MICHIGAN WELDING CO MIGSTICK130 130A Mig Stick Welding Machine Instruction Manual

WELDING CO MIGSTICK130 130A Mig Stick Welding Machine
Instruction Manual

130A MIG STICK WELDER
PART NO: MIGSTICK130 (..172841)
TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE.
OPERATING INSTRUCTIONS
SAVE THESE INSTRUCTIONS

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 MIGSTiCK130 until they have read this manual and have developed a thorough understanding of how the MIGSTICK130 operates.
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 that cannot be built into this product but must be supplied by the operator.

IMPORTANT SAFETY CONSIDERATIONS

Your Welding Environment

• Keep the environment you will be welding in free from flammable materials.
• Always keep a fire extinguisher close to your welding environment.
• Always have a qualified person install and operate this equipment.
• Make sure the area is clean, dry and well-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.

Your Machine’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.

Use of Your Machine

• Do not operate the welder if the output cable, electrode, MIG gun, 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 the welder in the off position when not in use.
• Connect ground lead as close to the area being welded as possible to ensure good ground.
• Do not allow any body part to come in contact with the welding wire if you are in contact with the 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, and 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 a 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.

Specific Areas of Danger, Caution, or Warning
Electrical Shock

• Electric arc machines can produce a shock that can cause injury or death. Touching electrically live parts can cause fatal shocks and severe burns.
• While cutting, all metal components connected to the wire are electrically hot. Poor ground connections are a hazard, so secure the ground lead before cutting.
• Wear dry protective apparel: coat, shirt, gloves, and insulated footwear.
• Insulate yourself from the workpiece. Avoid contacting the workpiece 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 it immediately if found.
• Use only recommended replacement cables and cords.
• Always attach the ground clamp to the workpiece or work table as close to the weld area as possible.
• Do not touch the welding wire and the ground or ground workpiece 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, or respirator with an 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
• Always use a helmet that covers your full face from the neck to the top of the 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 the 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 the wire back to Ve 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 the 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.

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 the cable around your body while welding.
• Wrap MIG gun and ground cable together whenever possible.
• Keep the 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 the cylinder with a MIG gun.
• Do not weld on the cylinder
• Always secure the 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 a protective cylinder cap whenever possible

PROPER CARE, MAINTENANCE, AND REPAIR

WARNING
Always have the power disconnected when working on internal components.
Do not touch or handle the PC board without being properly grounded with a wrist strap. Put the PC board in the static-proof bag to move or ship.
Do not put hands or fingers near moving parts such as drive rolls of fan.
MIGSTICK130 Use and Care
Do not modify the MIGSTICK130 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 the MIGSTICK130 was designed.

• Always check of damaged or worn-out parts before using the MIGSTICK130. Broken parts will affect the MIGSTICK130 operation. Replace or repair damaged or worn parts immediately.
• When MIGSTICK130 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.

Caring for the Environment
When a tool is no longer usable it should not be disposed of with household waste but in an environmentally friendly way. Please recycle where facilities exist. Check with your local council authority for recycling advice. Recycling packaging reduces the need for landfill and raw materials. The reuse of recycled material decreases pollution in the environment. Please recycle packaging where facilities exist. Check with your local council authority for recycling advice.
Transport and Storage

• Hold the handle or the bottom to move it.
• The machines should be firmly secured during transportation.
• The machines should be stored out of the rain.
• Keep the notice of the Attention sign on the packing box.

DESCRIPTION
The MIGSTICK130 series is a DC inverter MIG & STICK welder. This unit uses 1—Phase 240V, 50/60HZ AC power. A time delay fuse or circuit breaker is recommended. The MIGSTICK130 series is ideal for Do-it yourself projects or for light maintenance.

