AWT MIG-140 Inverter Welding Machine

1. Packing

The following items are included in the package:

• 1. MIG Welder
• 2. MIG Torch With 6.6ft (2m) cable
• 3. Ground clamp with 10ft (3m) cable
• 4. Electrode holder with 10ft (3m) cable
• 5. .030"/2lbs Flux Cored Wire
• 6. Brush/hammer
• 7. Knurl Groove Drive Roller: .030”/.035" (pre-installed on the machine)
• 8. Contact tip: .030” & .035"
• 9. Nozzle
• 10. Glove
• 11. Mask

2. Safety Precautions - Read Before Using

Protect yourself and others from injury. Read, follow, and save these important safety precautions and operating instructions.

2.1 Symbol Usage

DANGER! Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

WARNING! Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

NOTICE – Indicates statements not related to personal injury.

2.2 Arc Welding Hazards

Welding can be dangerous. Read and understand this manual before using the AWT welding machine. Injury or death can occur if safe welding practices are not followed. The symbols below are used throughout this manual to call attention to possible hazards. Watch out and follow the related instructions to avoid the hazard.

ELECTRIC SHOCK CAN KILL

• The electrode and work (or ground) circuits are electrically "hot" when the welder is on. Do not touch these "hot" parts with bare skin or wet clothing.
• Always wear dry, protective clothing and leather welding gloves and insulated footwear. Use suitable clothing made from durable flame-resistant material.
• Always operate the Welder in a clean, dry, well-ventilated area. Do not operate in humid, wet, rainy, or poorly ventilated areas.
• Do not touch live electrical parts.
• Disconnect the welder from the power supply before assembly, disassembly, or maintenance of the torch, contact tip, and when installing or removing nozzles.
• Frequently inspect the input power cord and ground conductor for damage or bare wiring. Replace immediately if damaged, as bare wiring can kill.
• Ensure the work piece is properly supported and grounded before beginning an electric welding operation.
• Always attach the Ground Clamp to the piece to be welded and as close to the weld area as possible for least resistance and best weld.

Fumes And Gases Can Be Hazardous

• Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes.
• Work in a confined space only if it is well-ventilated, or while wearing an air-supplied respirator.
• Do not weld in locations near degreasing, cleaning, or spraying operations, as the heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
• Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel.

Arc Rays Can Burn Eyes And Skin

• Arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
• Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks.
• Wear approved safety glasses with side shields under your helmet.
• Use protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc.
• Wear body protection made from durable, flame-resistant material (leather, heavy cotton, wool). This includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

Welding And Cutting Sparks Can Cause Fire Or Explosion

• Electric welding produces sparks which can ignite flammable or explosive vapors and materials.
• DO NOT operate the welder in areas where flammable or explosive vapors are present.
• DO NOT use near combustible surfaces. Remove all flammable items from the work area where welding sparks can reach (minimum of 35 feet).
• Always keep a fire extinguisher nearby while welding.
• Use welding blankets to protect painted and/or flammable surfaces.
• Ensure the power supply has properly rated wiring to handle power usage.

ELECTROMAGNETIC FIELDS CAN BE A HEALTH HAZARD!

• The electromagnetic field generated during arc welding may interfere with electrical and electronic devices such as cardiac pacemakers. Anyone using such devices should consult their physician prior to performing any electric welding operations.
• Exposure to electromagnetic fields while welding may have other health effects which are not known.

FLYING METAL or DIRT can injure eyes.

• Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
• Wear approved safety glasses with side shields even under your welding helmet.

Hot Parts Can Burn

• Do not touch hot parts bare-handed.
• Allow a cooling period before working on equipment.
• To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

Buildup Of Gas Can Injure Or Kill.

• Shut off compressed gas supply when not in use.
• Always ventilate confined spaces or use an approved air-supplied respirator.

CAUTION: INADEQUATE WIRING CAN CAUSE FIRE AND INJURY!

• Verify that the facility power source has properly rated wiring to handle power requirements of this Welder.

3. Product Description

3.1 How To Use This Manual

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

3.2 Receipt of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect it for possible shipping damage. If there is any damage, notify the carrier immediately to file a claim. Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging the equipment when un-crating.

3.3 Description

This MIG140 simplifies welding with its SYNERGIC SET function, allowing users to weld like a Pro with no previous experience necessary.

