HUSKY MIG140 Inverter Welder Machine User Guide

HUSKY MIG140 Inverter Welder Machine User Guide

Safety Information

WORK AREA SAFETY

WARNING: Operating the welding machine without preparation and caution can cause death, injury to yourself or bystanders. To reduce the risks, the operator should read, understand and follow the safety instructions. Bystanders in the area should also follow the safety instructions under the guidance of operator.

• Ensure your work area is clean and well lit.
• Keep the welder on a stable and clean surface while operating.
• Keep children, bystanders and visitors away while operating welding machine. Distractions can cause you to lose control.
• Do not operate machine in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Flying sparks during welding may ignite the dust or fumes.
• Do not leave energized machine unattended. Always turn off the machine before servicing parts, replacing components or when the machine is not in use.

PERSONAL SAFETY

WARNING: Welding processes generate high-temperature arc, welding sparks, hot slag and hot spatters. Welding arc generates extremely intense ultraviolet and infrared light. Failure to wear protective equipment during welding can severely damage your eyes and burn your skin. To reduce the risks, the operator should read, understand and follow the safety instructions. Bystanders in the area should also follow the safety instructions under the guidance of operator.

WARNING: Welding processes generate fumes, gases and vapors which can cause discomfort, illness and death. To  reduce the risks, the operator should read, understand andfollow the safety instructions. Bystanders in the area should also follow the safety instructions under the guidance of operator.

• Do not weld without proper protection. Flying sparks can cause burn injury. Always wear protective clothing and face shield. The intensive light of the electrical arc can also burnskin. Ensure to wear closed-toe shoes, gloves and clothing with heavy material with long sleeves and collar.
• Do not look at an electric arc without proper eye protection. An electric arc is extremely bright and intense which can burn the eye retina and cause permanent damage when equipped with inadequate or no eye protection.
• Do not weld in a confined areas without adequate ventilation. Otherwise, wear an air-supplied respirator.
• Remind bystanders before striking a weld arc and makesure they are at a safe distance and aware of coming intensive welding arc.
• Make sure you are in a proper position while operating the welder. Do not overreach. Keep proper footing and balance at all times, which enables better control of the welder in unexpected situation.
• Stay alert when operating a welding machine. Do not use a machine while you are tired or under the influence of drugs, alcohol or medication. Avoid unintentional starting.
• Make sure you read the user manual and are well prepared before welding.

ELECTRICAL SAFETY

WARNING: Improper use of welding machines will cause electric shock. Electric shock can kill. To reduce the risks, the operator should read, understand and follow the safety instructions. Bystanders in the area should also follow the safety instructions under the guidance of operator.

• Do not expose welding machine to rain or come in contact with a wet surface. Water entering a machine will increase the risk of electric shock.
• Do not make contact with any welding current circuits such as ground clamps, electrodes, welding wires, MIG/TIG guns, workpieces, any metal parts/conductive materials in contact with electrode holder/workpieces.
• Do not make contact with any grounded metal surfaces such as metal pipes, radiators and refrigerators. There will be an increased risk of electric shock when your body is grounded.
• Ensure power is disconnected before setting up any TIG torch/MIG gun/electrode holder, adjustment and services.
• Do not abuse any cords. Never carry, pull or unplug the welder by its cord. Keep any cords away from heat, oil, sharp edges or moving parts. Damaged or entangled cords could increase the risk of electric shock.
• Inspect the welder before using it. Do not weld if you observe any damaged and cracked parts, including but not limited to damaged/cracked cables, electrode holders, ground clamps and so on. Replace them before using the welder.
• Use an extension cord specific for outdoor use when operating a welder outdoors.
• Do not point torches/welding guns at people when torches/welding guns are energized. Do not point MIG gun at your eyes in any situation.
• Do not weld in damp area or when welding equipment is in contact with water or wet surface.
• Do not weld when body or clothes are wet.

FIRE PREVENTION

WARNING: Failure to protect combustible materials against welding sparks, hot slag and hot spatters can cause fire and even explosion. Fire and explosion can cause death, injury and property damage. To reduce the risks, please read, understand and follow the safety instructions.

• Check the area before welding. Ensure the work area is checked and cleared of combustible and flammable materials. A minimum distance of 35 feet (10 meters) is required between work area and combustibles because 35 feet is an average distance welding sparks and slags can fly.
  If the minimum 35 feet distance requirement cannot be met, protect consumable/flammable materials with fire resistant covers or shields.

• Do not weld or cut on or near materials with combustible coating or combustible internal substance, such as materials in walls or ceilings, without any approved methods to eliminate the hazard.

