pro-
cedures will not cause flammable or toxic vapors from sub-
stances inside. They can cause an explosion even though
they have been “cleaned”. For information, purchase “Rec-
ommended Safe Practices for the Preparation for Welding
and Cutting of Containers and Piping That Have Held Haz-
ardous Substances”, AWS F4.1 from the American Weld-
ing Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting
or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear
oil free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes and a cap over your
hair. Wear ear plugs when welding out of position or in con-
fined places. Always wear safety glasses with side shields
when in a welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy,
MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders con-
taining the correct shielding gas for the
process used and properly operating reg-
ulators designed for the gas and pres-
sure used. All hoses, fittings, etc. should
be suitable for the application and main-
tained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode stinger or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve out-
let when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas cylin-
ders, associated equipment, and CGA publication P-l, “Pre-
cautions for Safe Handling of Compressed Gases in Cylin-
ders,” available from the Compressed Gas Association,
14501 George Carter Way Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off the power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Elec-
trical Code, all local codes and the manufacturer’s recom-
mendations.
8.c. Ground the equipment following the U.S. National Electri-
cal Code and the manufacturer’s recommendations.

TECHNICAL SPECIFICATIONS: MIG-205DS
INSTALLATION
- 05 -
Read entire installation section before you starting in-
stallation.
INSTALLATION
WARNIG
ELECTRIC SHOCK can kill.
ŸOnly qualified personnel should perform
this installation.
ŸOnly personnel that have read and un-
derstood the MIG205DS Operator’s Man-
ual should install and operate this equip-
ment.
ŸMachine muse be plugged into a receptacle which is
grounded per any national, local or other applicable electrical
codes.
ŸThe MIG205DS power switch is to be in the OFF(“O”) position
when installing work cable and gun and when connecting
power cord to input power.
SELECT SUITABLE LOCATION
STACKING
Locate the MIG205DS in a dry location where there is free cir-
culation of clean air into the louvers in the back and out the
front of the unit. A location that minimizes the chance of dirt ac-
cumulation that can block air passages and cause overheating.
MIG205DS cannot be stacked.
TILTING
Each machine must be placed on a secure, level surface, di-
rectly or on recommended cart. The machine may topple over if
this procedure is not followed.
Standard Voltage/Frequency
220V±10% 50/60Hz
110V±10% 50/60Hz
Input Current
I1 max=34A, I1 eff=26.3A
I1 max=43A, I1 eff=33.2A
INPUT-SINGLEPHASEONLY
RATEDOUTPUT-DCONLY
OUTPUT RANGE
OTHER PARAMETERS
PACKING DIMENSIONS
TEMPERATURERANGE
Voltage
220V
110V
Mode
GMAW
SMAW
GTAW
GMAW
SMAW
GTAW
Duty Cycle
60%
100%
60%
100%
60%
100%
60%
100%
60%
100%
60%
100%
Current
205A
158A
180A
139A
205A
158A
160A
123A
145A
112A
160A
123A
VoltsatRated
Current
24.2V
21.9V
27.2V
25.5V
18.2V
16.3V
22V
20.1V
25.8V
24.5V
16.4V
14.9V
Voltage
220V
110V
Mode
GMAW
SMAW
GTAW
GMAW
SMAW
GTAW
Open Circuit
Voltage
65V
Welding
Current Range
30A~205A
20A~180A
20A~205A
30A~160A
20A~145A
20A~160A
Welding
VoltageRange
15.5V~24.2V
20.8V~27.2V
10.8V~18.2V
15.5V~22V
20.8V~25.8V
10.8V~16.4V
Machine PowerFactor Efficiency ProtectionClass InsulationClass
1 ≥80% IP21S F
MIG-205DS
Machine Length Width Height Weight
510mm 330mm 395mm 16Kg
OperatingTemperatureRange
-10°C~+40°C(14°F~104°F)
StorageTemperatureRange
-25°C~+55°C(-13°F~131°F)
MIG-205DS

1. Welder
2. Work Clamp
3. Electrode Stringer
4. V Knurl Groove
Drive Roller: .023"/.0
30" (.030" & .035" on
the machine)
5. W Knurl Groove
Drive Roller: .030" & .035"
6. U Knurl Groove Drive
Roller: .035" & .045"
7. 220V~110V Adapter
8. MIG Gun
9. Graphene Feeding Liner
10. MIG Gun Tips X 4
11. Gas Hose
12. Manual
ACCESSORIES
11
12
10
8
7
2
34
56
9
1
- 06 -

