Wire Feeding; Earth Connection; Gas Connections; Welding Voltage Adjustment - Welding Industries Malaysia WIM200 Instruction Manual

3.5 Wire Feeding

Release the wire end from reel and cut off the bent wire end, taking care that the wire does not
unwind. Remove the nozzle and contact tip from the welding gun. Straighten about 10cm of the wire
and make sure that the end is as blunt as possible (file off if necessary). A sharp end could damage
the cable liner and the contact tip of the welding torch. Ensure the wire is placed correctly on to the
feed rolls. Thread some wire through the feed rolls into the guide tube and liner of the welding cable.
Close the wire feed pressure arm. The pressure adjustment of the feed rolls must be set so that the
wire is fed evenly into the liner and light restriction of the wire can be made without feed rolls slipping.
Note: Excessive pressure will cause flattening of the wire, loosening of the wire coating and
undue wear of the rolls.

3.6 Earth Connection

The earth connection from the welder should at all times be made directly on to the piece to be
welded. The contact between the earth and the job should be as large and flat as possible. All rust
and paint on the work piece should be removed.
3.7 Gas Connection
Fit hose tail and nut to the gas hose and hold captive with the hose clamp,(found in the wire feed
compartment of the machine adjacent to the wire feed rolls). Connect the gas hose to the regulator,
open the cylinder valve and the gas flow rate is automatically set to 15 liters per minute.
NOTE: PLUG TOP MUST BE FITTED BY A QUALIFIED ELECTRICIAN

3.8 Welding Voltage Adjustment

The welding voltage is regulated by a 6 position switch on the front panel.
WARNING: If the welding voltage is set too high, the weld can burn through light gauge
sheet metal. In this case, the voltage should be reduced. If set too low, the
weld will have little penetration and will just "sit on" the plate.

3.9 Wire Feed Speed

The wire feed speed is regulated from 0-18m/min by the potentiometer dial above the voltage
switch. It is most important to select the wire feed speed in relation to the voltage setting. The
correct wire feed/speed voltage setting is recognizable by:
1. A continuous cracking sound when welding, the characteristics of dip transfer of short-arc
welding method normally used by small-medium sized MIG/MAG welders.
2. A correct shaped weld bead not too high or low with correct fusion along the edge of the
weld, without undercut in the heat affected zone.

3.10 Protection Device

Protection against the effects of overheating is provided by thermal protection devices mounted
on the transformer assembly . In the event of overheating, power to the unit is interrupted,
indicated by a light on the front panel. The protection device automatically resets once the unit
cools.
Note: The fan continues to run during this time.

3.11 SHIELDING GAS

The gas provides a shield over the weld pool to prevent contamination from the surrounding air.
The shield gas also contributes to arc stability, weld strength, and appearance, so care should be
taken to ensure that the correct gas type/mixture is selected for the metal being welded. The gas
flow also provides cooling for the Mig Torch.The gas flow rate is preset by the regulator.
Excessive gas flow rates should be avoided as they are wasteful, and in some instances, can
cause weld porosity.
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posal such as copying and passing on to third parties. Specification may vary from country to country. V1.1.06