Reboot RBM2100D MIG Welding Machine Instruction Manual

Reboot RBM2100D MIG Welding Machine

Specifications

• Model : RBM2100D
• Technology : Single tube IGBT inverter
• Inverter Frequency Range: 25-50KHz
• Power Supply: 50/60Hz AC
• Output : High-power DC power supply
• Conversion Efficiency : Increased by more than 30%
• Welding Types: Gas shielded welding, MIG gas, MIG gasless, Lift TIG, STICK welding, spool gun function
• Duty Cycle: 60% at 200A

Version

• Due to product version upgrades or other reasons, the contents of this document are not regularly updated. Unless otherwise agreed, this document is intended as a guide only and all statements, information and recommendations in this document do not constitute any guarantee, expressed or implied.
• The pictures in this document are for reference only. If the picture is different from the real one, then use the pictures for guidance only.

Brief Product Introduction

Summarize

**** 1| IGBT Inverter Technology| This device uses single tube IGBT inverter technology (the inverter frequency range is from 25-50KHz) to convert 50/60Hz alternating current (AC) to direct current (DC) and then to high frequency and lower voltage rectification. The resulting pulse width modulation (PWM) output can be used for the high-power DC power supply, Due to switching power inverter technology adopted, the weight of the welder has been significantly decreased and the conversion efficiency of the whole machine is increased by more than 30%.
---|---|---
2| Superior Performance| The machine can be used for gas shielded welding. The welder is equipped with a unique digital electronic reactor circuit. The welding process of short circuit transition and mixed transition can be controlled very precisely. It has excellent welding characteristics .Compared with silicon controlled welders and tapped welders, it has the following advantages: stable wire feeding speed, low energy consumption, energy saving and no electromagnetic noise .It also has the characteristics of reduced spatter, stable arc, deep pool and high load.
3| Wide Voltage| Our welding machine is equipped with a power supply voltage compensation device The power supply voltage will work when the rated voltage is within 15% of requirements. When using extension cords, in order to reduce voltage drop, use a heavy duty extension cord (10 or 12AWG or greater) or use the recommended configuration length.
4| Multifunction| The machine is a versatile product which include MIG gas, MIG gasless, Lift TIG , STICK welding and spool gun function. It has the advantages of high efficiency and power saving, and it is suitable for welding of multi-metal and multi-process requirements.
5| Easy Control| You can use the amperage knob to select the appropriate amperage according to the material and thickness of the work piece and you can get very good welding results by setting the voltage knob to the same angle as the amperage knob.
6| Portability| This welder is suitable for home use. Its portability, light weight and 60% duty cycle on 200A make it the perfect machine for on-site job and DIY projects. With fluxed core wire, this welder allows you to work without bringing along a heavy gas cylinder. This is your ultimate welding partner!
7| Attention|

• Wire spool hold down not put on correctly, this will make the wire not come off the spool smoothly. To much tension on the drive roller or not enough tension.
• Using the wrong size roller for wire.
• Not connecting the MiG to the + or- terminal before trying to weld.

Technical Parameters

• 110V
• 37 (MIG)
• 30.2 (MMA)
• 17.6 (TIG)

|

• 220V
• 30 (MIG)
• 27.4 (STICK)
• 16.7 (TIG)

Output current adjustment (A)|

• 110V
• 31-150 (MIG)
• 32-150 (STICK)
• 32-150 (TIG)

|

• 220V
• 31-200 (MIG)
• 32-200 (STICK)
• 32-200 (TIG)

---|---|---
Output voltage (V)|

• 110V
• 15.6-21.5 (MIG)
• 21.3-26(STICK)
• 11.3-16 (TIG)

|

• 220V
• 15.6-24.0 (MIG)
• 21.3-28.0(STICK)
• 11.3-18 (TIG)

No load voltage (V)| 50±5
Duty cycle (%)| 60
Power factor| 0.7
Efficiency (%)| 85
Wire feeder type| All-in-one
Wire feed speed(m / min)| 2-15
Wire diameter (mm)| 0.8/1.0
Insulation grade| F
Enclosure protection class| IP21
Suitable plate thickness (mm)| 0.5-5
Net Weight (kg)| 14
Overall dimension (mm)| 470×320×376

Accessories list

Installation Instructions

Welding Wire Installation Steps

• To install a fresh reel of welding wire into the wire feeder. The hole position of the wire plate should be aligned with the fixed plug on the shaft.

• The wire reel should be rotated so that the wire feeds from the bottom of the reel into the wire feeder. Following the diagrams below as a guide, place the reel over the spindle in the machine and fasten it into place with the washers, spring and nut. There should be slight tension on the reel, just enough to prevent it from unwinding. While using one hand to prevent in the wire from suddenly unwinding from the reel, loosen the free end of the wire from the edge of the reel. Snip off the crooked or bent tip and insert the tip of the wire into the metal spring wire guide of the wire feeder.