This small portable wire feed welder is capable of MIG(GMAW/
flux-cored (FCAW) welding on steel, mild steel, stainless steel.
The wire feed welder is also capable of STICK welding
(SMAW) and DC lift TIG welding (GTAW).
This machine does not have a built in Gas Solenoid so a one
piece gas valve TIG Torch is required, The gas valve must be
opened manually before welding and closed manually when
welding is completed. The arc is activated using a lift arc tech-
nique.
DESCRIPTION
- 07 -
GMAW(MIG)
• GasMetalArcWelding
FCAW(INNERSHIELDOROUTERSHIELD)
• FluxCoreArcWelding
SMAW(STICK)
• StickArcWelding
GTAW(TIG)
• Lift TIG Arc Welding
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
ŸDo not touch electrically live parts such as
output terminals or internal wiring.
ŸInsulate yourself from the work and
ground.
ŸAlways wear dry insulating gloves.
FUMES AND GASES
can be dangerous.
ŸKeep your head out of fumes.
ŸUse ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS
can cause fire or explosion
Read entire operation section before operating
the WIRE FEEDER WELDER.
ŸKeep flammable material away.
ŸDo not weld on closed containers.
ARC RAYS can burn eyes and skin.
ŸWear eye, ear and body protection.
WARNING
Observe all safety information
throughout this manual.
COMMON WELDING ABBREVIATIONS
PRODUCT DESCRIPTION (PRODUCT CAPABILITIES)
MIG welding stands for Metal Inert Gas welding and requires a
shielding gas to protect the weld until it cools. Appropriate
shielding gas based on the type of material you are welding
can be purchased separately from your local welding gas dis-
tributor. MIG welding is ideal for welding on thinner and clean
materials when a very clean excellent cosmetic looking weld is
required. Anexample would be automotive body panels.
Self Shielding Flux-cored Welding does not require a separate
shielding gas to protect the weld since the welding wire has spe-
cial additives known as flux to protect the weld until it cools.
Flux-cored welding is ideal for medium to thicker material and if
welding on painted or rusty steel. Flux-cored welding is also
ideal in outdoor applications where windy conditions might blow
the MIG shielding gas away from the weld. Flux-cored welding
produces a good looking weld but does not produce an excel-
lent weld appearance as MIG welding does.

1. Adjustment knob:
1). Press and select welding parameters;
2). Rotate and adjust the values.
2. Process Selection Button: Allows the user to toggle between processes Synergic MIG/Manual
MIG/Lift TIG/Stick.
3. Material Selector: CO2 100%/CO2 25% Argon 75%/Flux Cored/AL.
4. Wire Feed Button: Press the Wire Feed button to feed the wire through the gun assembly.
Controls and Settings
1
345
6
5. Wire Diameter Selector Button: .023" 0.6mm/.030" 0.8mm/.035" 0.9mm/.045" 1.2mm.
6. Selector Button: Permits selecting Output Current, Output Voltage, Welding Speed.
7. Gun Connection (Euro Connect): Permits attachment of a MIG welding gun. Ensure the gun is
fully seated into the brass receptacle.
8. Wire Drive Polarity Lead: Permits configuring the wire drive to positive or negative polarity by
inserting into the positive or negative receptacle. Ensure connector is tightly locked into place by
rotating clockwise.
9. Spool Gun Trigger Connector Receptacle: Plug the 2 pin gun trigger connector into this
receptacle.
10. Positive Output Receptacle: Permits attaching a work lead, electrode stinger or the center wire
drive polarity lead to DC positive polarity. Rotate clockwise to lock into place.
11. Negative Output Receptacle: Permits attaching a work lead, electrode stinger, or the center
wire drive polarity lead to DC negative polarity. Rotate connector clockwise to lock into place.
12. Power Switch: Turns power on and off to the machine.
13. Gas Inlet: Shielding gas connects to this inlet, gas fitting: 5/8"~18 RH.
14. Input Power Cable.
15. Fan.
2
- 08 -