3.4 Duty Cycle

The rated Duty Cycle refers to the amount of welding that can be done within a specific time. The AWT MIG-140 has a duty cycle of 25% at 120 Amps for 110 Volts. This means that in a 10-minute block, you can weld for 2.5 minutes and require 7.5 minutes of cooling. If the Duty Cycle is exceeded, the Welder will automatically shut off, but the fan will continue running to cool the components. Once a safe temperature is reached, the Welder will automatically switch back on. To increase the duty cycle, you can turn down the Voltage Output control.

3.5 Technical Specifications

4. Installation

Read the entire installation section before starting.

Safety Precautions

WARNING: ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.
• Disconnect input power by removing the plug from the receptacle before working inside the MIG-140. Allow the machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
• Always connect the MIG-140 to a power supply grounded according to the National Electrical Code and local codes.

Select Suitable Location

This machine can operate in harsh environments. However, it is important that simple preventative measures are followed to assure long life and reliable operation:

• Do not use this machine for pipe thawing.
• This machine must be located where there is free circulation of clean air without restrictions for air movement to and from the air vents. Do not cover the machine with paper, cloth, or rags when switched on.
• Keep dirt and dust that can be drawn into the machine to a minimum.
• This machine has a protection rating of IP21S. Keep it dry when possible and do not place it on wet ground or in puddles.
• Locate the machine away from radio-controlled machinery. Normal operation may adversely affect the operation of nearby radio-controlled machinery, which may result in injury or equipment damage. Read the section on electromagnetic compatibility in this manual.
• Do not operate in areas with an ambient temperature greater than 40°C.

Stacking

The Invertec MIG-140 cannot be stacked.

Tilting

Place the machine directly on a secure, level surface. Do not place or operate this machine on a surface with an incline greater than 15° from horizontal. The machine may topple over if this procedure is not followed.

Input Connections

WARNING: ELECTRIC SHOCK can kill.

• Have a qualified electrician install and service this equipment.
• Disconnect input power by removing the plug from the receptacle before working inside the MIG-140. Allow the machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment.
• Do not touch electrically live parts.

Ground Connection

The frame of the welder must be grounded. A ground terminal marked with the ☷ symbol is located on the under panel for this purpose. See your local and national electrical codes for proper grounding methods.

CAUTION: A grounding conductor is supplied in the input cord; it is important that the supply receptacle ground is connected.

WARNING: This installation should be performed by a qualified electrician to ensure correct connections of the leads to the plug spades.

• The electrical system must be made by skilled technicians with the specific professional and technical qualifications and in compliance with the regulations in force in the country where the equipment is installed.
• The welding power source supply cable is provided with a green or yellow/green wire that must ALWAYS be earthed. This green or yellow/green wire must NEVER be used with other voltage conductors.
• Install only plugs that conform with safety regulations.

Input Power Connection

Check the input voltage, phase, and frequency supplied to this machine before turning it on. The allowable input voltage is indicated in the technical specification section of this manual and on the rating plate of the machine. Be sure that the machine is grounded. Make sure the power available at the input connection is adequate for normal operation of the machine.

Output Connections

A quick disconnect system using Twist-Mate cable plugs is used for the welding cable connections. Refer to the following sections for more information on connecting the machine for operation of flux-core welding, stick welding (MMA).

WARNING: ELECTRIC SHOCK can kill.

• Keep the electrode holder and cable insulation in good condition.
• Do not touch electrically live parts or electrode with skin or wet clothing.
• Insulate yourself from work and ground.
• Turn the input line Switch on the MIG-140 "off" before connecting or disconnecting output cables or other equipment.

4.1 Installation and Setup For MIG with Gas less

1. Ensure that the power switch is "OFF".
2. Connect the weld power cable and tighten it.
3. Connect the earth clamp into the Positive socket(+) and tighten it. IMPORTANT: Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal. Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.
4. Select a suitable wire according to the process being used (W knurled drive roller for gasless flux-cored welding). The wire diameter must be matched to the drive roller and contact tip.
5. Place the Wire Spool onto the Spool Holder. Note: the spool retaining nut is a top thread. Snip the wire from the spool, being sure to hold the wire to prevent rapid uncoiling. Feed the wire into the wire feeder inlet guide tube through to the drive roller.
6. Carefully feed the wire over the drive roller into the outlet guide tube, feed through about 150mm into.
7. Align the wire into the groove of the drive roller and close down the top roller, making sure the wire is in the groove of the bottom drive roller. Lock the pressure arm into place.
8. Apply a light amount of pressure to the drive roller. Too much pressure will crush the cored wire.
9. Remove the gas nozzle and contact tip from the torch neck.
10. Switch the power source to "ON".
11. Press and hold the MIG Torch switch to feed the wire through to the torch neck.
12. Fit the correct sized contact tip and feed the wire through it. Screw the contact tip into the tip holder of the torch head and nip it up tightly. Screw the nozzle to the torch head.
13. Screw the nozzle to the torch head. Use pliers to cut the wire to about 10mm.

