MigSonic 145
Contents
1. 2 m ali ICT dA 5 Ze Cylinder Figure 2 2 Page 9 2 3 installing welding torch Correct Incorrect Figure 2 3 1 Gun Securing Knob 2 Gun End Loose knob Insert gun end through opening until it bottoms against drive assembly Tighten knob 3 Gun Trigger connector Insert into receptacle and tighten Close door Page 10 2 4 Ground cable installation Figure 2 4 1 Ground cable 2 Output Terminal Block 3 Insert ground cable through opening in front panel and route along back of front panel to output terminal block Close door 2 5 Process Polarity Table Cable Connections Polarity Cable To Gun Cable To Work GMAW Solid wire Reverse Connect to positive output Connect to negative output with shielding gas polarity terminal terminal FCAW Self shielding Straight Connect to negative output Connect to positive output wire no shielding gas Polarity terminal terminal Table 2 2 2 6 Install procedure 2 6 1 Welding machine should be installed in a stable position and with good ventilation Avoid direct sun outdoors Use forklift to move avoid transport in invert or side position 2 6 2 Be sure machine is well grounded Connect the bolt marked earth with earth in network then connect to network firmly 2 6 3 Before starting a new machine or the machine idled for a period check the insulation resist2. zT puase 230V e P Process MIG GMAW Flux cored FCAW Arc Welding Power Source and Wire Feeder Machine Number Where Purchase Date of purchased MIGSONIC145 OWNER S MANUAL www Weldking com Table of Contents SECTION 1 SAFETY PRECAUTIONS ee 1 SECTION 1 CONSIGNES DE SECURITE 1 1 1 dn USIJE en ees ean eee 1 Symboles utilises oo 1 1 2 Arc welding Hazards 1 Dangers relatifs au soudage l arc 1 1 3 Safety Standards Normes de s curit 6 1 4 EMF Information EMF Information 6 SECTION 2 INSTALLATIONS ute m iei tits e E tee 7 2 1 Welding power source specifications 7 2 2 Connection diagram 8 2 3 installing welding torch 10 2 4 Ground cable installation 11 2 5 Process Polarity oot edet eb ca 11 2 6 Install geen EE 11 2 7 ElIeclnic serviceguldgen ue ete 12 2 8 Extension Cable Selection Chart 13 SECTION 3 OPERATION 14 3 1 Front panel Ee UE 14 3 2 Opberatlon ee 15 3 3 Vol
3. Nozzle Self Insulated 21 37F BN Nozzle Self Insulated 21 62F Nozzle Self Shielding LA8201 Contact Tips ITEM DESCRIPTION ORDER NO a Contact 0 023 0 6 11 23 Page 29 Contact Tip 0 030 0 8mm Ecu 11 30 Contact Tip 0 035 0 9mm Ecu 11 35 4 ip O Es Contact 0 040 1 0mm Ecu 11 40 Contact Tip 0 045 1 2mm Ecu 11 45 Liners ITEM DESCRIPTION ORDER NO Steel Liner 0 030 0 035 0 8 0 9mm X15ft 42 3545 15 N EM Teflon Liner 0 030 0 035 0 8 0 9mm X15ft 42T 3035 15 EL M Default Component ae RN ae ET _ Page 30 NOTES WELDKING MIGSONIC145 Page 31 FF oOo GT T m m DG GT GT GT m m m m m m m m m A a va va ZE KE 4 Kga xem sam sum SSeS Sal Sal SECTION7 WARRANTY POLICY Malo Welding Products Ltd Warranty Policy Effective August 1 2004 revision at April 1 2011 LIMITED WARRANTY Subject to the terms and conditions below Malo Welding Products Ltd WELDKING endeavors to provide high quality products and product support to its customers and therefore backs up all of its new products purchased from Malo Welding Products Ltd WELDKING or any authorized Malo Welding Products Ltd WELDKING distributor service center after the effective date of this limited warranty and is free of defects in material and workmanship
4. Extension cord 14 AWG Extension length 8m with 14AWG 12 AWG for up to 10 m Page 12 MigSonic145 input voltage W Input Amperes at rated output A Max recommended standard fuse Rating in Amperes Circuit breaker time delay Normal operation Min input conductor size in AWG ra Min Grounding conductor Size in AWG Table 2 3 2 8 Extension Cable Selection Chart 44 CAUTION USE SHORTEST CABLE POSSIBLE Input Conductor Size in Maximum Cord Length allowed in Ft M AWG mm 14 2 08 23 7 56 17 Table 2 2 Page 13 SECTION 3 OPERATION 3 1 Front panel Layout WELD KING Mason i AMP 145 90 VOLT eu E 7EBH DUTY CYCLE 6095 OCW eeu m fe eee P WELTHNMG TORCH bw 1 Power indicator 2 welding current adjust knob 3 Over heat protection indicator 4 Torch terminal Acre vem Sra ep 199 2 130 PROTECT JON WIRE FEED POWER 18 18 5 17 5 19 19 5 16 5 oo OFF 16 20 5 POWER VOLTAGE Gent d K CONTROL Figure 3 1 5 Control receptacle 6 Earth clamp 7 Main switch 8 Voltage adjust knob Page 14 3 2 3 2 1 3 2 2 3 2 3 3 2 4 3 2 5 3 2 6 3 2 3 2 8 Operation Check the connection of work piece earth cable welding torch wire feeder gas cylinder regulator and hose make sure they are firm and reliable Install the wire spool to the wire spool spin sele
