SIP Portable MIG Welders Manual

Introduction

This manual provides guidance for operating SIP MIG/MAG/MOG welding units, enabling users to achieve professional finishes in car bodywork and other applications. It details the advantages and processes involved in MIG/MAG/MOG welding.

THE MIG / MAG / MOG WELDING PROCESS

The welder produces a direct current (D.C.) output with a static flat characteristic. An arc is struck between a continuously fed consumable electrode (wire) and the workpiece. Power is supplied by a transformer with a rectified DC output. The wire is fed by a DC drive motor via feed rollers, with current passed through a copper contact tip in the torch nozzle. The wire melts in the arc and transfers to the weld pool as droplets.

MIG/MAG PROCESS

Shielding gas is supplied through the machine and torch, exiting via the shroud to protect the arc and molten metal from air contamination.

MOG PROCESS

This process uses flux-cored wire. When melted, the flux produces a gas that shields the weld pool from air contamination. A flux coating forms on the weld, which can be removed by brushing after cooling.

Both processes offer low heat input, minimizing heat spread and distortion, making them ideal for thin materials.

GUARANTEE

The welder is guaranteed against manufacturing defects for 12 months from purchase. Repairs are free of charge, excluding damage from misuse, lack of maintenance, or tampering. Wear items like torches, tips, shrouds, and liners are not covered. Faulty units must be returned to the place of purchase with the original receipt.

Safety

SAFETY: Before operating, pay close attention to the safety notes.

GENERAL SAFETY

• Electrical repairs must be performed by qualified personnel only, with the unit disconnected from the mains.
• Access to the unit's interior should be restricted to trained personnel. Do not operate with covers removed.
• Ensure the unit is correctly installed as per the "SETTING UP" section.
• A voltage of 18-41V DC is present between the wire (contact tip) and work return lead when the torch switch is pressed. Disconnect from mains before servicing.
• MIG welding units are simple and safe under normal conditions. Exercise caution in unusual environments (e.g., wet, damp, elevated positions, boats, oil rigs). The unit has IP 21 protection and must not be exposed to rain. It is suitable for environments with increased hazard of electric shock; seek professional advice if in doubt.
• Never lift the unit with the gas cylinder mounted on the rear platform. ALWAYS REMOVE THE GAS CYLINDER BEFORE LIFTING.
• The unit can be used on a sloping flat surface up to 15°. If using the optional wheel kit, chock the wheels before tilting.

FIRE SAFETY

• Remove all flammable materials from the welding area.
• DO NOT strike an arc on or near the gas cylinder.
• DO NOT attempt to weld fuel or gas containers until all vapour has been removed. Thoroughly steam cleaning fuel tanks is recommended.

FUMES

Toxic gases are produced during MIG welding. Ensure adequate ventilation, especially in confined areas. Use a fume extractor if necessary.

GLARE

The welding arc emits heat and ultra-violet radiation. Protect eyes with a facesheld or welding helmet fitted with the correct glass filter.

HEAT AND DRESS

Wear welding gloves to protect hands from UV radiation and heat. Wear overalls buttoned at the wrists and neck. For thicker materials, consider a leather apron for spatter protection and a skullcap/scarf for overhead welding. Use industrial footwear.

IMPORTANT INFORMATION

• Do not expose units to rain or snow.
• Do not use in wet or damp environments.
• Do not use for thawing pipes.
• Connect units to the mains supply through a circuit breaker with the following ratings:
  • HANDYMATE: 6 A
  • HANDYMIG: 6 A
  • MIGMATE 105: 6 A
  • MIGMATE 130: 16 A
  • MIGMATE 150: 16 A

Setting up

1) ELECTRICAL

Connect to a suitable socket using a quality three-pin plug or fused isolator. Wiring: BROWN (or red/black) = live, BLUE (or white) = neutral, GREEN/YELLOW (or green) = earth/ground. This appliance MUST BE EARTHED/GROUNDED.