• According to the type and diameter of the wire, select the appropriate wire feed roller. V-grove roller for stainless steel and carbon steel, Knurled-grove roller for flux cored wire and U-grooved roller for welding aluminum in the spool gun (spool gun and U-groove roller are not included with the machine and must be purchased separately.) Please match diameter size on the roller with the welding wire diameter. Please note that the wire feeder feeds the wire over the inboard side of the feeder mechanism make sure you install the drive roller so that the desired groove is towards the machine!
• Release the drive tension mechanism by rotating the drive tension knob down. Now pass the wire through the wire guide spring over the top of the groove of the drive wheel. Using your finger to aim the wire thought the second guide that is at the front of the machine. Push the wire out a few inches or centimeters. Now bring down the top roller mechanism and raise the tension knob to lock it into place. Adjust the tension knob so that the pressure on the welding wire, guarantees the welding wire is not slipping if the wire is blocked, and not continuing to fed the wire, This would cause a huge mess called a bird’s nest inside the machine.

Roller size: external diameter ∮30mm/ internal diameter ∮10mm/ height 10mm

• Guide the wire sticking out the front of the machine into the welding gun cable. Now insert the welding gun cable into the socket on front panel and screw it in firmly. Unscrew the nozzle and contact tip from the MIG gun and feed the wire through the cable by pulling the trigger on the gun. To ensure the wire feeds quickly, you can turn tew amperage knob on the front panel to it’s maximum setting. After the wire successfully fed reinstall install the contact tip and appropriate nozzle. For fluxed core wire, install a ceramic nozzle, for solid wire install a copper nozzle.

MIG & TIG Torch Exploded Diagram -TIG torch is not included in standard accessories

• Torch nozzle 1 and contact tip 2 are consumables. Please change when needed.

Gas Shielded Welding Installation.

1. MIG Welding
   The gas cylinder containing the carbon dioxide gas, mixture gas or argon gas must be tightly connected to the regulator or flow meter must to tightly so that there are no gas leaks.
   Connect a gas hose between the machine’s rear gas connector and gas regulator or flowmeter with the gas hose clamps provided. Once again there must be no leaks.

2. LIFT TIG Welding
   The regulator or flowmeter attached to the gas cylinder containing the argon gas is tightly connected with the gas tube on torch so that there are no leaks.
   

MIG Spool Gun Installation.

Operating Instructions

Operation Panel Interface

adjusting the amperage. You can get very good welding results when pointing the current[3] voltage[4] knob to the same positions.
4| Adjust voltage: Adjustment is only effective in MIG mode, it has no effect in STICK, and lift TIG modes.[2] The current display does not change when adjusting the voltage. You can get very good welding results when pointing the current[3] voltage[4] knob to the same positions.
5| Mode switch: MIG/SPOOL GUN/STICK /LIFT-TIG functions. In MIG Mode, the button [6] is only effective.it has no effect in STICK, and lift TIG modes.
6|

• 2T/4T switch. 2T is manual, that is, always press the switch for welding
• 4T is semi-automatic, that is, pressing the trigger once strikes an arc, when the trigger is released the machine continues to weld until the trigger is pressed again.

7| Over current or over heat protection light
When the cutting load is overloaded and the output current of the machine is too large, the internal temperature of the machine is too high, and the machine fault light will be on. This is normal. The machine can recover after the heat dissipation becomes normal. Please restart the power supply; When damaged, the fault light will be on, in this case, the machine is abnormal and needs maintenance, please contact the supplier.

Welding Operation Instruction

Polarity Selection Procedures

• There are two basic ways to configure the welder
• Direct Current Electrode Positive (DCEP) :The electrode cable (MMA stinger, MIG gun) connected to the positive (+) connector on the front panel, The workpiece is connected to negative (-) connector by the work clamp cable. Suitable for positive wire or stick electrode.
• Direct Current Electrode Negative (DCEN ):The workpiece is connected to the positive (+) connector on the front panel.
• The welding electrode cable (MMA stinger, MIG gun, TIG Gun) is connected to the negative (-) connector pole. Suitable for negative wire stick electrode.
• The polarity is selected according to the welding process requirements of the workpiece, use of incorrect polarity may cause arc instability, spatter and lack of fusion.

STICK Manual Welding Operation Procedures

• Make sure the electrode cable is connected to the positive front panel connector. The working clamp clamps the workpiece and is connected to the negative connector on the front panel. When using alkaline welding electrode, use DCEP connection mode. Cellulose electrodes cannot be used .Pull welding is recommended, which is called right welding, that is, pull welding from the left to the right.
• Make sure the [5 Mode Switch] at Stick Mode. Adjust [3 Adjust current] The welding current can be changed.

Operation of LIFT TIG function

• Please follow installation instructions to install the TIG torch and working clamp. In Lift TIG welding mode ,adjust [3 Adjust current] the welding amperage can be changed.
• The TIG welding function is for thin workpiece welding or stainless steel welding. Use 100% Argon gas as shielding gas. Connect the gas hose with gas tube on torch. Connection of gas cylinder （Refer to 2.3）
• Connect the TIG torch on negative connector.
• Connect the working clamp cable on positive connector(DCEN).
• Tungsten needle electrode contact workpiece arc striking.