• Do not weld or cut in areas (such as gas station) where the air may contain flammable substances such as combustible dust, gas, or liquid vapors.

• Do not wear gloves, hair preparations, shoes and other clothing that contains oil, grease, or other flammable substances. Wear fire-resistant protective clothing to protect upper and lower body against fire and heat. Protective clothing includes but is not limited to leather gloves, heavy long sleeve and cuffless shirts, heavy and cuffless pants, high-topped shoes and helmet.

• Do not dispose of hot slag in containers holding combustible materials. Keep a fire extinguisher nearby and know how to use it.

• Follow requirements in OSHA and NFPA for hot work and have an extinguisher nearby.

• When finished welding, do not leave without a check for evidence of potential fire. Overlooked smoke or flame have risks to cause fire hazard. Check and make sure the welding areas are free of sparks, slags, and flames before leaving the welding area.

USE AND CARE

• Ensure you choose the right welder model and welding mode recommended for your application. Use the welder and accessories in compliance with these instructions. Operating a welder under improper conditions could cause unpredictable safety issues.
• Store idle welders out of reach of children. Do not allow people who are unfamiliar with the welder and operational instructions to operate the welder. Ignorance of any safety instructions or operational guidance will result in potential safety risk.
• Replace damaged parts immediately before use. Many accidents are caused by poorly maintained welders.
• Have your welder serviced by a qualified service person if you encounter problems.

ARC WELDING

CAUTION: High frequency and electromagnetic energy generated from the welding process could cause damage to your electronical devices. To reduce the risks, please read, understand and follow the safety instructions

• Follow manual to install and ground machine. Be sure nearby equipment is compatible with electromagnetic energy.
• Electronic products such as computer, computer-driven equipment and communication equipment can be interfered or even harmed by electromagnetic energy. Users with pacemakers should consult with their physician before using a welder because a pacemaker can be damaged by electromagnetic energy if exposed to it.
• TIG welder and TIG welding process can generate high frequency. High frequency can interfere with radio navigation, safety services, computers and communication equipment.
• It is the user’s responsibility to have a qualified electrician promptly correct any interference problem resulting from installation or operation of the welder. The welder should be regularly inspected and maintained. If necessary, shield the work area or move the welding machine.
• The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations. It must be understood by the users that common sense and caution are factors which cannot be built into this product, but must be provided by the operator.

Warranty

3 YEAR LIMITED WARRANTY
If this Husky product ever fails due to a defect in material or workmanship, return the product to any Home Depot retail store for replacement with an item of equal or greater value. This warranty excludes incidental / inconsequential damages due to misuse, abuse, or normal wear and tear. This warranty gives you specific rights, and you may also have other rights, which vary from state to state. Please see store or call 1-888-HD-HUSKY for details.

Pre-operation

SPECIFICATIONS

Process| MIG (GMAW – gas metal arc welding)Flux Core (FCAW – ux core arc welding)
---|---
Power Plug| 120V/20A
Open Circuit Voltage| 85V
Duty Cycles| 90A @ 30%
Welding Current Ranges| 30A – 140A
Welds Up To| 1/8 in. steel
Weldable Metals| Steel, stainless steel
Wire and Wire Spool Capacity| 0.025 in. to 0.035 in.; up to 11 lb spool

SYMBOLS

| Inverter power source DC| | Warning! Please read user manual.
| MIG/MAG welding| | Electric shock hazard. Do not touch energized parts.
| Suitable for welding in an environment with increased risk of electric shock| | Fire hazard. Keep ammable materials away during welding.
1~50/60Hz| Power supply type of electric device| | Arc ray hazard. Wear welding mask with properly rated ter lens.
| Input voltage indicator| | Inhalation hazard. Keep ventilation.
| Tripped protection/alert indicator| | Wire feed speed control socket
**| Output amperage indicator| WIRE or** WFS| Wire feed speed
| Output voltage| | Inductance
| Positive DINSE socket| | Negative DINSE socket

PACKAGE CONTENTS (DIAGRAM)

PACKAGE CONTENTS (LISTS)

Operation Instruction

1. Preparing for Welding

   • Designate a work area that is clean and well lit. Keep children and pets out of the work area.
   • Read the user manual and safety guidelines before operating the welder.
   • Ensure you understand the basic specification of your welder.
   • Wear PPEs to protect your eyes and skins from hot welding sparks and intensive arc rays. Ensure same protections are provided to any bystanders nearby.
   • Ensure all the combustible, flammable, hazardous substances are removed from the work area. Make sure a fire extinguisher within reach is available.
   • Inspect your welder before each use and do not operate a welder with damaged cables and components. Replace all the damaged parts before use. Have a qualified technician help you if needed.
   • For flux core wire, shielding gas is not required.
   • For solid core wire, shielding gas is required. Check the
     “Connecting the Gas Cylinder” instruction for more details.