16. Wire Spool Spindle and Brake: Holds a 4 inch diameter spool. Use the 2 inch I.D. spindle
adapter included with the machine to use 8 inch diameter spools. The Wing Nut sets the brake
friction to prevent the spool from over rotating when the trigger is released.
17. Wire Drive & Components: Feeds wire from the wire spool through the drive and through the
welding gun to the weld.
18. Spool Gun/Standard Selector Switch: Pre-Installed switch permits either spool gun welding
with the YesWelder LBT150 or standard spool guns with European connection.
7
8 9 10 11
12
14
15
13
16
17
18
- 09 -

• Attach the standard MIG welding gun to the EURO CONNECT on the front of the welder.
The gas cylinder (not supplied) should be located near the rear of the welder, in a well-ventilated area and securely fixed to
the work bench or to the wall to ensure that it will not fall.
For safety and economy, ensure that the regulator is fully closed (turned counter-clockwise) when not welding and when fit-
ting or removing the gas cylinder.
• Turn the regulator adjustment knob counter-clockwise to ensure the valve is fully closed.
• Screw the gas regulator down on the gas bottle valve and tighten.
• Connect the gas hose to the regulator, securing with the clip/nut provided.
• Connect the other end to the GAS Inlet (13) on the back of the machine.
• Open the cylinder valve, then set the gas flow to approximately 20~35 CFH (cubic ft. per hour) on the regulator.
• For MIG welding: Depress the gun trigger to ensure that the gas is flowing through the gun.
WARNING: Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or mis-
use of compressed gas cylinders. Do not drop the cylinder, knock it over, expose it to excessive heat, flames or sparks. Do
not strike it against other cylinders or strike an arc on it.
ENSURE GAS AND ELECTRICAL SUPPLIES ARE DISCONNECTED. Before proceeding, remove the nozzle and the con-
tact tip from the gun.
WARNING: ELECTRIC SHOCK CAN KILL! Always turn the ON/OFF SWITCH to the OFF position and unplug the welder’s
INPUT POWER CABLE from the AC power source before installing wire. When the gun trigger is depressed, the drive rolls,
spool of wire, wire being fed, and electrode are all electrically live (hot).
8" 4"
AC E D E B C E D E
I
H
J
GK L M
- 10 -
2" Spindle
Adapter (For 8" Reel of Wire)
Installing The MIG Gun Assembly
Gas Cylinder And Regulator Connection
Installing The Welding Wire