Operating Procedures for MIG

• Gas Protection Welding-Solid wire
• Welding wire Installation. ( Refer to 2.1)
• Use the V-groove roller for stainless steel and carbon steel. Connection of the gas cylinder(Refer to 2.3)
• Insert the quick connect end of the MIG Gun selection cable into the positive connector on the front panel (DCEP).Insert the quick connect end of the working clamp cable into the negative connector on the front panel on the machine. Check wire

operation press torch trigger, the wire feeder will feed the wire through the torch tip. Select MIG mode on the front control panel(Make sure you are not in SPOOL GUN state).After that, select the right material and diameter you are welding with. Adjust amperage according your workpiece thickness.
To find the best welding performance and suitable for your welding habits. You may also adjust voltage to build a perfect welding bead and penetration. Push welding is recommended, which is called left welding, that is, push welding from the right to the left.
Gasless Welding-flux cored wire

• Welding wire Installation.(Refer to 2.1)
• Use the proper diameter Knurled roller for flux cored wire.
• Insert the quick connect end of the MIG Gun selector cable into the negative connector on the front panel of the machine
• (DCEN).Insert the quick connect end of the working clamp cable
• into the positive connector on the front of the machine. Check wire
• operation： press torch switch, the wire feeder will feed the wire through the torch tip. Select MIG mode on the front control
• panel(Make sure you are not in SPOOL GUN state). After that, select the right material and diameter you are welding with. Adjust amperage according your workpiece thickness.
• To find the best welding performance and suitable for your welding habits. You may also adjust voltage to build a perfect welding bead and penetration. Pull welding is recommended, which is called right welding, that is, pull welding from the left to the right.

Spool gun torch welding

• This machine can be connected to a Spool gun. (the package does not include a spool gun).
• The use of spool gun is similar to that of MIG gun, except that the wire is fed through the wire feeding mechanism of the spool gun itself. In the spool gun mode, the feeding mechanism of the original machine does not work.
  Select spool gun mode on the front control panel. Aluminum welding is supported in spool gun mode.

|
---|---
Direct Current Electrode Positive (DCEP): The electrode cable (Stick stinger, MIG gun) connected to the positive (+) connector on the front panel, The workpiece is connected to negative (-) connector by the work clamp cable. Suitable for positive wire or stick electrode.|

Direct Current Electrode Negative (DCEN): The workpiece is connected to the positive (+) connector on the front panel. The welding electrode cable (MMA stinger, MIG gun, TIG Gun) is connected to the negative (-) connector pole. Suitable for negative wire stick electrode.

Solid Wire, Welding aluminum @MIG Mode ,alkaline welding electrode@Stick Mode| Flux Cored Wir e@ MIG Mode, LIFT TIG Mode

How to welding aluminum

• Because aluminum dissipates heat very quickly, more heat is required during welding, and the cooling speed of the work piece is too fast, resulting in that the gas generated by various reasons cannot be discharged in time during the welding process, resulting in the formation of pores.
• The melting point of aluminum is only 600 ℃, and the welding current is slightly high, causing the work piece to burn through. Aluminum is also very easy to oxidize. The melting point of the surface Aluminum oxide is 2000 ℃, which is very different from that of aluminum. The Aluminum oxide will form welding protection for aluminum; Aluminum has good ductility and soft material, which makes wire feeding difficult; The expansion coefficient of the welding line is large, and it is easy to deform and produce cracks, which brings great difficulties to the welding of aluminum.

Precautions for aluminum welding

• Clean the oxide film on the aluminum surface with a stainless steel brush, and clean the aluminum welding wire surface with acetone.
• Select MIG mode for machine function and switch the gun mode to spool gun mode.
• Correctly connect the spool gun to the machine(DCEP).
• Install the aluminum welding wire with matching diameter to the spool gun.
• Welding aluminum must be protected with 100% argon.
• Push welding is adopted, which is called left welding, that is, push welding from the right to the left.
• Select the appropriate current according to the thickness of aluminum material. You can try to start with a small current until you find the appropriate current.
• The position and angle of the gun head shall be adjusted according to the position of the welding space, and the speed of the technique shall be determined according to experience. However, when the molten pool is initially formed, the welding gun shall be pushed forward.

Fault display

OC light

• When the welding load is overloaded and the output current of the machine is too large, the internal temperature of the machine will become too high, and the machine fault light will come on. This is normal. The machine will recover after it cools down and the temperature has returned to normal. If it does not, please shut the machine down and restart it. If the machine is damaged, the fault light will be on, in this case, the machine needs maintenance, please contact the supplier.

Polarity Conversion Joint

• This machine has the polarity conversion; There are positive and negative connector on the front panel. When using solid wire with gas shielding, the polarity selection cable should be connected to the positive connector, the working clamp cable should be connected to the negative connector; When using flux-cored wire the polarity selection cable should be connected to the negative connector and the working clamp cable should be connected to positive connector.