Specifications and Dimensions

Front Control Panel

1. Power Indicator: When the machine is turned on, the power indicator will be on.
2. Thermal Overload Indicator: When the thermal indicator is on, it shows the machine is overloaded and the internal temperature is too high. Weld output will turn off automatically but the fan will still be working. When the internal temperature is decreased, the overload light will turn off and the machine will be ready to weld.
3. Welding Amp and Voltage Knob: Adjust welding amp in STICK mode and welding voltage in MIG mode
4. Mode Selection: Switches between MIG & STICK mode
5. Wirespeed Knob: Adjust wire feed speed in MIG mode

Unpacking
1. Remove cartons, bags or Styrofoam containing the welder and accessories.
2. Check the contents with the packing list below.

3. After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Check for loose, missing, or damaged parts. A shipping damage claim must be filed with the carrier.

INSTALLATION

Power Requirement
AC single phase 240V, 50/60 Hz fused with a suitable time delay fuse or circuit breaker is required
WARNING
High voltage danger from power source! Consult a qualified electrician for proper installation of receptacles. This welder must be grounded while in use to protect the operator from electrical shock. Do not remove the grounding prong or alter the plug in any way. Do not use any adapters between the welder’s power cord and the power source receptacle. Make sure the POWER switch is OFF when connecting your welder’s power cord to a properly grounded 240Vac, 50/60fiz, single-phase power source.
Extension Cord
It is strongly recommended that an extension cord should not be used 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 at least 6mm2 and less than 8 min in length.
Setting Up The Work Piece
Welding positions
There are two basic positions, for welding: Flat and Horizontal. Flat welding is generally easier, and faster, and allows for better penetration. If possible, the workpiece should be positioned so that the bead will run on a flat surface.
Preparing the joint Before welding, the surface of the workpiece needs to be free of dirt, rust, scale, oil or paint. Or it will create a brittle and porous weld. If the base metal pieces to be joined are thick or heavy, it may be necessary to bevel the edges with a metal grinder. The correct bevel should be around 60 degrees.
See the following picture:
Based on different welding positions, there are different welding joints, see the following images for more information

Ground Clamp Connection
Connect the earth clamp cable to the negative terminal on the front of the machine, and the clamp to the work piece. Clear any dirt, rust, scale, oil or paint on the ground clamp. Make certain you have a good solid ground connection. Make sure the ground clamp touches the metal.

Gas Installation

1. Settings of different wire welding ways.
WARNING
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 touch the cylinder with a MIG gun.
• Do not weld on the cylinder
• Always secure the 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
• When MIG (solid) wires are used, shielding gas is required.
  

1. Change the welding mode to the MIG welding mode;
2. For gas, welding use a DCEP setup, with an earth clamp plugged into the negative polarity socket.
3. For gasless welding use a DCEN setup, with an earth clamp plugged into the positive polarity socket.

2. The gas hose
The gas hose, regulator, and gas cylinder connection. Attach one end of the gas hose to the gas solenoid valve (gas inlet) located on the back panel of the welder. Attach the other end to the gas regulator which is attached to the shielding gas cylinder. See the illustration below:

1. Cylinder valve: Controls GAS CYLINDER gasflovr.
2. Cylinder pressure gauge
3. Gas flow gauge, see set up charts for recommended settings
4. Regulator
5. Adjustment knob controls gas ‘, assure to the welder.
6. Gas hose
7. Gas cylinder

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 (check the setup guide on the machine for guidelines on the gas flow. 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. Avoid unnecessary gas loss by closing the tank valve when finished welding.
3. Gas selection
Different materials require different shielding gas when MIG welding, refer to the setup chart inside the wire feed compartment.
Materials — Shielding Gas
Types Mild steel: Use Argon 5/2 for reduced spatter and reduced penetration for thinner materials.

• Mild Steel: Use CO2 for deeper penetration but increased spatter.
• Stainless steel: Use Argon 98% and CO2 2%
• Aluminum or bronze: Use 100% Argon

Installation of the wire spool
Turn the machine power switch to the OFF (“0”) position before working inside the wire feed enclosure. Make sure that the wire feed drive roll and the contact tip of the gun match the diameter and type of wire used.