2. Connecting the Gas Cylinder

   • Always make sure your gas cylinder is fully closed (turned counterclockwise) when not welding or moving the cylinder.
   • Before welding, make sure your gas cylinder is securely fixed to a wall or a steady workbench. Hitting by falling gas cylinder can cause severe injury. Dropping gas cylinder can cause hazard.
   • Turn the regulator adjustment knob counterclockwise to ensure the gas regulator’s valve is fully closed. □ Connect one end of the gas regulator with the gas cylinder.
   • Attach the other end of the gas regulator with a gas hose.
   • Connect the other end of gas hose to the gas input (N) on the back of the machine.
   • Make sure all connectors are tightened or sealed.
   • Open the gas cylinder valve and set the gas flow to approximately 21-40 cu ft/h on the regulator.
   • Press the gun trigger to ensure that the gas is flowing through the gun.
     WARNING: Welding processes generate hightemperature arc, welding sparks, hot slag and hot spatters. Welding arc generates extremely intense ultraviolet and infrared light. Failure to wear protective equipment during welding can severely damage your eyes and burn your skin
     WARNING: Failure to protect combustible materials against welding sparks, hot slag and hot spatters can cause fire and even explosion. Fire and explosion can cause death, injury and property damage.

3. Installing the Wire Spool

   • Make sure ON/OFF power switch (O) is OFF and unplug the welder before proceeding.

   • Open the welder case by pushing the buckle located on the side panel.

   • Unscrew the wing nut (1), and remove key washers (2), spring (3) and spool cap (4).

   • For 10 lb wire spool: Keep the spool adapter (6) on the wire spool spindle in a manner as shown on the upper diagram. For 2 lb wire spool: Remove the spool adapter (6) from the wire spool spindle.

   • For 10 lb wire spool: Install the wire spool (5) on the wire spool adapter and match the hole on the wire spool with the “stick out” (7) of the spool adapter.
     
     For 2 lb wire spool: Install the wire spool on the wire spool spindle.
     NOTE: After installation, ensure the wire spool rotating in a counterclockwise direction when operating.

   • For 10 lb wire spool: Place the spool cap (4), spring (3), key washers (2) and wing nut (1) back. For 2 lb wire spool: Place the spring (3), key washers (2) and wing nut (1) back.
     

   • To make sure wire spool can spin properly, avoid overtightening or insuf cient tightening of the spool cap. Overtightening may cause inconsistent wire feeding while insuf cient tightening will cause uncontrolled wire feeding.

   • Next, please check the “Setting Up the Welding Wire” to feed the welding wire through MIG gun.

4. Setting Up the Welding Wire

   • Release the drive roll pressure arm (11) by lifting up the pressure arm adjustment knob (10).
   • Rotate the drive roll knob (13) counterclockwise to remove it ( See Figure 2. and Figure 3.).
     

   1. Locked Wire Feeder

   2. Released Drive Roll Pressure Arm,

   3. Removed Drive Roll Knob

   • Check your drive roll (14) size. Ensure it matches with your welding wire size.
     NOTE: Drive roll (14) has two grooves and each groove has a different size. Make sure you are using the rightsize.

   • Place the drive roll knob (13) back and rotate clockwise totighten it.

   • Before inserting your wire into the wire feeder, ensure your wire end is straight. Cut the bent end with wire cutter if necessary.

   • Feed your wire into the wire inlet guide tube (12) of the wire feeder and line the wire up with the groove of the drive roll. Push the wire across the inner drive roll groove  into the other side of the wire feeder.

   • Pull the pressure arm adjustment knob (10) back and lock it by pushing the drive roll pressure arm (11) down.

   • Remove the nozzle from the end of the MIG/Flux core MIG gun.
     NOTE: Metal nozzle is for MIG gun; non-metal nozzle is for Flux core MIG gun.

   • Remove the contact tip from the tip of the gun by unscrewing in counterclockwise direction.

   • Plug the welder into power source and switch the ON/OFF switch (O) to ON. Ensure you are not pointing the MIG/Flux core MIG gun to yourself and any other bystanders.

   • Press the trigger on the MIG/Flux core MIG gun. Feed the wire continuously until at least one inch of the wire extends out of the gun.