Machine parameter adjustment

Stick Mode

• Stick mode of multi-function machines, only the current can be adjusted. Try to start with the minimum current, then gradually increase the current until the best welding effect.Excessive welding current will cause excessive heat input and coarse weld grain, which will affect the mechanical properties and strength of the weld; Burn through ;If the welding current is too small, the weld will not be fused; Incomplete penetration; Slag inclusion and air hole caused by too small welding current and poor arc stiffness; The transition between weld and base metal is not smooth due to low heat input;

• I = D * K
• I: Welding Current (A);
• D: Welding Rod Diameter(mm); K: Empirical Coefficient

• During vertical welding, the current shall be 15% ~ 20% less than that during flat welding; For horizontal and overhead welding, the current shall be 10% ~ 15% less than that during flat welding
  The welding current shall be comprehensively selected according to the type of welding rod, diameter of welding rod, thickness of weldment and other factors. Generally speaking, under the condition of ensuring good welding penetration and forming of weldment, a larger welding current shall be used as much as possible, and the welding speed shall be appropriately increased to improve the welding productivity..

Lift Tig Mode

• There are many technological parameters that affect the quality of TIG welding. It includes the type, polarity and size of welding current, welding voltage, welding speed, flow of shielding gas, welding direction, tungsten electrode diameter and end shape, tungsten electrode extension length, nozzle diameter, shape, distance between nozzle and work piece,

Cerium tungsten

| tungsten| Thorium tungsten

Cerium tungsten

| tungsten| Thorium tungsten

Cerium tungsten

0.5| 5~20| 5~20| –| –| 5~15| 5~15
1.0| 10~75| 10~75| –| –| 15~55| 15~70
1.6| 40~130| 60~150| 10~20| 10~20| 45~90| 60~125
2.0| 75~180| 100~200| 15~25| 15~25| 65~125| 85~160
2.4| –| 150~250| –| 15~30| 70~130| 100~180
2.5| 130~230| 170~250| 17~30| 17~30| 80~140| 120~210
3.2| 160~310| 225~330| 20~35| 20~35| 150~190| 150~250
4.0| 275~450| 350~480| 35~50| 35~50| 180~260| 240~350
4.8| –| 500~675| –| 50~70| 190~300| 290~390
5.0| 400~625| 500~700| 50~70| 55~80| 240~350| 330~460
6.3| 550~675| 650~950| 65~100| 65~100| 300~450| 430~575
8.0| –| –| | | | 650~830
Thickness(mm)| welding layers| Tungsten electrode

diameter(mm)

| Welding wire(mm)| Current(A)| Argon flow(L/Min)| Nozzle diameter(mm)| Wire feeding speed(Cm/Min)
---|---|---|---|---|---|---|---
1| 1| 0.5~1.0| 1.6| 110~130| 5~6| 8~10| ——
2| 1| 1.2| 1.6~2.0| 130~160| 12~24| 8~10| 108~117
3| 1~2| 1.6| 2.4| 160~220| 14~18| 10~14| 108~117
4| 1~2| 2.0| 2.0~3.0| 220~260| 14~18| 10~14| 117~125

• The argon protective layer is flexible. When encountering the lateral wind force or the welding speed is too fast, the argon gas flow will bend and deviate from the weld pool, affecting the gas protection effect, and the welding speed will affect the weld formation. Therefore, an appropriate welding speed should be selected. The distance from nozzle to welding shall not exceed 15mm, and the length of tungsten electrode extending out of nozzle shall be 3~4mm. The diameter of filler wire shall be selected according to the thickness of weldment.

MIG Mode

• The parameter adjustment of MIG welding machine is mainly to achieve two balances: one is to ensure that the wire feeding speed is equal to the fuse speed, so as to achieve the best welding feel; Secondly, it is necessary to ensure the balance between the thickness of the weldment and the melting energy required by the welding process, so as to achieve the best welding effect.

• In general, the above two goals are achieved mainly through the regulation of voltage and current. Voltage will determine the dissolution speed of welding wire, while current regulation generally refers to regulating the wire feeding speed. There is always a drop like metal ball at the end of the welding wire, which indicates that the welding voltage is high. Increase the welding current to accelerate the Wire feeding speed, or the welding voltage should be reduced;

• When the wire extension of the welding wire is short, it can be welded normally, and the wire jacking phenomenon occurs when it is too long. which indicates that the welding voltage is low. At this time, the current should be reduced by reducing the wire feeding speed, or the welding voltage should be increased. If the current and voltage are well proportioned, the sound will be the same as the buzzer, otherwise the sound will be crackling, splashing, jacking wire and large welding particles.
  During gas shielded welding, the higher the voltage, the larger the weld pool will be. Therefore, it is necessary to increase the flow of shielding gas.

• The welding angle and speed will affect the welding effect.When the nozzle is perpendicular to the weldment, the spatter will be large and the arc will be unstable. To avoid this situation, the nozzle can be tilted back by 10-15 degrees (the welding position is different, and the welding gun angle is also different), which can ensure good weld formation and stable welding process.Too fast welding speed will lead to poor gas protection, air holes and other defects. At the same time, the cooling speed of the weld will be correspondingly increased, thus reducing the plastic toughness of the weld metal. When the welding speed is too slow, the weld pool becomes larger and the weld becomes wider, which is easy to cause coarse weld metal structure or burn through due to overheating.

• If the weld seam is floating on the weldment surface, it indicates that the weldment is too thick or the welding voltage is too low.If the weld seam is wide and the penetration is deep, the welding particles are large, or even the weldment is burned through, it indicates that the voltage is too high.