1. Push the spool onto the spindle so that the wire feeds off the bottom of the spool, toward the drive roll.
2. Push the spool spacer onto the spindle, against the spool.
3. Slide the spring onto the spool, then press on the spool lock, turning it clockwise to lock the spool assembly onto the spindle.
4. Release the spring-loaded thumb screw and rotate the idle roll arm away from the wire feed drive roll. Ensure that the visible, stenciled size on the drive roll side facing you matches the wire size being used.
5. Carefully detach the end of the wire from the spool. Maintain tension on the wire to prevent the spool from unwinding and do not release the wire until after step 5.
6. Cut the bent portion of the wire off and straighten the first 4″ (100 mm).
7. Thread the wire through the Incoming guide tube, over the drive roll, and into the gun liner.
8. Close the idle roll arm and turn down the thumbscrew until the idle roller presses down firmly on the wire. (Now you can release the welding wire). Make sure the wire is positioned in the groove of the lower drive roll.
9. The spring-loaded thumbscrew on the idle roll arm adjusts the pressure on the wire. Adjust the pressure by turning the thumbscrew to prevent spool overrun, but still allow smooth and easy wire feeding. Start with the pressure set to an intermediate value. Readjust, if necessary. If the drive roll slips while feeding the wire, the pressure should be increased until the wire feeds properly.

**

**MIG OPERATION

WARNING
HIGH VOLTAGE DANGER FROM POWER SOURCE! Consult a qualified electrician for the proper installation of receptacles at the power source.
This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician.
Do not cut off the grounding clamp or alter the plug in any way and do not use any adapters between the welder’s power cord and the power source receptacle. Make sure the POWER switch is OFF before connecting your welder’s power cord to a properly grounded 240VAC(220v-240v), 50/60Hz, single-phase power source.
Main control component
a) 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.
b) Voltage selector -The voltage selector controls the welding heat. This unit has infinite voltage control.
c) 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 to be used.
Note: The wire will feed faster without an arc. When an arc is drawn, the wire speed will slow down.
Holding the torch
The best way to hold the welding torch is the way that feels most comfortable to you and ensures the torch nozzle is at the correct angle. While practicing to use your new welder, experiment with holding the torch in different positions until you find the one that seems to work best for you.
Position the torch to the work piece
There are two angles of the torch nozzle in relation to the workpiece that must be considered when welding.
ANGLE A: This can be varied, but in most cases, the optimum angle will be 60 degrees, the point at which the torch handle is parallel to the workpiece. If angle A is increased, penetration will increase. If angle A is decreased, penetration will decrease also.
ANGLE B: This can be varied for two reasons: to improve the ability to see the arc in telation to the weld puddle and to direct the force of the arc.
Distance from the work piece
If the nozzle is held off the workpiece, the distance between the nozzle and the workpiece should be kept constant and should not exceed 6.4mm or the arc may begin sputtering, signaling a loss in welding performance.
Fine-tuning the wire speed
This is one of the most important parts of MIG welder operation and must be done before starting each welding job or whenever any of the following variables are changed: heat setting, wire diameter, or wire type.

1. Connect the Ground Clamp to a scrap piece of the same type of material that you will be welding. It should be equal to or greater than the thickness of the actual workpiece, and free of oil, paint, rust, etc.
2. Select a heat setting.
3. Hold the torch in one hand, allowing the nozzle to rest on the edge of the work piece farthest away from you, and at an angle similar to that which will be used when welding. (See HOLD THE TORCH if you are uncertain of the angle at which you will be welding).
4. With your free hand, turn the Wire Speed Dial to maximum and continue to hold onto the knob.
5. Lower your welding helmet and pull the trigger on the torch to start an arc, then begin to drag the torch toward you while simultaneously turning the Wire Speed Dial counter-clockwise.