1. Open the access panel.
2. Unscrew and remove the wire spool retention cap used for 8-inch spools (A) and store it someplace safe.
3. Remove the spindle adapter for 8-inch spools (B) and store it someplace safe.
4. Remove the nut (C), spring (D), and washers (E).
5. Remove the outer wrapping from the included spool of wire and then find the leading end of the wire (it goes through a hole in the
outer edge of the spool and is bent over the spool edge to prevent the wire from unspooling) but do not unhook it yet.
6. Place the spool on the WIRE SPOOL SPINDLE in such a manner that when the wire comes off the spool. The wire should
unspool from the bottom, and the spool will rotate in a counterclockwise fashion.
7. Place the washer, wire spool locking bushing, spring, and nut back in place.
8. Proceed to “FEEDING WIRE THROUGH THE MIG GUN” instructions below.
- 11 -
1. Unhook the wire and hold the wire end and the spool in one hand. With the other hand tighten the nut (C) just enough so that
when the spool is released it does not spin freely and uncoil the wire. Tightening the nut too much may cause inconsistent wire
feeding. Leaving it too loose will allow the wire to uncoil freely from the spool, leaving a mess of wire in the cabinet.
2. While holding the wire in place, use a wire cutter to cut the bent end of the wire so that only a straight end remains.
3. Continue to hold the wire end in one hand and release the drive roller pressure arm (I) by pulling the pressure arm adjustment
knob (G) toward you. Hold the drive roller pressure arm up off of the drive roller and insert the leading end of the wire into the in-
let guide tube (H). Push the wire across the drive roller (J) and into the gun assembly approximately six inches.
4. Line the wire up in the inner groove of the drive roller and allow the drive pressure arm to drop onto the drive roller. Pull the pres-
sure arm adjustment knob back over the pressure arm and tighten (turn clockwise) the pressure adjusting knob until the pressure
roller is applying enough force on the wire to prevent it from slipping out of the drive assembly.
NOTE: Too much pressure will cause wire to feeding problems and may burn out the wire feed motor.
5. Let go of the wire.
6. Remove the nozzle (K) and contact tip (L) from the end of the gun assembly (M).
7. Plug the welder’s INPUT POWER CABLE into the AC power source. Adjust the settings on the front panel per the setup chart on
the inside panel door of the welding machine according to the size of the wire and workpiece.
8. Pull the trigger on the MIG gun to feed the wire through the gun assembly. Check if the drive roller is slipping on the wire and in-
crease pressure on the pressure arm adjustment knob if necessary.
9. When at least an inch of wire sticks out past the end of the gun, release the trigger.
10. Slide the contact tip (L) over the wire protruding from the end of the gun (M). Screw the contact tip into the end of the gun and
hand tighten securely.
11. Install the nozzle (K) on the gun assembly.
1. Open the access panel.
2. Unscrew and remove the wire spool retention cap (A).
NOTE: If the wire spool retention cap and the spindle adapter for 8-inch spools (B) are not present (machine was last used
with a 4-inch spool) put the spindle adapter for 8-inch spools back in place.
3. Make sure all of the components used for a 4-inch spool are still in place. They are necessary for 8-inch spools as well (nut (C),
spring (D), and washers (E)).
4. Remove the outer wrapping from the spool of wire and then find the leading end of the wire (it goes through a hole in the outer
edge of the spool and is bent over the spool edge to prevent the wire from unspooling) but do not unhook it yet.
5. Place the spool on the spindle adapter for 8-inch spools in such a manner that when the wire comes off the spool. The wire
should unspool from the bottom, and the spool will rotate in a counter-clockwise fashion.
NOTE: Be sure the alignment pin near the base of the spindle adapter for 8-inch spools is inserted in the corresponding
hole on the spool.
6. Thread the wire spool retention cap back in place.
Installing 4-Inch Spool (See Figure For Part Identification):
Feeding Wire Through The Mig Gun:
Installing 8-Inch Spool (See Figure For Part Identification):

12. Cut off the excess wire that extends past the end of the nozzle.
13. Fine tune the wire drive pressure with the pressure arm adjustment knob (G).
a. Turn the wire drive pressure adjustment knob clockwise, increasing the drive pressure until the wire seems to feed smoothly
without slipping.
NOTE: If TOO MUCH pressure is applied you can crush the wire and create wire feeding problems. If TOO LITTLE pres-
sure is applied, the wire will slip on the drive rolls and wire will not feed.
b. When the drive pressure is set correctly, there should be no slippage between the wire and the drive roller. But if an obstruc-
tion occurs along the wire feed path, the wire should then slip on the drive roller. This can be checked by squeezing the wire be-
tween two fingers with moderate force as it comes out of the gun. If this stops the wire from feeding, increase pressure until the
wire feeds through your fingers without issue.
14. Double check your spool tension: After feeding the wire and releasing the trigger, the wire coming off the spool should not re-
main under tension (in a straight line from the spool to the WIRE FEEDER). It should relax a little bit and take on some of the
curvature the coiled wire naturally reverts to. It should also not relax so much that the wire begins to loosen on the spool.
KEEP THE GUN STRAIGHT. WHEN FEEDING A NEW WIRE THROUGH THE LINER, MAKE SURE THE WIRE IS CUT
CLEANLY (NO BURRS OR ANGLES) AND THAT AT LEAST 1" FROM THE END IS STRAIGHT (NO CURVES). FAILURE
TO FOLLOW THESE INSTRUCTIONS COULD CAUSE DAMAGE TO THE LINER.
WHEN CHECKING THE CORRECT EXIT OF THE WIRE FROM THE GUN DO NOT BRING YOUR FACE NEAR THE
GUN. YOU MAY RUN THE RISK OF BEING WOUNDED BY THE OUTGOING WIRE. DO NOT BRING YOUR FINGERS
CLOSE TO THE FEEDING MECHANISM WHEN WORKING! THE ROLLS, WHEN MOVING, MAY CRUSH FINGERS. PE-
RIODICALLY CHECK THE ROLLS. REPLACE THEM WHEN THEY ARE WORN AND COMPROMISE THE REGULAR
FEEDING OF THE WIRE.
On the machine, there is a plate that includes all the operating specifications for your new unit.
The duty cycle rating of a welder defines how long the operator can weld and how long the welder must rest and be cooled. Duty cy-
cle is expressed as a percentage of 10 minutes and represents the maximum welding time allowed. The balance of the 10-minute
cycle is required for cooling.
For example, a welder has a duty cycle rating of 30% at the rated output of 90A. This means with that machine, you can weld at 90
A output for three (3) minutes out of 10 with the remaining seven (7) minutes required for cooling.
The duty cycle of your new welder can be found on the data plate affixed to the machine. It looks like the diagram below. Referring
to the sample below, the “X” row lists duty cycle percentages while the “I2” row lists the amp draw corresponding to the duty cycle.
Various duty cycles at other amperages are listed on your data plate.
CORRECT INCORRECT
- 12 -
Performance Data Plate And Duty Cycle
OPERATION