• See the attached table for parameter suggestions: Appendix Ⅰ Welding Parameter List

• The values listed in the following table are the general specification values under standard condition.

| Plate thickness

（mm）

| Wire diameter

（mm）

| Current

（A）

| Voltage

（V）

| Welding speed

（cm/min）

| Wire extension

（mm）

| Gas flow rate

（L/min）

---|---|---|---|---|---|---|---
Fillet butt welding| 1.6| 0.8,0.9| 60～80| 16～17| 40～50| 10| 10
2.3| 0.8,0.9| 80～100| 19～20| 40～55| 10| 10～15
3.2| 1.0,1.2| 120～160| 20～22| 35～45| 10～15| 10～15
4.5| 1.0,1.2| 150～180| 21～23| 30～40| 10～15| 20～25
| Plate thicknes （mm）| Wire diamete （mm）| Welding gun vertical angle(°)| Current（A）| Voltage（V）| Weldingspeed (cm/min)| Wire extension

（mm）

| Gas flow rate

（L/min）

---|---|---|---|---|---|---|---|---
Horizontal fillet butt welding T joint| Low welding speed| 1.0| 0.8,0.9| 45| 70～80| 17～18| 50～60| 10| 10～15
1.2| 0.9,1.0| 45| 85～90| 18～19| 50～60| 10| 10～15
1.6| 1.0,1.2| 45| 100～110| 19～20| 50～60| 10| 10～15
2| 1.0,1.2| 45| 115～125| 19～20| 50～60| 10| 10～15
2.3| 1.0,1.2| 45| 130～140| 20～21| 50～60| 10| 10～15
3.2| 1.0,1.2| 45| 150～170| 21～22| 45～50| 15| 15～20
4.5| 1.0,1.2| 45| 140～200| 22～24| 45～50| 15| 15～20
6| 1.2| 45| 230～260| 24～27| 45～50| 20| 15～20
8.9| 1.2,1.6| 50| 270～380| 29～35| 45～50| 25| 20～25
12| 1.2,1.6| 50| 400| 32～36| 35～40| 25| 20～25
High welding speed| 1.0| 0.8,0.9| 45| 140| 19～20| 160| 10| 15
1.2| 0.8,0.9| 45| 130～150| 19～20| 120| 10| 15
1.6| 1.0,1.2| 45| 180| 22～23| 120| 10| 15～20
2| 1.2| 45| 210| 24| 120| 15| 20
2.3| 1.2| 45| 230| 25| 110| 20| 25
3.2| 1.2| 45| 270| 27| 110| 20| 25
4.5| 1.2| 50| 290| 30| 80| 20| 25
6| 1.2| 50| 310| 33| 70| 25| 25
Horizontal fillet welding joint| Low welding speed| 0.8| 0.8,0.9| 10| 60～70| 16～17| 40～45| 10| 10～15
1.2| 0.8,0.9| 30| 80～90| 18～19| 45～50| 10| 10～15
1.6| 0.8,0.9| 30| 90～100| 19～20| 45～50| 10| 10～15

2.3

| 0.8,0.9| 47| 100～130| 20～21| 45～50| 10| 10～15
1.0,1.2| 47| 120～150| 20～21| 45～50| 10| 10～15
3.2| 1.0,1.2| 47| 150～180| 20～22| 35～45| 10～15| 20～25
4.5| 1．2| 47| 200～250| 24～26| 45～50| 10～15| 20～25
welding| ****

2．3～3.2

| ****

1.2

| 47| 220| 24| 150| 15| 15
47| 300| 26| 250| 15| 15

Trouble Shooting And Error Checking

Notes : The following operations must be performed by qualified electricians with valid certifications. Before maintenance, you are suggested to contact local distributor to verify qualification.

• Confirm the power switch is on.
• Power supply available for input cable.
• Check if the three phase commute bridge is damaged.
• There is malfunction occurs in the supplementary power source on control board (contact dealers).

The meter shows; Fan works normally; No welding output|

• Check if all the sockets in the machine are connected well.
• There is open circuit or badness of connect at the joint of output terminal.
• The control cable on the torch is broken off or the switch is damaged.
• • The control circuit is damaged.(contact to dealers)

the meter shows; Fan works normally; Abnormal indicator lights.|

• It might be over-current protection, please turn off the power switch; restart the machine after the abnormal indicator light winked.

• • It might be overheating protection, please wait for about 2-3 minutes until the machine renew without turn off the power switch.

• It might be multifunction of inverter circuit. (contact dealers)

• Even if the machine comes up with abnormal phenomenon such as unable to weld, arc unstable or bad welding effect, it is still early to judge that there is malfunction in the machine.

• The above-mentioned abnormal phenomenon may be caused by some reasons. For example: tight parts loosen, forgetting to switch on, wrong set up, cable broken and gas rubber pipe cracked, etc. Therefore, please test and inspect these factors before deliver it back to the factory because a large number of troubles may be easily solved probably.

• For this reason, an initial diagnosis list for general welding troubles is shown below. A trouble happened may be found in the column of “Abnormal items” on up-right of the list, please inspect and maintain for the corresponding items which have “〇” mark in the column according to the following list respectively.