As you decrease the wire speed, the sound that the are makes will change from a sputtering to a high-pitched buzzing sound and then will begin sputtering again if you decrease the wire speed too much. The point on the wire speed adjustment where the high-pitched buzzing sound is achieved is the correct setting. You can use the wire speed control to slightly increase or decrease the heat and penetration for a given heat setting by selecting higher or lower wire speed settings, Repeat this tune-in procedure if you select a new heat setting, a different diameter wire, or a different type of welding wire.
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 bums. Never strike an arc or begin welding until you are adequately protected. Wear flame- proof welding gloves, a heavy long sleeved
a WARNING shirt, trousers without cuffs, high topped shoes, and an AS/NZS 1338.1.1992 SAFETY STANDARD approved welding helmet.
ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded work.
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.
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 image above
The WEAVE BEAD is 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.
Welding position

FLAT POSITION is the 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 much the same as 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 is to help prevent the weld puddle from running downward while still allowing slow enough travel speed. A good starting point for
angle B is about 30 degrees DOWN from being perpendicular to the workpiece.
VERTICAL POSITION is easier for many people to Pull the torch from top to bottom. It can be difficult to prevent the puddle from running downward. Pushing the torch from bottom to top may provide better puddle control and allow slower rates of travel speed to achieve deeper penetration. When vertical welding, angle B (see HOLDING THE TORCH) is usually always kept at zero, but angle A will generally range from 45 to 60 degrees to provide better puddle control.

OVERHEAD POSITION Is the most difficult welding position. Angle A (see HOLDING THE TORCH) should be maintained at 60 degrees. Maintaining this angle will reduce the chances of molten metal falling into the nozzle. Angle B should be held at zero degrees so that the wire is aiming directly into the weld joint. If you experience excessive dripping of the weld puddle, select a lower heat setting. Also, the weave bead tends to work better than the stringer.
Multiple pass welding

BUTT WELD JOINTS when butt welding thicker materials you will need to prepare the edges of the material to be joined by grinding a bevel on the edge of one or both pieces of the metal being joined. When this is done, a“V” is created between the two pieces of metal that will have to be welded closed. In most cases more than one pass or bead will need to be laid into the joint to close the“V”. Laying more than one bead into the same weld joint is known as a multiple-pass weld.
The illustrations in the following figure show the sequence for laying multiple pass beads into a single “V” butt joint.
Note: When using self-shielding flux-core wire it is very important to thoroughly chip and brush the slag off each completed weld bead before making another pass or the next pass will be of poor quality.
FILLET WELD JOINTS Most fillet weld joints, on metals of moderate to heavy thickness, will require multiple pass welds to produce a strong joint. The illustration below shows the sequence of laying multiple pass beads into a T fillet joint and a lap fillet joint.
Spot welding
There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap. Each has advantages and disadvantages depending on the specific application as well as personal preference.

PUNCH AND FILL METHOD produces a weld with the most finished appearance of the three spot weld methods. In this method, a hole is punched or drilled into the top piece of metal and the arc is directed through the hole to penetrate into the bottom piece. The puddle is allowed to fill up the hole leaving a spot weld that is smooth and flush with the surface of the top piece. Select the wire diameter, and heat setting, and tune in the wire speed as if you were welding the same thickness material with a continuous bead.
BURN-THROUGH METHOD welds two overlapped pieces of metal together by burning through the top piece and into the bottom piece. With the burn-through method, larger wire diameters tend to work better than smaller diameters. Wire diameters that tend to work best, with the burn-through method are 0.035-inch self- shielding flux-core wire. Do not use .030-inch self-shielding flux core wires when using the burn-through method unless the metal is VERY thin or excessive filler metal build-up and minimal penetration is acceptable. Always select the HIGH heat setting with the burn-through method and tune in the wire speed prior to making a spot weld.
LAP SPOT METHOD directs the welding arc to penetrate the bottom and top pieces, at the same time, right along each side of the lap joint seam. Select the wire diameter,
heat setting, and tune in the wire speed as if you were welding the same thickness material with a continuous bead.
Spot welding instructions

1. Select the wire diameter and heat setting recommended above for the method of spot welding you intend to use.
2. Tune in the wire speed as if you were going to make a continuous weld.
3. Hold the nozzle piece completely perpendicular to and about 1/4 inch off the workpiece.
4. Pull the trigger on the torch and release it when it appears that the desired penetration has been achieved.
5. Make practice spot welds on scrap metal, varying the length of time you hold the trigger, until the desired spot weld is made.
6. Make spot welds on the actual workpiece at desired locations.