Note:

• Flux core / Gas less wire not used for a long time (more than 3 days) needs to be stored sealed.
• The recommended electrode for the flux-cord, self-shielded process are 0.8 or 0.9mm diameter spools.
• Flux-cord wire is excellent for single-pass lap, fillet, and butt welding of thin-gauged galvanized and mild steels.

Wire Loading and Threading

• Turn the machine power switch to the OFF 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.

Installation of Wire Spool

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.

Wire Threading Details

1. 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.
2. 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 8.
3. Cut the bent portion of wire off and straighten the first 4" (100 mm).
4. Thread the wire through the incoming guide tube, over the drive roll, and into the gun liner.
5. Close the idle roll arm and turn down the thumbscrew until the idle roller presses down firmly on the wire. Make sure the wire is positioned in the groove of the lower drive roll.
6. The spring-loaded thumbscrew on the idle roll arm adjusts the pressure on the wire. Adjust 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 wire, the pressure should be increased until the wire feeds properly.

Warning: When feeding the welding wire through the gun, the drive roll, the gun connector block, and the gun contact tip are always energized relative to work and ground.

Wire Stick Out

1. Remove the contact tip and nozzle from the gun.
2. Turn the machine ON.
3. Straighten the gun cable assembly.
4. Depress the gun trigger switch and feed welding wire through the gun and cable. (Point the gun away from yourself and others while feeding wire). Release the gun trigger after wire appears at the end of the gun.
5. Turn off the machine.
6. Install the nozzle and contact tip. Cut the wire off so the 3/8" to 5/8" (10-15mm) protrudes from the end of the tip.
7. Turn on the machine. The machine is now ready to weld.

Stick Welding (MMA)

1. Ensure that the power switch is "OFF".
2. A primary power supply cable is available for this welding machine. Connect the power supply cable to the rated input power.
3. The primary cable should be tightly connected to the correct socket to avoid oxidization.
4. Check whether the voltage value varies in an acceptable range with a multi-meter.
5. Insert the cable plug with electrode holder into the "+" socket on the front panel of the welding machine, and tighten it clockwise.
6. Insert the cable plug with earth clamp into the "-" socket on the front panel of the welding machine, and tighten it clockwise.
7. Insert the electrode to be used into the electrode holder.
8. Connect the ground clamp to a clean bare metal surface of the part to be welded.
9. Turn on the power switch at the back panel of the welder.
10. The welder is now ready to use.

5. Operation

Safety Precautions

Read entire operation section before operating the WIRE FEEDER WELDER.

WARNING: ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from the breathing zone.

WELDING SPARKS can cause fire or explosion

• Keep flammable material away.
• Do not weld on closed containers.

ARC RAYS can burn eyes and skin.

• Wear eye, ear, and body protection.

Observe all safety information throughout this manual.

Product Description (Product Capabilities)

This small portable wire feed welder is capable of flux-cored (FCAW) welding on steel, mild steel, and stainless steel. The wire feed welder is also capable of STICK welding (SMAW).

Self Shielding Flux-cored Welding does not require a separate shielding gas to protect the weld since the welding wire has special additives known as flux to protect the weld until it cools. Flux-cored welding is ideal for medium to thicker material and if welding on painted or rusty steel. Flux-cored welding is also ideal in outdoor applications where windy conditions might blow the MIG shielding gas away from the weld. Flux-cored welding produces a good looking weld but does not produce an excellent weld appearance as MIG welding does.

Controls and Operational Features

Front Panel Controls:

1. Current Display
2. Voltage Adjustment
3. Amp/Wire Feed Knob
4. Welding Mode Selection
5. Power Light
6. Over Heating Protection Indication
7. MIG Gun Socket
8. Positive Output Terminal
9. Negative Output Terminal

Rear Panel Controls:

10. Input Power Cable
11. Power Switch
12. Cooling Fan
13. Rating Plate

Note:

• The 'protection indicator light' will come on if the duty cycle is exceeded. It shows that the inner temperature is over the permitted level; the machine should be stopped being used to allow it to cool down. Welding can continue after the 'protection indicator light' is off.
• The power source should be switched off when not in use.
• Welders should wear protective clothing and welding helmet to prevent injury from arc and thermal radiation.
• To prevent others from being affected by the welding arc, it is recommended to use shielding.
• Do not weld near flammable or explosive materials.