Initial problems diagnose

Abnormal Items Area and Item to be Inspected and Maintained| No arc Starting| No Gas out| No Wire Feeding| Bad Arc Ignition| Unstable Arc| Dirt on Edge of Weld bead| Wire Stick to material| Wire Stick to Conductive Tip| Blowhole Formed
---|---|---|---|---|---|---|---|---|---
Distribution Boxes (Input Protection Devices)|

• Turn on power supply or not?
• Fuse burnt out
• Connection joint loose

| ****

〇

| | ****

〇

| ****

〇 〇

| | ****

〇 〇

| | |
Input Cable|

• Examine whether the cable is cut off.
• Connection joint loose
• Over heat

| ****

〇

| | | ****

〇

| | ****

〇 〇

| | |

Daily Maintenance And Checking

Daily Maintenance

• Remove dust regularly with dry compressed air. If the welding machine is used in surroundings with heavy smoke and polluted air, it is necessary to remove dust at least one time one month.
• The pressure of compressed air shall fall to required level to prevent damage to small components in the machine.
• Examine inside electric joints and ensure perfect contact (Especially plugs and sockets). Fasten the loosing joints. In case of oxidation, remove oxide film with sand paper and connect again.
• Prevent water from entering into the machine and prevent the machine from getting moist. If any, blow and dry. Measure the insulation with megohmmeter to make sure it is qualified to use.
• If the welding machine is not used for a long time, pack the machine in original package and store in dry surroundings.
• Every time the wire feeder operates for 300hours, grind the electrical carbon brush and clear up the armature commutator. Rinse speed reducer, apply 2# Molybdenum Disulfide lubricant to the turbine, whirlpool rod and bearing.
• All the maintenance and testing must be carried out when the power supply is totally cut off. Please make sure the power is off before opening the closure.

Daily Checking

WELDING POWER SUPPLY

Position| Checking keys| Remarks
Control panel|

• Operation, conversion and installation of the switch
• Check the state of the power indicator light

| Lead to unstable arc and

wire sending

Cooling fan|

•  Check if the fan state and the sound is normal or not

| Clean the residue and

check the reason and solve it

Power part|

• Check if there is abnormal liberation and sound when the power is on
• Check if there is smell when the power is on
• Whether the outside color change or get warm

|
Outer parts|

• Whether the wire feeder pipe is broken, and the connector is loosen
• Whether the outer shell or other connect parts are loosen

|
WELDING TORCH

Position| Checking keys| Remarks
Loophole|

•  If installment fixed, the front distorted

| Reason for air hole.

• Attach splash or not.

| Reason for burning the torch.

（can use splash-proof material ）

Electric hole|

• If installment fixed

| Reason of torch screw thread damage

• Damage of its head and hole blocked or not

| Reason of unstable arc and broken arc
Wire sending tube| Check the extended size of the pipe| Have to be changed when less than 6mm, when the extended part too small, the arc will be

unstable.

|

• Wire diameter and the tube inner diameter match or not

| Reason of unstable arc, please use the suitable

tube.

---|---|---

• **** Partial winding and extended

| Reason of poor wires sending and unstable arc,

please change.

• Block caused by dirt in the tube, and the remains of the wire plating lay.

| Reason of poor wire sending and unstable arc,

(use kerosene to wipe or change new one.)

• Wire sending tube broken O circle wear out

| Procyon dentation tube broken, change new tube.

Change new O circle

Gas bypass|

• Forget to insert or the hole blocked, or different factory component.

| May lead to vice (splash) because of poor gas shield, torch body get burned (arc in the torch),

please handle.

|

• Wire diameter and the tube inner diameter match or not

| Reason of unstable arc, please use the suitable tube.
---|---|---

• Partial winding and extended

| Reason of poor wires sending and unstable arc,

please change.

• Block caused by dirt in the tube, and the remains of the wire plating lay.

| Reason of poor wire sending and unstable arc,

(use kerosene to wipe or change new one.)

• Wire sending tube broken O circle wear out

| Pyrocon densation tube broken, change new tube.

Change new O circle

Gas bypass

|

• **** Forget to insert or the hole blocked, or different factory component.

| May lead to vice (splash) because of poor gas shield, torch body get burned (arc in the torch),

please handle.

Welding Problems And Solutions

The phenomenon listed below may happen due to relevant accessories used, welding material, surroundings and power supply. Pleas improve surroundings and avoid these problems..

Arc starting difficulty. Arc interruption happens easily

• Examine whether the working clamp has good contact with the work pieces.
• Examine all cable connections and make sure they are tight.

The output current fails to reach rated value

• The deviation of power voltage from rated value may cause the output current to not achieve the adjusted value. When the power voltage is lower than rated value, the maximum output current may be lower than rated value.

The current can not keep stable during operation

• This situation may relate to the following factors
• The voltage of electric power network changes;
• Serious interference from electric power network or other electric facilities.

Porosity in welds

• Examine whether the gas supply circuit has any leaks.
• Examine whether there is contaminants such as oil, dirt, rust, paint etc. on the surface.