STICK (MMA) OPERATION

Electrode
The welding electrode is a rod coated with a layer of flux. When welding, electrical current flows between the electrode (rod) and the grounded metal workpiece. The intense heat of the arc between the rod and the grounded metal melts the electrode and the flux. The most popular electrodes are:

• E6011 60,000 PSI tensile strength deep penetrating applications.
• E6013 60,000 PSI tensile strength used for poor fit-up applications
• E7014 70,000 PSI tensile strength used for high deposition and fast travel speeds with light penetration
• E7018 70,000 PSI tensile strength, used for out-of-position and tacking.

Selecting The Proper Amperage For The Electrode
There is no golden rule that determines the exact rod or heat setting required for every situation. The type and thickness of metal and the position of the workpiece determine the electrode type and the amount of heat needed in the welding process.
Heavier and thicker metals required more amperage.
Electrode/Amperage Guide
2.5mm diameter E6013 Electrodes – 60 to 100amps
3.2mm diameter E6013 Electrodes – 80 to 150amps
It is best to practice your welds on scrap metal that matches the metal you intend to work with to determine the correct heat setting and electrode choice. See the following troubleshooting tips to determine if you are using the correct electrode.

1. When the proper rod is used:
   a) The bead will lay smoothly over the work without ragged edges
   b) The base metal puddle will be as deep as the bead that rises above it
   c) The welding operation will make a crackling sound similar to the sound of bacon frying

2. When a rod too small is used
   a) The bead will be high and irregular
   b) The arc will be difficult to maintain

3. When the rod is too large
   a) The area will burn through light metals
   b) The bead will undercut the work
   c) The bead will be flat and porous
   d) Rod may be frozen or stick to the workpiece

Note: The rate of travel over the work also affects the weld. To ensure proper penetration and enough deposit of rod, the arc must be moved slowly and evenly along the weld
seam. Electrode holder connection

1. Attach the Twist-lock electrode holder to the +ve terminal on the MIGSTICK130
2. Open the electrode holder by turning the head and handle in opposite directions until the head clamp opens.
3. Place the exposed end of the electrode into the lead clamp and hold it in place.
4. Turn the handle to close the head clamp.