If you exceed the duty cycle of the welder, the thermal protection system will engage, shutting off all welder output. After cooling, the
thermal protector will automatically reset and the welding functions can resume. This is normal and automatic behavior of the ma-
chine, and does not require any user action. However, you should wait at least ten minutes after the thermal protector engages be-
fore resuming welding. You must do this even if the thermal protector resets itself before the ten minutes is up or you may experi-
ence less than specified duty cycle performance.
CAUTION: DO NOT REGULARLY EXCEED THE DUTY CYCLE OR DAMAGE TO THE WELDER CAN RESULT.
An important factor in making a satisfactory weld is preparation. This includes studying the process and equipment and practicing
welding before attempting to weld finished product. An organized, safe, ergonomic, comfortable, and well-lit work area should be
prepared for the operator. The work area should specifically be free of all flammables with both a fire extinguisher and a bucket of
sand available to smother potential fires that may occur.
To properly prepare for welding with your new welder, it is necessary to:
ŸRead the safety precautions at the front of this manual.
ŸPrepare an organized, well-lit work area.
ŸProvide protection for the eyes and skin of the operator and bystanders.
ŸAttach the work clamp to the bare metal to be welded, making sure of good contact.
ŸWhen MIG, MAG, Aluminum Welding or Flux-Cored Arc Welding, make sure that the wire-roller groove in the roller corresponds to
the diameter and type of wire being used.
ŸPlug the machine into a suitable outlet, recommend NEMA5-50.
ŸCompletely open the gas cylinder valve. Adjust the gas pressure regulator to the correct flow rate. (Not applicable to Stick “SMAW”
process).
- 13 -
Internal Thermal Protection
Welding Preparation
U0=65V
U0=65V
30A/15.5V~160A/22V 30A/15.5V~205A/24.2V
X
I2
U2
X
I2
U221.9V
158A
100%
24.2V
205A
60%
20.1V
123A
100%
22V
160A
60%
U1=110V
20A/10.8V~160A/16.4V
X
I2
U2
60% 100%
160A 123A
16.4V 14.9V
U1=220V
20A/10.8V~205A/18.2V
X60% 100%
I2
U2
205A 158A
18.2V 16.3V
U1=110V
U1=220V
U0=65V
100%
139A
25.5V
X
I2
U2
U1=110V U1=220V
20A/20.8V~145A/25.8V 20A/20.8V~180A/27.2V
X
I2
U2
60% 100% 60%
180A
27.2V
112A
24.5V
145A
25.8V
U1=220VU1=110V
I1 max=43A I1 eff=33.2A
I1 eff=26.3AI1 max=34A
ANSI/IEC STD.60974-1
Cooling Mode: Fan Cooling Insulation Grade: F
1~50Hz/60Hz