   • Check if the drive roll is feeding the wire properly. If the drive roll is slipping on the wire, increase pressure on the pressure arm adjustment.

   • Check the contact tip and ensure it matches the welding wire. Install the contact tip back to the MIG/Flux core MIG gun.

   • Install the nozzle back to the gun.

   • Cut off the over-extended wire that sticks out of the Flux core gun if needed.

5. Setting Up for MIG/Flux Core Welding
   

   • Check your welding wire type.
     Flux core wire: Connect the ground clamp cable to positive (+) DINSE socket (M) and electrode polarity jumper (H) to the negative (-) DINSE socket (L). Solid core wire: Connect the ground clamp cable to the negative (-) DINSE socket (L).
     Solid core wire: Connect the ground clamp cable to the negative (-) DINSE socket (L) and electrode polarity jumper (H) to the positive (+) DINSE socket (M).

   • For flux core wire, no shielding gas is needed.

   • For solid core wire, follow instruction “Connecting the Gas Cylinder.” Connect one side of gas hose to gas regulator on the gas cylinder and the other side to the gas input (N) at the back of welder.

   • Ensure your workpiece is clean and dry and the ground clamp has a good connection to the workpiece.

   • Connect your MIG/flux core MIG gun to the gun cable socket (G) and control socket (I).

   • Open the side panel. Load the wire spool and feed the wire into the wire feeder. For detailed instructions please see “Installing the Wire Spool” and “Setting Up the Welding Wire.”

   • Ensure you are not pointing the MIG/flux core MIG gun to yourself and any other bystanders. Switch the ON/OFF power switch (O) to ON at the back of the welder.

   • Follow instructions “Setting Up the Welding Wire,” and feed the welding wire into the wire feeder and flux core gun. Press the MIG/flux core MIG gun trigger to load welding wire through the flux core gun.

   • Adjust the wire feed speed adjustment knob (E) to set your wire feed speed.

   • Adjust the voltage adjustment knob (D) to set your welding voltage.

   • Hold the MIG/flux core MIG gun to the workpiece and press the gun trigger. The weld arc can be initiated by touching the weld wire to the workpiece.

6. Setting Up the Spool Gun

   • NOTE: Spool gun is not included in the package.
   • Double check the MIG gun/spool gun switch (S) is set to MIG gun.
   • For the shielding gas hose on the spool gun, pass through the hole for gas hose (F) and connect to the shielding gas connector (R) on the welder.
   • Connect the remaining two cables on spool gun to the gun cable socket (G) and control socket (I).
   • For welding set up with spool gun, please follow instructions “Setting Up for MIG/flux core Welding,” and exclude the portion of “Installing the Wire Spool” and “Setting Up for Welding.”

Maintenance

• Before each use, inspect the general condition of the welder. Check for loose screws, cracked or broken parts, damaged circuit wiring or cables, and any other potential risks that may cause safety issues. Replace damaged or worn parts, cords/cables or gun assembly.
• After each use of the welder, clean external surfaces of the welder with clean cloth.
• Periodically clean the welder using compressed air to blow out all dust and debris from the interior. If necessary, use compressed air to clean the liner, especially when changing wire spools.
• If the unit continuously shuts down due to thermal overload, please turn off the  welder and have a qualified electrician to inspect thewelder and repair it.
• Store the welder and accessories in a clean and dry location out of reach of children.
• Wire feed drive rolls are consumable accessories. The grooves of the drive roll will wear deeper after long-time usage. The wear out will cause a contact between the idler roll and the drive roll. In this situation, the wire feed drive roll should be replaced.
• Use a wire brush to scrub the outside of the contact tip. Use a tip cleaner (sold separately) to clean the inside.
• Contact tips are also consumable accessories. After long-time usage, the worn round hole of the contact tip will turn to an elliptical shape or form some bulges. Thus, replace the contact tip when it wears out.
• Nozzle must be cleaned periodically because spatter and slag will build up inside the nozzle during welding process.

Troubleshooting

NOTE: When yellow tripped protection/alert indicator turns on, the possible causes are 1) tripped overheat protection; 2) short circuit alert; 3) tripped overvoltage protection; 4) overcurrent alert; 5) MIG gun switch issue alert. Please refer to a qualified electrician to check your welder.

Problem

| Possible Cause|

Solution

---|---|---
Wire feed motor works but no wire feeds.|

• Insufficient pressure given to the wire feed drive roll.

|

• Rotate the pressure arm adjustment knob clockwise to increase the pressure on drive roll. See “Operation Instruction – Setting Up the Welding Wire” (page 11) for more details.

• Incorrect drive roll size.

|

• Replace the drive roll with the correct size.