Front Panel Controls Explained

1. Power Light: The Power indicator will not illuminate when the power source is on. It will be on when the torch switch is triggered.
2. Protection Indicator: This indicator will turn on when the machine is overheated or over-current. When the indicator turns off, normal operation is resumed.
3. Mode switch For switching welding mode: .030"Flux-core Wire / .035"Flux-core Wire / Stick Welding
4. Voltage Knob: Use this dial to adjust the arc voltage or "heat" of your welder (low to high). Different materials and material thickness will require different voltage settings. You will need to adjust your voltage accordingly for different welding conditions. By properly adjusting your voltage settings and wire feed speed, you will produce clean welds. NOTE: This is a scale, not actual voltage.
5. Amp/WFS knob:
   • MMA: for welding amperage adjustment.
   • Flux-core mode: use this dial to adjust the output current to control the speed at which the welder feeds wire to the gun. The welder comes with synergic MIG control setting. The wire feeding speed will automatically be changed when you adjust the amperage.

6. Amp Display

Display of MMA and Flux-core Amp.

7. SYN light

Synergic mode. The light will turn on when you press and hold button 3 for 3 seconds. Synergic MIG welding, the wire feed speed and Voltage will be auto-fitted by adjusting wire diameter.

MMA Welding

MIG Welding

Welding Getting Started

Work Piece Cleaning Before Welding

The joint to be welded must be clean; remove existing rust, greasy dirt, water, and paint etc.

Flux-core (Gasless) Synergic MIG

• Press and hold button "choose" for 3 seconds to start "synergic" function.
• Press "choose" button on Flux wire .030"/.035".
• The wire feed speed and Voltage will be auto-fitted by adjusting wire diameter.
• Point the wire into the joint to be weld, press down the gun trigger; the wire feeds automatically. The arc is started once the wire is touched the work piece.

Flux-core (Gasless) Manual MIG

• Press "choose" button on Flux wire .030"/.035".
• Adjust the welding current and welding voltage to match the wire being used.
• Point the wire into the joint to be weld, press down the gun trigger; the wire feeds automatically. The arc is started once the wire is touched the work piece.

MMA/Stick Welding

• Connect the Electrode lead to the (+) output terminal on the front of the machine.
• Connect the work clamp lead to the (-) output terminal on the front of the machine.
• Press "choose" button on MMA.
• Adjust the welding current.
• Take up the electrode holder, install the electrode-point the electrode into the joint to be welded, scratch the work piece to start the arc.

6. Maintenance

Safety Precautions

WARNING: ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.
• Turn the input power off at the fuse box, disconnect supply lines, and allow the machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment.
• Do not touch electrically hot parts.

WARNING: Do not open this machine and do not introduce anything into its openings. Power supply must be disconnected from the machine before each maintenance and service. After each repair, perform proper tests to ensure safety.

CAUTION: Power supply must be disconnected from the machine before each maintenance and service. Always use gloves in compliance with the safety standards.

Input Filter Capacitor Discharge Procedure

WARNING: The machine has internal capacitors which are charged to a high voltage during power-on conditions. This voltage is dangerous and must be discharged before the machine can be serviced. Discharging is done automatically by the machine each time the power is switched off. However, you must allow the machine to sit for at least 5 minutes to allow time for the process to take place.

Routine Maintenance

The frequency of the maintenance operations may vary in accordance with the working environment. Any noticeable damage should be reported immediately.

• Check cables and connections integrity. Replace, if necessary.
• Clean the power source inside by means of low-pressure compressed air.
• Keep the machine clean. Use a soft dry cloth to clean the external case, especially the airflow inlet/outlet louvers.

7. Troubleshooting

How to Use Troubleshooting Guide

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. Locate Problem (Symptom).

Look under the column labeled "PROBLEM (SYMPTOMS)". This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. Possible Cause.

The second column labeled "POSSIBLE CAUSE" lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. Recommended Course of Action

This column provides a course of action for the Possible Cause.

Troubleshooting Guide

Troubleshooting

8. Circuit Diagram

A detailed circuit diagram of the AWT MIG-140 is provided for reference.