This welder can work with solid steel wire from .023"~.035" (0.6~0.9mm) diameter (MIG welding, “GMAW”) and with .023"~.035"
(0.6~0.9mm) diameter flux-cored wire (flux-cored wire welding, “FCAW”).
ŸPress the PROCESS SELECTOR BUTTON on the front panel.
ŸConnect the MIG gun into the EURO CONNECT SOCKET.
ŸConnect the Wire Drive Polarity Lead(10) to the appropriate DINSE SOCKET:
1. Flux-cored wire welding (FCAW): Connected to NEGATIVE (-) DINSE SOCKET.
2. MIG Welding (GMAW): Connected to POSITIVE (+) DINSE SOCKET.
ŸConnect the ground cable to the appropriate DINSE SOCKET:
1. Flux-cored wire welding (FCAW): Ground cable to POSITIVE (+) DINSE SOCKET.
2. MIG Welding (GMAW): Ground cable to NEGATIVE (-) DINSE SOCKET.
ŸEnsure the ground clamp has a good connection to the workpiece and is connected on clean, bare metal (not rusty or
painted).
ŸLoad the spool of wire inside the cabinet and feed it through the WIRE FEEDER into the gun (see “Installing the Welding
Wire”, page 10).
ŸSwitch the unit ON with the ON/OFF SWITCH.
ŸPress the gun trigger or wire feed button (6) to load the wire through the gun.
ŸSet the welding parameters:
1. Adjust the output current.
Press selector button (1) to select output current, adjust the current with adjustment knob, wire feed speed & arc
voltage match automatically.
2. Press selector button (1) to select voltage modifying, adjust the voltage from -10~+10 with adjustment knob, modify
voltage based on type of material and thickness being welded.
3. Press selector button (1) to select inductance, adjust the inductance from -10~+10 with adjustment knob, The
effects of the inductance can help reduce spatter, produce a “softer” arc and help wetting out. There is a wetting-
out/softness trade off against penetration/stiff/arc-force/dig qualities.
Ÿ(GMAW only) Turn on the gas cylinder, pull the trigger or press gas checking button to check for gas flow and adjust the
flow rate.
ŸBring the gun close to the workpiece and press the trigger.
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN. PROLONGED EXPOSURE TO
A WELDING ARC CAN CAUSE BLINDNESS AND BURNS. NEVER STRIKE AN ARC OR BEGIN WELDING UNLESS
YOU ARE ADEQUATELY PROTECTED. WEAR FIRE RESISTANT WELDING GLOVES, HEAVY LONG SLEEVED SHIRT,
CUFFLESS PANTS; HIGH TOPPED SHOES AND A WELDING HELMET.
Select the appropriate shielding gas in accordance to material being welded and wire being used. The table below can give you
some useful indications:
METAL GAS NOTE
Argon controls spatter
Carbon Steel
Stainless Steel
100% CO2
75% Argon + 25% CO2
Welding Wire Selection
Gas Selection
Setup for MIG (GMAW) & Flux-Cored Wire (FCAW) Welding
- 14 -
100% Argon
Aluminum
98% Argon + 2% CO2

1. Install optional YesWelder LBT150 spool gun into Euro MIG torch connection socket on the front panel, and tighten it. Connect
the Spool Gun control cable to the receptacle and tighten it.
IMPORTANT: When connecting the torch be sure to tighten the connection. A loose connection can result in the connector
arcing and damaging the machine and gun connector. This damage is not covered under warranty.
2. Plug the 2 pin gun trigger connector into the Spool Gun Trigger Connector Receptacle.
3. Connect to Wire Drive Polarity Lead to the Positive (+) socket.
4. Connect the Work Clamp into the Negative (-) socket .
5. Connect the gas line to the regulator and connect to the gas cylinder with 100% Argon shielding Gas.
6. Push the Cover Release clip on the spool gun to unlock the wire housing cover.
7. Place the wire on the spool holder, taking care to put the parts back on correctly.
(Note: the tensioner part need to remove first and remember to fit back.)
8. Hold and snip the wire from the spool being sure to hold the wire to prevent rapid uncoiling.
9. Feed the wire in the groove of the drive roller through the outlet guide tube into the torch neck. Make sure the wire being used
complies with the size for the roller groove.
10. Adjust spool holder tension and apply suitable pressure for the drive roller.
11. Remove the gas nozzle and contact tip from the torch neck.
12. Pull the trigger to drive the wire through the neck until it exits the contact tip holder.
13. Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch neck and nip it
up tightly.
14. Fit the gas nozzle to the torch head and close the wire spool cover.
15. Turn the power source on and select the Manual MIG function with the Manual MIG/Synergic MIG/Lift TIG/Stick selector switch.
16. Choose material Aluminum.
17. Set gun selector toggle switch to Spool Gun position inside the wire feeding door.
18. Turn on the gas cylinder valve and set the flow rate to between 20~30 CFH.
19. Set the welding parameters and begin aluminum welding.
Setup for Aluminum Welding with Spool Gun
- 15 -