• Damaged flux core gun or damaged/blocked wire inlet guide tube.

|

• Replace the flux core gun.
• Clean the wire inlet guide tube with compressed air or replace the wire inlet guide tube.

Wire creates a bird’s nest during operation.|

• Clogged or damaged contact tip.

|

• Clean the contact tip or replace with a new one.

• Too much pressure on the drive roll.

|

• Rotate the pressure arm adjustment knob counterclockwise to decrease the pressure on drive roll. See “Operation Instruction – Setting Up the Welding Wire” (page 11) for more details.

No arc while wire feeds.|

• Loose ground clamp connection.

|

• Check and make sure the ground clamp is well attached to the workpiece.

Arc works but no wire feeds.|

• Insufficient pressure on the wire feed drive roll.

|

• Rotate the pressure arm adjustment knob clockwise to increase the pressure on drive roll. See “Operation Instruction – Setting Up the Welding Wire” (page 11) for more details.

• No wire left on the wire spool.

|

• Check whether the wire spool is used up. Replace with a new one if used up.

Wire burns back to contact tip.|

• Wire feed speed is too low.

|

• Increase wire feed speed by rotating wire feed adjustment knob clockwise.

• Wrong size contact tip.

|

• Replace with a correct size contact tip.

• Clogged or damaged contact tip.

|

• Clean the clogged tip with a tip cleaner.
• Replace the damaged tip.

Weak arc strength/non- penetrating weld.|

• Long or improper extension cord.

|

• Use a proper extension cord.

• Input power is too low.

|

• Verify your welder’s output voltage and current. Ask a qualified electrician for help if necessary.

• Poor ground clamp, torch or electrode holder connection.

|

• Check connection of ground cable, torch or electrode holder and make sure they are well connected.

• Wrong size or worn contact tip.

|

• Replace with the correct size contact tip or replace with a new contact tip.

• Wrong welding wire size or type.

|

• Recommended welding wires are 0.030/0.035 in. flux core welding wire.

Difficult to start an arc.|

• Welding amperage is low.

|

• Increase welding amperage.

• Clogged contact tip.

|

• Clean or replace contact tip.

No welder output when switched on and neither indicator LED is illuminated.|

• Loose ground clamp connection.

|

• Check and make sure the ground clamp is well attached to the workpiece.

• No input power supply.

|

• Check and make sure welder is plugged in.
• Verify outlet output power.
• Check the circuit breaker to see whether it is tripped or not. Reset if necessary.

No welder output when switched on and tripped protection/alert indicator is illuminated.|

• Tripped thermal protector by overheating (tripped protection/aler indicator turns on).

|

• Cool the welder for at least 10 minutes. The tripped protection/alert indicator LED should turn off after welder cools down.

• Reduce the duration of the welding period, or duty cycle, or duration of use.

• Check whether the fan inside the welder is working properly.

• Overheat caused by environmental factor (high room temperature or insufficient air flow).

|

• Relocate to a cool working environment.

• Check whether there is obstruction blocking air flow in the room. Clear the obstruction if needed.

• Incorrect input voltage to welder.

|

• Check the outlet voltage.

Frequent circuit breaker trips.|

• Circuit breaker is insufficient for the working current of the welder.

|

• Make sure the circuit breaker fits the working current of the welder.

• Refer to a qualified electrician if you are unable to resolve.

• Too much amperage is drawing due to the use of overlarge welding wire.

|

• Recommended welding wires are 0.030/0.035 in. flux core welding wire.

Poor welds.|

• Improper current/voltage setting.

|

• Make sure the welding current/voltage matches the recommended setting on chart.

• Workpiece is not clean (such as rusty, painted or greasy).

|

• Ensure workpiece is clean and dry.

• Poor ground clamp or torch/electrode holder connection.

|

• Check and make sure ground clamp/workpiece have good connection; torch/electrode holder and machine have good connection.

• Rusty or dirty welding wire.

|

• Check your wire. Clean it or replace with a new wire spool.

• Insufficient shielding gas at welding area.

|

• Check whether gas cylinder is empty or not.
• Check gas regulator setting and make sure the settings are correct.
• Check whether the shielding gas is being blown away. If yes, move to a shielded area.

Service Parts

ASSEMBLY DIAGRAM

Questions, problems, missing parts? Before returning to the store,
call Husky Customer Service
8 a.m. – 7 p.m., EST, Monday-Friday, 9 a.m. – 6 p.m., EST, Saturday
1-888-43-HUSKY
HUSKYTOOLS.COM
Retain this manual for future use.

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