Setting the amperage control
The welder has an infinite output current control.
There is no golden rule that determines the exact amperage required for every situation. It is best to practice your welds on scrap metal that matches the metals you intend to work with to determine the correct setting for your job. The electrode type and the thickness of the workpiece metal determine the amount of heat needed in the welding process. Heavier and thicker metals require more voltage (amperage), whereas lighter and thinner metals require less voltage (amperage).
Electrode/Amperage Guide
2.5mm diameter E6013 Electrodes – 60 to 100amps
3.2mm diameter E6013 Electrodes – 80 to 150amps
Welding techniques
The best way to teach yourself how to weld is with short periods of practice at regular intervals. All practice welds should be done on scrap metal that can be discarded.
Do not attempt to make any repairs on valuable equipment until you have satisfied yourself that your practice welds are of good appearance and free of slag or gas inclusions.
Holding the electrode
The best way to grip the electrode holder is the way that feels most comfortable to you. To Position the Electrode to the workpiece when striking the initial arc, it may be necessary to hold the electrode perpendicular to the workpiece. Once the arc is started the angle of the electrode in relation to the workpiece should be between 10 and 30 degrees. This will allow for good penetration, with minimal spatter.
Striking the arc
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN.
WARNING Never strike an arc or begin welding until you have adequate protection. Wear flame-proof welding gloves, a heavy long-sleeved shirt, trousers without turn-ups, safety shoes, and a welding helmet or face mask. Scratch the workpiece with the end of the electrode to start the arc and then raise it quickly at about a 0.32cm gap between the rod and the workpiece. See picture (right).
It is important that the gap be maintained during the welding process and it should be neither too wide nor too narrow. If too narrow, the rod will stick to the workpiece. If too wide, the arc will be extinguished. It needs much practice to maintain the gap. Beginners may usually get sticking or arc extinguishing. When the rod sticks to the workpiece, gently rock it back and forth to make them separate. If not, the circuit is short in connection, and it will overload the welder. A good arc is accompanied by a crisp, cracking sound. The sound is similar to that made by eggs frying. To lay a weld bead, only 2 movements are required; downward and in the direction, the weld is to be laid, as in the following figure:
Types of weld bead
The following paragraphs discuss the most commonly used arc welding beads.
The STRINGER BEAD is formed by traveling with the electrode in a straight line while keeping it centered over the weld joint.
The WEAVE BEAD is 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 electrode. It is best to hesitate momentarily at each side before weaving back the other way to improve penetration.
Welding position
FLAT POSITION is the 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.

The HORIZONTAL POSITIONS are performed very much the same as the flat weld except that the angle is different such that the electrode, and therefore the arc force, is directed more toward the metal above the weld joint. This more direct angle helps prevent the weld puddle from running downward while still allowing slow enough travel speed to achieve good penetration. A good starting point for your electrode angle is about 30 degrees DOWN from being perpendicular to the workpiece.
How to judge a good weld bead
When the trick of establishing and holding an arc has been perfected, the next step is learning how to run a good bead. The first attempts in practice will probably fall short of acceptable weld beads. Too long of an arc will be held or the travel speed will vary from slow to fast (see following):

1. Weld speed is too fast.
2. Weld speed is too slow.
3. Arcis too long.
4. Ideal weld.

A solid weld bead requires that the electrode be moved slowly and steadily along the weld seam. Moving the electrode rapidly or erratically will prevent proper fusion or create a lumpy, uneven bead. To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded work.
How to finish the bead
As the coating on the outside of the electrode burns off, it forms an envelope of protective gasses around the weld. This prevents air from reaching the molten metal and creating an undesirable chemical reaction. The burning coating, however, forms slag. The slag formation appears as an accumulation of dirty metal scale on the finished weld. The slag should be removed by striking the weld with a chipping hammer.

SERVICE, MAINTENANCE, TRANSPORTATION & STORAGE

The welder needs regular maintenance as follows:

• Periodically clean dust, dirt, grease, etc. from your welder.
• Every six months, or as necessary, remove the cover panel from the welder and air-blow any dust and dirt that may have accumulated inside the welder.
• Replace the power cord, ground cable, ground clamp, or electrode assembly when damaged or worn.
• Store in a clean dry facility free from corrosive gas, excess dust, and high humidity. Temperature range from 10°F-120°F and the relative humidity not more than 90%,
• When transporting or storing the welder after use, it is recommended to repack the product as it was received for protection. (Cleaning is required before storage and you must seal the plastic bag in the box for storage.