5. at the time it is shipped THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE OF THE MALO WELDING PRODUCTS LTD WELDKING WARRANTY MALO WELDING PRODUCTS LTD WELDKING DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED REGARDING THE PRODUCTS INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR NONINFRINGEMENT IN THE UNITED STATES SOME STATES DO NOT ALLOW THE EXCLUSION OF THE IMPLIED WARRANTIES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU Malo Welding Products Ltd WELDKING shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor 1 3 Years Parts and Labor Power Sources Wire Feeders 2 90 Days Parts No Labor Guns Remote Controls Accessory Kits Replacement Parts No labor Malo Welding Products Ltd WELDKING Y s limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 All limited warranties are void for and Malo Welding Products Ltd WeldKing does not warrant in any way any product that evidences misapplication improper installation abuse lack of maintenance negligence
6. bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur Utiliser les quipements corrects les bonnes proc dures et suffisamment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit FALLING UNIT can cause injury LA CHUTE DE L APPAREIL peut blesser Use lifting eye to lift unit only NOT running gear gas oylinders or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit Utiliser l anneau de levage uniqueme
7. in use or care abnormal use alteration of design use of incompatible or corrosive chemicals and or servicing installation of parts or repairs by anyone other than Malo Welding Products Ltd WELDKING or a Malo Welding Products Ltd WELDKING authorized distributor or service center Malo Welding Products Ltd WELDKING may make changes in products it manufactures and markets at any time these changes are made without obligation to change retrofit or upgrade any product previously sold or manufactured MALO WELDING PRODUCTS LTD WELDKING JS PRODUCTS ARE FOR COMMERCIAL INDUSTRIAL USE AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING PLASMA CUTTING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Malo Welding Products Ltd WELDKING s option 1 repair or 2 replacement or where authorized in writing by Malo Welding Products Ltd WELDKING in appropriate cases 3 the reasonable cost of repair or replacement at an authorized service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense No compensation or reimbursement for transportation costs of any kind will be allowed LIMITATION OF DAMAGES THE REMEDY OF REPLACEMENT OR REPAIR OF ANY DEFECTIVE GOODS SHALL BE THE EXCLUSIVE REMEDY UNDER ANY WARRANTY MADE
8. souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC a fil tension constante est recommand e En outre ne pas travailler seul Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec
9. BY MALO WELDING PRODUCTS LTD WELDKING WHETHER EXPRESS OR IMPLIED IN NO EVENT SHALL MALO WELDING PRODUCTS LTD WELDKING BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES PROPERTY DAMAGES OR PERSONAL INJURIES ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MALO WELDING PRODUCTS LTD WELDKING IS EXCLUDED AND DISCLAIMED BY MALO WELDING PRODUCTS LTD WELDKING If any provision or portion of this limited warranty policy is found to be unenforceable then the remaining provisions and portions shall remain valid and enforceable If any provision or portion of this limited warranty policy is found to be limited by law then that provision or portion shall be construed to make it effective within the bounds of law To obtain warranty service you must active your product s s warranty online at weldking com or mail the product registration card included in the package to Malo Welding Products Ltd WELDKING right after the purchase When there is a warranty issue return the defective welding machine or plasma cutting machine along w
10. Consulter les symboles et les instructions afferents ci dessous concernant les mesures a prendre pour supprimer les dangers Dangers relatifs au soudage a The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard Only qualified persons should service test maintain and re pair this unit During servicing keep everybody especially children away Les symboles repr sent s ci dessous sont utilis s dans ce manuelpour attirer l attention et identifier les dangers possibles Enpr sence de l un de ces symboles prendre garde suivre lesinstructions aff rentes pour viter tout risque Les instructions enmatiere de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus completes fournies dans les normes de s curit num r es dans la Section 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonctionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil ELECTRIC SHOCK can kill UNE D CHARGE ELECTRIQUE entrainer la mort Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself fr