Attention

• The precautions listed in this manual are intended to ensure the safe use of the machine and to protect you and others from harm and injury.
• The design and manufacture of the welding machine power take full account of the safety, be sure to comply with the precautions in this manual, otherwise it will cause serious accidents.
• Wrong use of welding machine power supply will cause the following kinds of different degrees of harm and injury. Please read this manual carefully to avoid or minimize such harm.

Welding Environment And Safety

• Working surroundings

1. Welding should be carried out in dry surroundings. The air humidity level should not be higher than 90%.
2. The temperature should be between -10C to 40C.
3. Don’t use the welding machines in sunshine or rain. Keep it dry.
4. Don’t use the machines in the places of dust or corrosive air.
5. MIG welding should not be carried out in places with god ventilation.

Safety norms

• Over-voltage, over-current and over-heating circuits are built into the welding machine. It will stop working automatically when the input voltage, output current or internal temperature exceed the rated value. But if the machines are excessively used, such as with input voltage higher than the rated, the machine might be damaged. Please pay close attention to the following matters.

Keep good ventilation

• The welding machines work with high welding current.Normal air flow can’t provide the requirement of heat dissipation. So the fans are installed as cooling system to ensure stable performance.
• Make sure the ventilation windows are not covered or blocked. The distance between the machines and things around it should not be less than 0.3m. Good ventilation is good for welding performance and operational life.

Never over load!

• Check the maximum rated current (according to the Duty Cycle chosen). Make sure the welding current is never higher than the rated value. Over current running will obviously shortens the operational life, and can even damage the machine.

Never over voltage!

• The Input Voltage can be found in Technical data diagram. The auto-compensation function will keep the welding current in the rated range. If the input voltage exceed the permissible value, the machine will be damaged. Users should take protective measures in advance to avoid it.

Make sure earth connected before operation.

• On the rear panel of welding machine, a screw for earth connecting would be found. It must be ground connected with cable whose section is bigger than 6mm2 before operation, to avoid accidents caused by static or electricity leak.

Symbol Definition

This Manual contains symbols as blow, please refer to their means expressed

Symbol|

Definition

---|---
| Texts beginning with this symbol indicate potentially serious dangers and, if not avoided, could result in serious accidents that could result in death or serious injury to personnel.
| Texts beginning with this symbol indicates a potentially hazardous situation that, if not avoided, could result in minor injury to persons or property damage.
---|---
| Texts beginning with this symbol indicate potential risks which, if not avoided, may cause malfunction or damage to the equipment.

• To avoid accidents, please observe the following rules
• Do not use this machine for other works but welding.
• The construction of the input power source, the setting of the installation site, the use of high-pressure gas, storage and disposition, the storage of the workpiece after welding and the disposal of waste shall be carried out in accordance with the relevant regulations.
• Irrelevant staffs do not enter the welding work place.
• Pacemaker wearers should consult with their doctor before operating.
• Please let qualified people or persons which with relevant knowledge and skills to install, operate, maintain and repair the welder.
• To ensure safety, please understand the contents of this manual.
• Do not touch live parts.
• Let relevant technicians connect the welder and base metal grounding correctly.
• It must switch off the power when installation, maintenance, and waiting 5 minutes before operation. Capacitors can be charged, even if the power has been cut off, but also to ensure that the capacitor is not charged voltage, and then operate.
• Do not use cables that have insufficient cross-sectional area, damaged insulation sheath, or exposed conductors
• In the cable connection, please ensure the insulation.
• Do not use the welder when the case opened or removed.
• Do not use insulated gloves which is damaged or damped.
• Please use safety net when working at height.
• Regular maintenance and repair, and please repair the damaged parts before using.
• When not in use, turn off all input power.
• When using AC arc welder in narrow places or higher places, please observe the relevant national and local standards and regulations.
• Do not place flammable materials near the welding place.
• Do not welding near flammable gas.
• Do not place the hot finished base material close to flammable material.
• When welding in the patio, on the ground and the wall, please remove the combustible materials on the back.
• The cable connected with the base metal as close as possible to the welding spot.
• Do not welding gas-filled trachea, seal groove, etc.
• Place a fire extinguisher near the welding work site to prevent the fire from happening.
• To avoid breathing these fumes and gases hazardous to health, please use the required protective equipment.
• To prevent accidents such as gas poisoning and suffocation, please use the prescribed exhaust facilities and use respiratory protection equipment.
• To prevent welding fumes and other dust damage and poisoning, please use the prescribed local exhaust equipment and respiratory protective equipment.
• When working in cabinets, boilers, cabins, etc., CO2, which is heavier than air, stays at the bottom. To prevent lack of oxygen, please fully ventilate and use an air respirator.
• When working in a confined area, please accept the inspection of the supervisory staff, and fully breathe and use respiratory protection equipment.
• Do not weld in the degreasing, cleaning, and spray operation areas.
• When welding plated or coated steel plates, harmful fumes and gases are generated. Please use respiratory protection equipment.
• To avoid harm to you and others caused by arc, splashing, welding slag, noise, etc., please use the specified protective equipment.
• When using welding or supervising welding, use protective equipment with sufficient shading.
• Please wear protective glasses.
• Wear protective equipment such as leather gloves for protection from welding, long-sleeved clothes, feet, and aprons.
• Set up a protective barrier around the welding site to prevent the arc from endangering others.