(1) Install the spool gun into Euro MIG
torch connection socket and tighten it.
Connect the Spool Gun trigger connector
into the receptacle and tighten it.
(2) Push the Cover Release clip on the
spool gun to unlock the wire housing
cover.
(3) Place the wire on the spool holder, tak-
ing care to put the parts back on correctly.
(Note: the tensioner part need to remove
first and remember to fit back.)
(4) Feed the wire in the groove of the
drive roller through the outlet guide tube
into the torch neck. Make sure the wire
used complies with the size for the roller
groove.
(5) Adjust spool holder tension and apply
suitable pressure for the drive roller.
(6) Remove the gas nozzle and contact
tip from the torch neck.
(7) Fit the correct sized Aluminum contact
tip and feed the wire through it, screw the
contact tip into the tip holder of the torch
neck and nip it up tightly.
(8) Turn the power source on and select
the MIG func tion w ith th e Manual
MIG/Synergic MIG/Lift TIG/Stick selector
switch.
(9) Set gun selector toggle switch to Spool
Gun position inside the wire feeding door.
Setup For Aluminum Welding With MIG Gun With Graphene Liner
- 16 -
(1) Lay the gun straight on the ground and remove consumables on the front-end parts.
(2) Remove the liner retaining nut.
(3) Pull the steel wire feed liner out of the gun cable assembly.
(4) Unravel the graphene wire feed liner and feed the liner in short forward movements down the cable assembly all the way through
and out the torch end. Avoid kinking the liner. Kinking the liner will damage it and require replacement.
(5) Place the tip holder over the end of the liner and, screw it into the torch neck, tighten it up. Reassemble the consumables with a
special aluminum A+ contact tip, nozzle, and gas diffuser.
(6) Fit the O-ring, and liner retaining nut.
(7) Push the liner firmly into the torch lead and tighten the liner retaining nut.
(8) Disengage the drive roller.
(9) Use a screwdriver or other sharp object to push out outlet guide tube through the Euro connector.
(10) Loosen off the outlet guide tube retaining screw.
(11) Remove the outlet guide tube from the front-end euro connector using long nose pliers.
(12) Unscrew the inlet guide tube from the wire feeding mechanism.
(13) Feed the extended graphene liner section into the outlet guide tube hole of the machine Euro connector.
(14) Feed the extended graphene liner up and over the drive roller.
(15) Tighten the torch Euro connection to the machine Euro connector.
(16) Cut the extended liner with a sharp knife.
(17) Install the correct sized U Knurled Drive roller, and feed the correct diameter of aluminum welding wire.
(18) Remove the metal tube from the inlet guide tube.
(19) Cut a slightly longer tube based on the metal guide tube.
(20) Replace the inlet guide tube with the graphene liner and re-install the inlet guide to the wire feeding mechanism.
(21) Install the aluminum spool and feed the wire through.
(22) Set the welding parameters via Synergic MIG or Manual MIG.

- 17 -
ŸRemove the MIG torch consumables. ŸRemove the liner retaining nut. ŸPull out the liner completely.
ŸUntie the new liner. ŸFeed the liner in short forward move-
ments down the cable assembly all the
way through and out the torch end.
ŸPush the liner firmly into the torch lead
and tighten retaining nut.
ŸDisengage the drive roller. ŸUse a screwdriver or other sharp object
to push out outlet guide tube through the
Euro connector.
ŸLoosen the outlet guide tube screw. ŸRemove the outlet guide tube from the
front-end euro connector using long
nose pliers.
ŸUnscrew the inlet guide tube from the
wire feeding mechanism.
ŸFeed the extended graphene liner into
the outlet guide tube hole of the machine
Euro connector.
ŸFeed the extended graphene liner over
the drive roller into the inlet guide tube
part.
ŸTighten the torch Euro connection to the
Euro connector.
ŸCut the extended liner with a sharp knife.
The remaining part should be about
14ga~12ga away from the wire drive
roller.
ŸInstall the correct sized U Knurled Drive
roller, and with the correct diameter knurl
inside.
ŸRemove the metal tube from the inlet
guide tube.
ŸInstall a matched contact tip and other
front-end accessories to the torch. It is
ready for welding.