11. ance of circuit which is connected to the network The resistance must be higher than 2 5M Q otherwise the machine must be dried 2 6 4 Connect torch earth cable wire regulator cylinder according to connection diagram Note Connection hardware must be tightened with proper tools Do not just hands tighten hardware A loose electrical connection will cause poor weld performance and excessive heating at the terminal Page 11 block 2 6 5 Use 8 heat resistant PVC hose connect the flow meter with the gas connection nipple at rear of the machine 2 6 6 Install wire spool 4 in 100mm wire spool 8 gt A hS a Figure 2 5 8 in 200mm wire spool de d 2 L e O Figure 2 6 Commission the machine after the machine is installed and tested Release the pressure roller the wire feeder push the torch switch and adjust voltage switch from low to high Open circuit voltage should rise Evenly adjust the current knob the wire feed speed should increase evenly 2 7 Electric service guide CAUTION WARNING THIS WELDING MACHINE MUST BE CONNECTED TO POWER SOURCE IN ACCORDANCE WITH APPLICABLE ELECTRICAL CODES AVERTISSEMENT LE RACCORDEMENT DE CETTE MACHINE DE SOUDAGE A L ALIMENTATION DOIT ETRE CONFORME AUX CODES D ELECTRICITE PERTINENTS Use 115 volt single phase input 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required
12. champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherch soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website WwWwW csa international org Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to work piece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedu
13. ct correct feeding roller and tip according to the wire diameter Manually put wire into liner Set back the pressure roller with proper pressure Switch on the power source Set the welding voltage switch to proper position and current knob to a start value and refine during welding referring to the voltage wire feeding speed selection chart Turn on the gas valve adjust gas volume to 3 5L MIN Push the torch switch check if wire feed and gas is normal check if there is gas leaking Hold the torch and keep nozzle 8 12mm above the work piece and tilt 10 20 to vertical direction Aim wire to the welding seam Push torch switch after arc is ignited move the torch along seam evenly while keeping the stick out Fine tune the welding parameter to obtain exquisite welding seam Release the torch switch to finish a welding cycle Adjust the crater fill knob located above the polarity stud inside the machine see Figure 3 2 if there is a crater left at the end of the welding seam This knob Adjust current decline time in second after the gun switch is released Crater Adiust S Figure 3 2 After finish operation turn off the gas valve loose the pressure handle at wire feeder push torch switch to clear the residual gas in the regulator At the end turn off welding power source and wall switch Page 15 3 3 Voltage Wire speed selection chart P Wire feed speed 200 19 Voltage WELD KING 3 setting n
14. d to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding machines at the same time since double open circuit voltage will be present Use well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverter disconnect i
15. dio navigation et de communication les services de s curite et les ordinateurs Demander seulement a des personnes qualifi es familiaris es des quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un electrician qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles READ INSTRUCTIONS LIRE LES INSTRUCTIONS Pl Consult the Owner s b Manual for welding safety precautions Use only genuine replacement parts Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil Utiliser uniquement des pi ces de rechange Page 5 1 3 Safety Standards Normes de securite Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com 1 4 EMF Information EMF Information Consideration
16. er des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande 14 d OVERUSE can cause OVERHEATING L EMPLOI EXCESSIF i peut SURCHAUFFER L QUIPEMENT Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste H F RADIATION can cause interference LE SOUDAGE L ARC risque de provoquer des interf rences High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipements de ra