Maintenance and Service

• The MIGSTICK130 welder is a semi-automatic gas shielded welder. To properly operate & maintain the welder can assure it of good performance and prolong its operating life. Only qualified personnel are allowed to be in charge of repairing. It is strongly recommended customers contact our company or agent for technical, repair, accessories supply, and service back-up when they feel unable to work out the technical hitch or problems.
• The maintenance job should be conducted by an authorized service agent.
• The newly installed welder or if it is not been in use for some time needs to be surveyed the insulation resistances between each winding and every winding to case with a multimeter, which can not be less than 2.5M0.
• Keep from rain, snow, and long-term exposure to sunlight when the welder is used outdoor,
• If the welder is not in use either for a long time or temporarily, it should be kept dry and have good ventilation to free it from moisture, eroded or toxic gas. The tolerable temperature ranges from -20°C+55°C, and the relative humidity can not be more than 90%.
• Dust removal: The professional maintenance personnel should use dry compressed air (using an air compressor or bellows) to remove the dust inside of the machine. The parts which have grease adhering to it must be cleaned with a cloth while making sure there are no loose parts inside the machine and on the connection cables. It is recommended that the machine is cleaned annually at a minimum and quarterly if the machine has heavy use and dust accumulation.
• Regularly check the gas system, for any abnormal sounds and for any loose components.
• Keep torch cable straight when welding.
• Regularly clean the nozzle (Do not knock the torch head to remove debris. Do not remove the feeder device by pulling the torch cable).
• Use welding-specific wire, not inferior or rusty wire.
• Replace the feed roll if it is showing wear and tear to prevent the wire from feeding unevenly.
• The welder voltage is high, so safety precautions should be implemented before repairing to avoid accidental shock.

ATTENTION

• Under no circumstance can anyone except an authorized service agent should open the case of the machine.
• Switch off the power source each time when removing dust.

Do not touch inside the cable or workpiece while removing dust. While practicing to use your new welder, experiment with holding the torch in different positions until you find the one that seems to work best for you.

TROUBLE SHOOTING CHART

temperature is low down.
2| Wide fitting the motor does not work| Potentiometer not in the Change PO|
The nozzle is blocked up| Change nozzle
The feed roller is loose| Tighten the bolts
3| The cooling Fan not working or turning very slowly| Switch broken| Replace the switch
Fan broken| Replace or repair the fan
Wire broke or fell off| Check the connection
4| Arc is not stable and splash is large| Too large contact tip makes the current unsteady| Change the proper contact tip or roller
Too thin power cable makes the power asceticism| Change the power cable
Too low input voltage| Enhance the input voltage
Wire feeding resistance is too large| Clean or replace the liner and the torch cable had better in the line direction.
5| Arc can’t be started| Earth cable break| Connect earth cable
The workpiece has grease or rust on the surface| Clean the surface
6| No shielded gas| Torch is not connected well| Connect the torch again
The gas pipe is pressed or blocked up| Check gas system
Gas system rubber pipe break| Connect gas system and bind firmly
7| Other| | Please contact Total Tools

PARTS BREAKDOWN

PARTS BREAKDOWN LIST

MAIN CIRCUIT CHART

WARRANTY INFORMATION

This warranty is provided by Total Tools (Importing) Pty Ltd 20 Thackray Road, Port Melbourne, VIC 3207 (we, us, our).
Express warranty
Subject to the exclusions set out below, we warrant that this product will be free from defects in materials or workmanship for a period of 12 months from the date of purchase. The benefits conferred by this warranty are in addition to all rights and remedies which you may be entitled to under the Australian Consumer Law, and any other statutory rights you may have under other applicable laws. This warranty does not exclude, restrict or modify any such rights or remedies.
Warranty exclusions
This express warranty does not apply where a defect or other issue with the product is caused by normal wear and tear, misuse, or abuse of the product.
Consumer guarantees
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
Warranty claims
To make a claim under this warranty, you must bring the product along with the proof of purchase and any other documentary evidence which you think is relevant to Total Tools’ place of purchase where the claim will be handled on our behalf. Any cost incurred by you in bringing the product to the place of purchase will be borne by you.
To make a claim under this warranty, the product and proof of purchase must be returned to the Total Tools place of purchase during the warranty period specified above. If your warranty claim is accepted, we (or the Total Tools store that handles the claim on our behalf) will, at our discretion, repair or replace the product, or refund money to you and take back the product.

Original main power rectifiers, printed circuit boards, and power switch semiconductors| 3 Year
MIGSTICK130 ACCESSORIES| Warranty Period
Electrode holder, earth clamp, and cables| 3 months

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>