2) FEEDING THE WIRE

To feed wire through the torch or fit a new reel:

• Remove the shroud and unscrew the contact tip.
• Fit the wire reel onto the spindle. The welder accepts 0.225-0.45kg cored wire reels or 0.35-0.70kg solid wire reels. 5kg reels require spacers marked S and Z, and may be available in different widths. Ensure the spring mounting is correctly fitted.
• Locate the wire end on the reel rim, remove it, and cut off any distorted wire, keeping the wire taut on the reel.
• Hinge back the pressure arm and feed the wire end into the liner, ensuring it enters the wire feed mechanism in a straight line.
• Fasten the pressure arm, ensuring the wire sits in the correct groove on the feed roller. The feed roller has grooves for 0.6mm and 0.8mm wire. The roller can be reversed by unscrewing its bracket. Always use the knurled roller for cored wire (gasless operation).

Diagram Description: Visuals show the TORCH, WIRE FEED MECHANISM, and WIRE REEL.

3) SELECTING POLARITY (DUAL PURPOSE MODELS ONLY)

Set torch and work lead polarity correctly for the welding type:

• Solid wire with gas (CO2, Argon, etc.): Torch connection to positive (+), work lead to negative (-).
• Cored wire (gasless operation): Work lead to positive (+), torch connection to negative (-).

Leads can be withdrawn by turning terminals anti-clockwise; refit by turning fully clockwise.

Note: The following setup procedures do not apply to GASLESS MACHINES.

4) FITTING THE GAS CYLINDER MOUNTING BRACKET (WHERE PROVIDED)

Attach the two brackets to the rear of the machine using the provided slots. The bracket with the smaller hole should be mounted at the bottom.

5) CONNECTING THE GAS PIPE

(Also applicable to dual purpose machines using solid wire) Connect the gas pipe to the cylinder regulator by pushing the free end into the connector.

6) FITTING THE GAS REGULATOR AND DISPOSABLE CYLINDER (WHERE PROVIDED)

• Remove the seal from the cylinder thread. PROTECT YOUR EYES. Depress the valve pin slightly to release a small amount of gas; the valve will close automatically when released.
• Connect the gas regulator to the cylinder thread, hand tightening only.
• IMPORTANT: Detach the flowmeter from the cylinder after welding to prevent small leakages that could empty the cylinder over time.

Note: Local regulations may affect the types of regulators supplied.

7) SETTING THE GAS FLOW

Turn the control knob fully clockwise, then back anti-clockwise approximately 1/2 - 1 turn, depending on welding conditions.

8) VOLTAGE SETTING

The machine features 2, 4, or 6 output settings controlled by rocker switch(es) on the front panel (see Fig. A).

Diagram Description (Fig. A): Shows voltage setting configurations: '2 SETTINGS' with HIGH/LOW; '4 SETTINGS' with HIGH/LOW and MIN/MAX; '6 SETTINGS' with HIGH/LOW and MIN/MED/MAX.

WIRE SPEED SETTING

Switching between settings automatically adjusts wire speed and welding output. Select 'LOW' settings for material from 0.6mm to 1.3mm, and 'HIGH' settings for thicker materials. Fine adjustments can be made using 'MAX', 'MED', 'MIN' settings. On 6-setting machines, 'MIN' and 'MED' are enabled only when the 'MAX' switch is depressed upwards.

Note: Wire feed speed is automatically adjusted with output selection; the wire speed control provides fine tuning (see Fig. B).

Diagram Description (Fig. B): A circular dial labeled 'WIRE SPEED SETTING' with 'SLOW' on one side and 'FAST' on the other, indicating adjustment direction.

Starting to weld

BEFORE WELDING ENSURE THAT:

• You have read the safety section of this manual.
• All oil, petrol, and flammable containers have been removed from the area.
• There is good all-round ventilation, particularly at the front and rear of the unit.
• You have an adequate fire-fighting appliance on hand.