17. ire liner or contact tip jammed Used wrong groove at the feeding roller Can not stop the gas Solenoid valve contaminated Contactor failure Check repair replace Adjust pressure See No 9 Check repair replace circuit board Check 20A Fuse repair replace Clean the workpiece surface Check repair replace Check repair replace Use the right groove Check repair replace solenoid Check replace the contactor Page 19 Wire feeding not stable Power supply switch jump Control board failure Wire out of feeding roller groove Wire feed pressure not set properly Feeding roller deformed Pressure roller deformed Feeding motor failure Current adjust potential meter failure Circuit board plug socket not properly contacted Control circuit failure Welding hose deformed Input voltage fluctuated Rectifier short circuit Main transformer short circuit Control transformer short circuit Solenoid valve short circuit Check repair replace Put wire back Adjust pressure Check and replace Check and replace Check and replace Check and replace Check and repair or replace Check and repair or replace Check and replace Use under rated input voltage Check and replace Check and replace Check and replace Check and replace Page 20 Cooling fan short circuit O
18. ith proof of purchase to any WeldKing Authorized Warranty Depot For the location of the nearest WeldKing Authorized Warranty depot or for service information in the United States or Canada please telephone toll free 1 866 686 5088 or visit www weldking com USA amp Canada available but may vary from province to province Page 32 O A A A A A A a a a a a a a he 1 Sa sa gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt i SECTION 8 AUTHORIZED SERVICE CENTER Please go to our website www weldking com to fill the warranty registration form Malo Welding Products Ltd will not distribute of disclose customer s private information to any third party and Will not sent promotion material to the customer Find your nearest warranty center at http www weldking com servicelocations aspx MALO WELDING PRODUCTS LTD 3275 14th ave Unit A Markham Ontario Canada L3R OH3 Tel 1 866 686 5088 Fax 1866 686 5090 www malowelding com Printed September 13 2010
19. nput power and discharge input capacitors according to instructions in Maintenance Section before touching any parts Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D autres consignes de s curit sont n cessaires dans les conditions suivantes risques lectriques dans un environnement humide ou si porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste
20. nt pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire Utiliser un quipement de levage de capacit suffisante pour lever l appareil En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil MOVING PARTS can cause injury DES ORGANES MOBILES peuvent provoquer des blessures Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power S abstenir de toucher des organes mobiles tells que des ventilateurs Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique Page 4 MOVING PARTS cause injury DES ORGANES MOBILES peuvent provoquer des blessures Keep away from moving parts Keep away from pinch points such as drive rolls Ne pas s approch
21. om work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the following electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoidable or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit 1 voltage In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connecte
22. ot recommended The setting in the following chart is just for start only and be fine tune during welding Material Steel Stainless steel ER308 ER308L ER Wire type Solid ER70S 6 DCEP Flux core E71T 1 DCEN 308L Si DCEP Wire size in 0 d 0 035 0 030 0 035 0 023 0 035 mm 0 9 0 8 0 9mm 0 6 0 9 EN 1 8 3 2mm 810721 280 195 280 195 250195 320215 300 21 14ga 2 0mm 200485 160 85 120185 1004185 230 21 210 20 mmm 16ga 1 6mm 120 175 100175 80 17 5 70175 12019 11048 18ga 1 2mm 80475 70 17 50 17 5 45 17 100 175 90 65 20 0 9mm 60 16 50 455 80 16 5 80 16 22ga 0 8mm 50 15 40 14 24ga 0 6mm 40 13 35 13 MIGSONIC145 Table 3 1 Page 16 SECTION4 TROUBLE SHOOTING a C Bh Power Indication lamp does not Loose contact at input Check contact on after switch on the main switch lead situation Lamp malfunction poor Check contact contact situation Replace lamp Main switch malfunction Check switch replace if necessary Cooling fan stops Power Cooling fan circuit Check fan circuit to rotate after indication malfunction machine has lamp on Cool fan failure Check fan worked a period replace if necessary Power See No 1 indication lamp off No gas flow out Gas pressure not Check gas after pushing the enough pressure gun trigger Poor gas hose Check gas connec
23. r grounded properly necessary Check and clean the oil or other contamination in the feeding roller and feeding tube If the V grooves have worn out change feeding roller immediately to avoid slipping or unstable feeding Table 5 1 Page 22 5 2 Lal 5 22 9 2 3 5 2 4 9 2 5 5 2 6 5 2 7 Safety precaution Welders must be equipped with welding mask gloves and tie the sleeves and collar properly There should be an arc shield around welding field to protect others from arc shock Do not weld near flammable explosive materials or gases Gas cylinder must be located at a safe and steady place to avoid injury others Keep finger hair and clothing away from the rotating fan The power source must be grounded when welding Welding machine should not work in a flammable and toxic environment avoid moisture rain and do not directly expose to sun Periodically maintain the machine and clean the dust inside Page 23 NOTES WELDKING MIGSONIC145 Page 24 SECTION 6 PARTS LIST Table 7 1 Page 25 vw L Figure 7 1 Page 26 Figure 7 2 Page 27 Wire feeder HANWAN 4D 24V Order No 2611017 Figure 7 3 DESCRIPTION ORDER NO QUANTITY Electric Machinery 26110171 Page 28 WeldKing NT1 Mig Torch Order No 07000422 Figure 7 4 Nozzles DESCRIPTION ORDER NO Nozzle Self Insulated 21 37 a ae Nozzle Self Insulated 21 62
24. res is recommended 1 les cables ensemble en les tordant ou en les enveloppant 2 Disposer les cables d un c t et a distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concer ne les sti mulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m decin approuve il est recommand de suivre les proc dures pr c dentes Page 6 SECTION 2 INSTALLATIONS 2 1 Welding power source specifications B Pee mamen e _ Wire feed speed IPM 31 590 0 8 15 m min Wire Diameter MM Steel Stainless Steel Solid 0 6 0 9mm 0 023 0 035in Flux cored 0 8 1 2mm 0 030 0 045in 4 F to 104 F 20 to 40 C Operating temperature 40 F to 185 F 40 C to 40 C Storage temperature Table 2 1 44 CAUTION WELDING LONGER THAN RATED DUTY CYCLE CAN DAMAGE GUN AND VOID WARRANTY Page 7 2 2 Connection diagram MIGSONIC145 115v input Gauge 419 dite Ze m Ar Mixed gas or CO2 Cylinder Power Cord To 115 volt 20 ampere individual branch circuit Torch Figure 2 1 Page 8 MigSonic145 208 230V input d 2
25. s About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de soudage causera des champs lectromagn tiques y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examine plus de 500 tudes qui ont t faites pendant une p riode de recherch de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et
26. strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards e tablir la connexion avec la arrette de terre avant de manipuler des cartes ou des pi ces Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes PC FIRE OR EXPLOSION hazard Risque D INCENDIE OU D EXPLOSION Do not place unit on over or near combustible surfaces e Do not service unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service FLYING METAL can injure eyes DES PARTICULES VOLANTES peuvent blesser les yeux e Wear safety glasses with side shields or face shield during servicing e Be careful not to short metal tools parts or wires together during testing and servicing Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter d
27. tage Wire speed selection 16 SECTION 4 TROUBLE 5 17 SECTION 5S MAINTENANCE 22 5 1 e 22 5 2 SAICIV DrecautloTi E 23 SECTION 6 PARTS BTE m 25 SECTION 7 WARRANTY POLICY sn GR eee ad 32 SECTION 8 AUTHORIZED SERVICE 33 SECTION 1 SECTION 1 1 1 Symbol Usage Symboles utilises Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Symbole graphique d avertissement Attention Cette procedure comporte des risques possibles Les dangers ventuels sont repr sent s par les symboles graphiques joints A Marks a special safety message Indique un message de s curit particulier Means Note not safety related Ls Signifie NOTE n est pas relatif la s curit 1 2 Arc welding Hazards SAFETY PRECAUTIONS CONSIGNES DE S CURIT Ee This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Ce groupe symboles signifie Avertissement Attention Risques d LECTROCUTION ORGANES MOBILES et PARTIES CHAUDES
28. tion connection Gun trigger failure Check gun trigger Solenoid valve failure Check and replace Solenoid valve Gas passage problem Check and repair the gas Page 17 Torch gas hose problem Control circuit failure Control transformer failure Failure of arc to ignite or does not Fuse melt or poor ignite properly contact Main power switch failure Control circuit board failure Welding cable broken or poor contact failure or poor contact Control transformer failure Main transformer failure or poor contact Gas hose not installed Unstable arc Gun trigger wire broken Gun cable broken Voltage adjustment knob properly gas mixed by alr passage Check and repair torch cable Replace circuit board Replace transformer Check and repair Check repair replace Check and repair the circiut board Check the connection Replace cable Replace cable Check repair replace Check repair replace Check repair replace Connect the gas hose firmly Page 18 Wire liner or gun cable broken and leak cause insufficient gas volume Wire pressure not setup properly Wire feed speed not stable Control circuit failure Gas heating failure the work piece surface contaminated by oil Poor contact inside the Arc ignited but the wire does not melt gun Wire does not feed while the feed roller is rotating W
29. to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient number of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association publication P 1 listed in Safety Standards Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normalement artie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les
30. u laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial HOT PARTS can cause severe burns DES PI CES CHAUDES peuvent provoquer des br lures graves Do not touches hot parts bare handed Allow cooling period before working on welding gun or torch e Ne pas toucher des parties chaudes mains nues Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche MAGNETIC FIELDS can affect pacemakers LES CHAMPS MAGNETIQUES peuvent affecter les stimulateurs cardiaques Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations Porteurs de stimulateur cardiaque rester distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Page 3 CYLINDERS can explode if damaged LES BOUTEILLES peuvent exploser si elles sont endommag es Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack
31. un cable distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me Page 2 temps cause de la pr sence d une tension vide doubl e N utiliser qu un mat riel en bon tat ou remplacer sur lechamp les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place Fixer le cable de retour de fa on a obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis pi ce pour viter le contact avec tout objet m tallique Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage reste une TENSION DC NON NEGLIGEABLE dans les sources de soudage onduleur quand on a coupe l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces STATIC ESD can damage boards LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s Put on grounded wrist
32. verheat light on Work excess the rate duty circle Input voltage is too high Table 4 1 Check and replace Use under rate duty circle Use under rate input voltage 21 SECTION 5 MAINTENANCE 5 1 Maintenance Periodic maintenance is necessary for keeping the machine work properly 44 CAUTION DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH BEFORE START OF MAINTENANCE Regular Check and Inspection 6 Month Routine Maintenance e Blow out with dry clean pressure air or vacuum inside machine especially transformer coil and power component e Clean spatter inside the nozzle when continuously use the machine Check liner frequently change if it has been contaminated by oil or worn out Check the electric connection of input output bar to avoid bad contact Check and change broken contact tip caused by loose or rusted screw and nozzle to avoid damage to the torch and machine Check the lubrication of the gear box in the feeder replace or fill lubricates oil if Check the function of all switches Check if the fan rotates properly and if there is air venting out from back of the machine Pay Attention to the abnormal vibration noise smell and gas leakage during operation Check if the welding cables are over heated Check if the cable connections are over heated Check if the cable is connected firmly and properly if it is broken and cause bad insulation e Check the cove
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