To prevent the dumping, cracking, etc. of gas cylinders, please observe the following regulations

• Please use the cylinder correctly as specified.
• Please use the gas regulator supplied with our company or recommended.
• Please read the gas regulator instruction manual before use, please observe the precautions.
• Use a dedicated cylinder holder and related parts to secure the cylinder.
• Do not leave cylinders exposed to high temperatures or sunlight.
• When opening the cylinder valve, do not approach the gas outlet on the face.
• When the cylinder is not in use, attach the cylinder cap.
• Do not place the welding torch on the cylinder. The electrode must not touch the cylinder.

Contact with rotating parts can cause injuries. Please observe the following rules

• Do not use the welder with the case removed.
• Persons with professional qualifications or relevant knowledge and skills can install, operate, overhaul, and maintain the welder.
• Do not put fingers, hair, clothing, etc. Close to the cooling fan and other rotating parts.

Wire ends can cause injuries. Please must observe the following rules

• When confirming whether to feed the wire, do not look into the hole of the contact tip. Otherwise, the wire will shoot to hurt the eyes and face.
• When manually feeding the wire or pressing the torch switch, do not place the end of the torch close to the exposed part of the body such as eyes or face.
• In order to work better and maintain the power of the welder, please must observe the following regulations
• If the power source of the welder is placed on an inclined plane, attention should be paid to preventing it from falling.
• It is forbidden to use welding power for the thawing of pipes.
•  When the welding power source is lifted using a forklift, it should be mounted sideways to prevent tipping.
• When the welding power supply is lifted by a crane, the cable should be tied at the lifting ring. The angle between the cable and the vertical should not exceed 15 degrees.
• When the welder is equipped with gas cylinders and wire feeders, these two devices should be taken from the power supply and the welder level should be kept as far as possible. When moving the gas shielded welding machine on the ground, be sure to When the welding power supply is lifted by lifting fork lift, to prevent dumping, please install from side.
• When the welding power supply is hoisted, the cable shall be attached to the hanging ring, and the Angle between the cable and the vertical direction shall not exceed 15 degrees.
• When the welding machine is equipped with gas cylinder and wire feeder, the two devices should be connected to the power supply and the welding machine level is maintained as far as possible. When moving the gas shielded welding machine on the ground, be sure to fix the cylinder with a belt or chain to prevent the dumping.
• If the wire feeding machine is used for welding, make sure it is firm and insulated.。
• If the device has a strap or handle, remember that it is only suitable for hand use. It is prohibited to use crane, forklift or other mechanical hoisting.

Attention to electromagnetic interference

• Additional precautions may be required when welding power is used in a local area.
• Before installing the welding equipment, the user should assess the potential electromagnetic problems in the installation environment area, as shown below

1. The upper, lower and adjacent power cables, control cables, signal cables and telephone cables of the welding equipment;
2. Radio and television transmitting and receiving devices;
3. Computer and other control equipment;
4. Safety identification equipment, such as the monitoring of industrial equipment
5. People Health conditions such as cardiac pacemakers and hearing AIDS;
6. Equipment used for calibration and measurement;
7. Interference of other equipment in the environment; Users shall ensure that other equipment in the environment is compatible with the environment; This may require additional protection;
8. The actual situation of welding or other activities carried out.

Users should comply with the following items to reduce radiation interference

1. According to the manufacturer’s suggestion, the welding equipment should be connected to the main supply line;
2.  According to the manufacturer’s suggestion, welding equipment should be maintained routine;
3. The welding cables should be as short as possible so that they are close to each other and close to the ground;
4. All the metal components of the welded assembly and its adjacent components shall be subject to safety verification;
5. The workpiece should be kept well grounded;
6.  Other cables and equipment in the environment can be selectively shielded and protected, thus reducing the impact of interference. The welding equipment can be completely shielded in special occasions.

The user should be responsible for the interference caused by welding.

Service Guarantee

• This product is made of high quality material and great care has been taken in its manufacture. It is designed to give good performance provided it is properly operated and maintained. The product is sold subject to the understanding that if any defect in manufacture or material shall appear within 12 months from date of consumer sale ,if any defect in main parts over 12 months, the warranty period is subject to country Consumer Law , Our Service will arrange for such defect to be rectified without change under the following warranty items and conditions.

Warranty Terms and Conditions

• The defect is not due to use of the product for other than domestic purposes , or an incorrect voltage, or use of improper accessories, or contrary to operating instructions ,or to accidental damage, misuse, neglect or inexpert repair, or incorrect installation, or the product is excessively used for improper purposes other than daily consumption, or accessories belonging to the product ,transportation.
• Thank you for choosing our products. Please feel free to give your precious suggestions, we will make efforts to perfect our products and service.

Warranty period from the purchase date

1. One year warranty for welding and cutting machine.
2. months warranty for welding accessories.
3. The warranty does not cover faults resulting from operation careless handing or not following instructions.
4. Please register your after-sales service information in the following way to obtain the services and benefits you deserve.

• Customer service: service@mirthtek.com
• WhatsApp :+86 18938887689

References

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