Welding Steps:

1. Connect the work earth clamp onto the metal to be welded.
2. Set output and wire feed speed according to material type, thickness, and wire size.
3. Plug in and switch on the machine.
4. Clip off any protruding wire to 3mm (1/8") from the tip.
5. Position the torch tip 6mm (1/4") from the point where welding is to commence.
6. Hold the mask in front of your eyes.
7. Press the trigger. When the arc strikes, move the torch slowly in the chosen direction.
8. Troubleshooting Arc Sounds:
   • Humming sound, blob on wire end: Insufficient wire speed; increase it.
   • Erratic sound, wire stubbing, excessive spatter: Too much wire speed; reduce it.
   • Correct speed: Steady, smooth crackling sound.
   • Porous weld: Insufficient gas flow; increase it.
9. Duty Cycle: The unit has a duty cycle (e.g., 60% means 6 minutes welding and 4 minutes rest in a 10-minute cycle). Exceeding the duty cycle will activate the internal thermal protector, indicated by a yellow lamp. For non-fan cooled machines, switch off to cool. For fan-cooled versions, leave the machine on for faster cooling.

Welding problems

WELDING PROBLEMS AND SOLUTIONS

• Weld deposit "stringy" and Incomplete: Torch moved too quickly, or gas flow incorrect. (Note: Wind can blow off shielding gas, affecting MIG welder performance).
• Weld deposit too thick: Torch moved too slowly, or welding voltage too low.
• Arc unstable, excessive spatter, and weld porosity: Torch too far from workpiece, workpiece contaminated (rust, grease, paint), no gas (check bottle/connections), or incorrect gas for material.
• Wire repeatedly burns back: Torch too close to workpiece, or intermittent break in the welding circuit (e.g., loose/damaged contact tip, incorrect tip size, corroded wire/liner, worn feed rollers, incorrect pressure roller adjustment, sticking pressure roller, or tangled wire).
• Burning holes in the workpiece: Torch moved too slowly or erratically, or welding output too high.
• Lack of penetration: Torch moved too fast, welding output too low, or wire feed speed too low.
• No arc: Check earth clamp connections; check earth lead or torch cable for open circuit.
• Machine does not operate when trigger pressed: Thermal overload cutout active (allow to cool), or check torch trigger/connections.
• Machine does not operate - Mains indicator not lit: Check supply fuse or mains connections.

Maintenance

GENERAL MAINTENANCE ADVICE

• Electrical repairs by qualified personnel only.
• Restrict access to the unit's interior to trained personnel; avoid operating with covers removed.
• Perform all maintenance and repairs with the unit disconnected from the mains.
• When replacing the mains lead, ensure conductors are securely fixed to prevent contact with hot internal parts.

Welding cables

Periodically inspect their connections.

The machine

Requires periodic internal cleaning, more frequently in dirty conditions or for fan-cooled versions. Remove side panel(s) after disconnecting from mains. Blow out with dry clean air, avoiding high-pressure air on sensitive components.

Torch

Clean the contact tip and shroud regularly to remove spatter, which can affect gas flow. Use anti-spatter spray to reduce build-up. Replace the tip regularly for good electrical contact. Avoid kinking the torch or using it to pull the machine. Blow through the liner with dry clean air if wire passage is restricted; replace the liner if necessary.

Spare parts list

Diagram Description: A diagram illustrates the internal components of the welder. Labels indicate: WIRE FEED SPEED CONTROL, MAINS SWITCH, SELECTOR, OUTPUT SOCKETS, MAINS LEAD on the front panel view. Internally, labels point to: FAN MOTOR, PRINTED CIRCUIT, RECTIFIER, TRANSFORMER, CHOKE, GAS BOTTLE BRACKETS, and WIRE FEED UNIT.

Wiring diagrams

Wiring diagrams are provided for different models:

• HANDYMATE: Shows mains switch, thermal protector, capacitor, power transformer, resistor, rectifier, choke, earth clamp, torch button, and wire feeder connections.
• HANDYMIG: Similar to HANDYMATE, includes connections for PCB MIG 05 IPF.
• MIGMATE 105 - 130 - 150: Features mains switch, power transformer with voltage/wire speed selectors (LOW/HIGH, MAX/MED/MIN), wire feeder, choke, earth clamp, torch button, and PCB MIG 05 IPF connections.
• MIGMATE 105 - 130 - 150 DP: A dual-purpose version with similar wiring configurations.

Weights and dimensions

Weights and dimensions for unpacked units are listed below: