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 ........................................................................ 1

SECTION 1 CONSIGNES DE SÉCURITÉ ..................................................................... 1
1-1. Symbol Usage ........................................................................................... 1

Symboles utilisés ...................................................................................................... 1

1-2. Arc welding Hazards................................................................................. 1

Dangers relatifs au soudage à l’arc ......................................................................... 1

1-3. Safety Standards Normes de sécurité .............................................. 6

1-4. EMF Information EMF Information .................................................... 6

SECTION 2 INSTALLATIONS ..................................................................................... 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 Table ........................................................................... 11

2-6. Install procedure..................................................................................... 11

2-7. Electric service guide ............................................................................. 12

2-8. Extension Cable Selection Chart........................................................... 13

SECTION 3 OPERATION ............................................................................................ 14
3-1 Front panel Layout ................................................................................. 14

3-2 Operation................................................................................................. 15

3-3 Voltage/Wire speed selection chart ...................................................... 16

SECTION 4 TROUBLE SHOOTING ............................................................................ 17
SECTION 5 MAINTENANCE ....................................................................................... 22
5.1. Maintenance ............................................................................................ 22

5.2. Safety precaution.................................................................................... 23

SECTION 6 ELECTRICAL DIAGRAMS .................................................................... 24
SECTION 7 PARTS LIST ........................................................................................... 26
SECTION 8 WARRANTY POLICY ............................................................................ 34
SECTION 9 AUTHORIZED SERVICE CENTER........................................................ 35
 SECTION 1 SAFETY PRECAUTIONS
SECTION 1 CONSIGNES DE SÉCURITÉ
1-1. Symbol Usage
Symboles utilisés

Means Warning! Watch Out! There are

possible hazards with this procedure!
The possible hazards are shown in the
adjoining symbols.

This group of symbols means Warning!

Symbole graphique
Watch Out possible ELECTRIC SHOCK,
d’avertissement ! Attention ! Cette
MOVING PARTS, and HOT PARTS hazards.
procedure comporte des risques
Consult symbols and related instructions
possibles ! Les dangers éventuels
below for necessary actions to avoid the
sont représentés par les symboles
hazards
graphiques joints.

Ce groupe de symboles signifie

Marks a special safety message.
Avertissement! Attention! Risques
Indique un message de sécurité particulier d’ÉLECTROCUTION, ORGANES MOBILES
et PARTIES CHAUDES. Consulter les
Means “Note”; not safety related. symboles et les instructions afferents
ci-dessous concernant les mesures à
Signifie NOTE ; n’est pas relatif à la
prendre pour supprimer les dangers.
sécurité.

1-2. Arc welding Hazards

Dangers relatifs au soudage à l’arc

‘ The symbols shown below are used ELECTRIC SHOCK can

throughout this manual to call attention kill.
to and identify possible hazards. When
you see the symbol, watch out, and UNE DÉCHARGE
follow the related instructions to avoid ÉLECTRIQUE entraîner
the hazard. la mort.
‘ Only qualified persons should service, y Do not touch live electrical parts.
test, maintain, and re- pair this unit. y Wear dry, hole-free insulating gloves and
body protection.
‘ During servicing, keep everybody,
especially children, away y Insulate yourself from work and ground
using dry insulating mats or covers big
enough to prevent any physical contact with
‘ Les symboles représentés ci-dessous the work or ground.
sont utilisés dans ce manuelpour attirer y Do not use AC output in damp areas, if
l’attention et identifier les dangers movement is confined, or if there is a
possibles. Enprésence de l’un de ces danger of falling.
symboles, prendre garde et suivre y Use AC output ONLY if required for the
lesinstructions afférentes pour éviter welding process.
tout risque. Les instructions enmatière
y If AC output is required, use remote output
de sécurité indiquées ci-dessous ne
control if present on unit.
constituent qu’un sommaire des
instructions de sécurité plus complètes y Additional safety precautions are required
fournies dans les normes de sécurité when any of the following electrically
énumérées dans la Section 2-5. Lire et hazardous conditions are present: in damp
observer toutes les normes de sécurité. locations or while wearing wet clothing; on
metal structures such as floors, gratings, or
‘ Seul un personnel qualifié est autorisé à
scaffolds; when in cramped positions such
installer, faire fonctionner, entretenir et
as sitting, kneeling, or lying; or when there
réparer cet appareil.
is a high risk of unavoidable or accidental
‘ Pendant le fonctionnement, maintenir à contact with the workpiece or ground. For
distance toutes les personnes, these conditions, use the following
notamment les enfants de l’appareil. 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

Page 1
 voltage. In most situations, use of a DC, utilisant des housses ou des tapis assez
constant voltage wire welder is grands afin d’éviter tout contact physique
recommended. And, do not work alone! avec la pièce à couper ou le sol.
y Disconnect input power or stop engine y Ne pas se servir de source électrique à
before installing or servicing this equipment. courant électrique dans les zones humides,
Lockout/tagout input power according to dans les endroits confinés ou là où on
OSHA 29 CFR 1910.147 (see Safety risque de tomber.
Standards). y Se servir d’une source électrique à courant
y Properly install and ground this equipment électrique UNIQUEMENT si le procédé de
according to its Owner’s Manual and soudage le demande.
national, state, and local codes. y Si l’utilisation d’une source électrique à
y Always verify the supply ground − check courant électrique s’avère nécessaire, se
and be sure that input power cord ground servir de la fonction de télécommande si
wire is properly connected to ground l’appareil en est équipé.
terminal in disconnect box or that cord plug y D’autres consignes de sécurité sont
is connected to a properly grounded nécessaires dans les conditions suivantes :
receptacle outlet. risques électriques dans un environnement
y When making input connections, attach humide ou si l’on porte des vêtements
proper grounding conductor first − mouillés ; sur des structures métalliques
double-check connections. telles que sols, grilles ou échafaudages ; en
y Frequently inspect input power cord for position coincée comme assise, à genoux
damage or bare wiring − replace cord ou couchée ; ou s’il y a un risque élevé de
immediately if damaged − bare wiring can contact inévitable ou accidentel avec la
kill. pièce à souder ou le sol. Dans ces
conditions, utiliser les équipements suivants,
y Turn off all equipment when not in use.
dans l’ordre indiqué : 1) un poste à souder
y Do not use worn, damaged, undersized, or DC à tension constante (à fil), 2) un poste à
poorly spliced cables. souder DC manuel (électrode) ou 3) un
y Do not drape cables over your body. poste à souder AC à tension à vide réduite.
y If earth grounding of the workpiece is Dans la plupart des situations, l’utilisation
required, ground it directly with a separate d’un poste à souder DC à fil à tension
cable. constante est recommandée. En outre, ne
pas travailler seul !
y Do not touch electrode if you are in contact
with the work, ground, or another electrode y Couper l’alimentation ou arrêter le moteur
from a different machine. avant de procéder à l’installation, à la
réparation ou à l’entretien de l’appareil.
y Do not touch electrode holders connected
Déverrouiller l’alimentation selon la norme
to two welding machines at the same time OSHA 29 CFR 1910.147 (voir normes de
since double open-circuit voltage will be
sécurité).
present.
y Installer le poste correctement et le mettre
y Use only well-maintained equipment. à la terre convenablement selon les
Repair or replace damaged parts at once.
consignes du manuel de l’opérateur et les
Maintain unit according to manual.
normes nationales, provinciales et locales.
y Wear a safety harness if working above y Toujours vérifier la terre du cordon
floor level.
d’alimentation. Vérifier et s’assurer que le fil
y Keep all panels and covers securely in de terre du cordon d’alimentation est bien
place. raccordé à la borne de terre du sectionneur
y Clamp work cable with good metal-to-metal ou que la fiche du cordon est raccordée à
contact to workpiece or worktable as near une prise correctement mise à la terre.
the weld as practical. y En effectuant les raccordements d’entrée,
y Insulate work clamp when not connected to fixer d’abord le conducteur de mise à la
workpiece to prevent contact with any metal terre approprié et contre-vérifier les
object. connexions.
y Do not connect more than one electrode or y Vérifier fréquemment le cordon
work cable to any single weld output d’alimentation afin de s’assurer qu’il n’est
terminal. pas altéré ou à nu, le remplacer
immédiatement s’il l’est. Un fil à nu peut
SIGNIFICANT DC VOLTAGE exists entraîner la mort.
after removal of input power on y L’équipement doit être hors tension lorsqu’il
inverters. n’est pas utilisé.
y Turn Off inverter, disconnect input power, y Ne pas utiliser des câbles usés,
and discharge input capacitors according to endommagés, de grosseur insuffisante ou
instructions in Maintenance Section before mal épissés.
touching any parts. y Ne pas enrouler les câbles autour du corps.
y Si la pièce soudée doit être mise à la terre,
le faire directement avec un câble distinct.
y Ne pas toucher aux pièces électriques sous y Ne pas toucher l’électrode quand on est en
tension. contact avec la pièce, la terre ou une
y Porter des gants isolants et des vêtements électrode provenant d’une autre machine.
de protection secs et sans trous. y Ne pas toucher des porte électrodes
y S’isoler de la pièce à couper et du sol en connectés à deux machines en même

Page 2
 temps à cause de la présence d’une y Ne pas surcharger l’installation électrique −
tension à vide doublée. s’assurer que l’alimentation est
y N’utiliser qu’un matériel en bon état. correctement dimensionnée et protégée
Réparer ou remplacer sur-lechamp les avant de mettre l’appareil en service.
pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
FLYING METAL can
y Porter un harnais de sécurité si l’on doit
injure eyes.
travailler au-dessus du sol.
y S’assurer que tous les panneaux et DES PARTICULES
couvercles sont correctement en place. VOLANTES peuvent
y Fixer le câble de retour de façon à obtenir blesser les yeux.
un bon contact métal-métal avec la pièce à y Wear safety glasses with side shields or
souder ou la table de travail, le plus près face shield during servicing.
possible de la soudure.
y Be careful not to short metal tools, parts, or
y Isoler la pince de masse quand pas mis à la wires together during testing and servicing.
pièce pour éviter le contact avec tout objet
métallique.
y Le soudage, l’écaillement, le passage de la
y Ne pas raccorder plus d’une électrode ou
pièce à la brosse en fil de fer, et le meulage
plus d’un câble de masse à une même
génèrent des étincelles et des particules
borne de sortie de soudage.
métalliques volantes. Pendant la période
Il reste une TENSION DC NON de refroidissement des soudures, elles
NÉGLIGEABLE dans les sources de risquent de projeter du laitier.
soudage onduleur quand on a coupe y Porter des lunettes de sécurité avec écrans
latéraux ou un écran facial.
l’alimentation.
y Arrêter les convertisseurs, débrancher le
courant électrique et décharger les
condensateurs d’alimentation selon les
HOT PARTS can cause
instructions indiquées dans la partie severe burns.
Entretien avant de toucher les pièces. DES PIÈCES CHAUDES
peuvent provoquer des
STATIC (ESD) can brûlures graves.
damage PC boards. y Do not touches hot parts bare handed.
LES CHARGES y Allow cooling period before working on
ÉLECTROSTATIQUES welding gun or torch
peuvent endommager
les circuits imprimés. y Ne pas toucher des parties chaudes à
mains nues.
y Put on grounded wrist strap BEFORE
y Prévoir une période de refroidissement
handling boards or parts.
avant d’utiliser le pistolet ou la torche.
y Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MAGNETIC FIELDS can
y Établir la connexion avec la arrette de terre affect pacemakers.
avant de manipuler des cartes ou des
pièces. LES CHAMPS
y Utiliser des pochettes et des boîtes MAGNÉTIQUES
antistatiques pour stocker, déplacer ou peuvent affecter les
expédier des cartes PC. stimulateurs
cardiaques.
FIRE OR EXPLOSION
hazard. y Pacemaker wearers keep away.
y Wearers should consult their doctor
before going near arc welding, gouging,
Risque D’INCENDIE OU or spot welding operations.
D’EXPLOSION. y Porteurs de stimulateur cardiaque, rester
y Do not place unit on, over, or near
y
à distance.
Les porteurs d’un stimulateur cardiaque
combustible surfaces.
doivent d’abord consulter leur médecin
y Do not service unit near flammables avant de s’approcher des opérations de
y Do not overload building wiring − be sure soudage à l’arc, de gougeage ou de
power supply system is properly sized, soudage par points.
rated, and protected to handle this unit.

y Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.
y Ne pas installer l’appareil à proximité de
produits inflammables.

Page 3
 CYLINDERS can explode soupape de la bouteille.
if damaged. y Le couvercle du détendeur doit toujours être
en place, sauf lorsque la bouteille est utilisée
LES BOUTEILLES ou qu’elle est reliée pour usage ultérieur.
peuvent exploser si elles y Utiliser les équipements corrects, les bonnes
sont endommagées. procédures et suffisamment de personnes
Shielding gas cylinders contain gas under high pour soulever et déplacer les bouteilles.
pressure. If damaged, a cylinder can explode. y Lire et suivre les instructions sur les bouteilles
Since gas cylinders are normally part of the de gaz comprimé, l’équipement connexe et le
welding process, be sure to treat them carefully. dépliant P-1 de la CGA (Compressed Gas
y Protect compressed gas cylinders from Association) mentionné dans les principales
excessive heat, mechanical shocks, physical normes de sécurité.
damage, slag, open flames, sparks, and arcs.
y Install cylinders in an upright position by FALLING UNIT can
securing to a stationary support or cylinder cause injury.
rack to prevent falling or tipping.
LA CHUTE DE
y Keep cylinders away from any welding or
other electrical circuits. L’APPAREIL peut
y Never drape a welding torch over a gas blesser.
cylinder. y Use lifting eye to lift unit only, NOT running
y Never allow a welding electrode to touch any gear, gas cylinders, or any other
cylinder. accessories.
y Never weld on a pressurized cylinder − y Use equipment of adequate capacity to lift
explosion will result. and support unit.
y Use only correct shielding gas cylinders, y If using lift forks to move unit, be sure forks
regulators, hoses, and fittings designed for the are long enough to extend beyond opposite
specific application; maintain them and side of unit
associated parts in good condition.
y Turn face away from valve outlet when y Utiliser l’anneau de levage uniquement
opening cylinder valve. pour soulever l’appareil, NON PAS les
y Keep protective cap in place over valve except chariots, les bouteilles de gaz ou tout autre
when cylinder is in use or connected for use. accessoire.
y Use the right equipment, correct procedures, y Utiliser un équipement de levage de
and sufficient number of persons to lift and capacité suffisante pour lever l’appareil.
move cylinders. y En utilisant des fourches de levage pour
y Read and follow instructions on compressed déplacer l’unité, s’assurer que les fourches
gas cylinders, associated equipment, and sont suffisamment longues pour dépasser
Compressed Gas Association (CGA) du côté opposé de l’appareil.
publication P-1 listed in Safety Standards.
MOVING PARTS can
Des bouteilles de gaz protecteur contiennent du cause injury.
gaz sous haute pression. Si une bouteille est
DES ORGANES
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement artie du MOBILES peuvent
procédé de soudage, les manipuler avec provoquer des
précaution. blessures.
y Protéger les bouteilles de gaz comprimé d’une y Keep away from moving parts such as fans.
chaleur excessive, des chocs mécaniques,
y Keep all doors, panels, covers, and guards
des dommages physiques, du laitier, des
closed and securely in place.
flammes ouvertes, des étincelles et des arcs.
y Have only qualified persons remove doors,
y Placer les bouteilles debout en les fixant dans
panels, covers, or guards for maintenance
un support stationnaire ou dans un
as necessary.
porte-bouteilles pour les empêcher de tomber
ou de se renverser. y Reinstall doors, panels, covers, or guards
when maintenance is finished and before
y Tenir les bouteilles éloignées des circuits de
reconnecting input power.
soudage ou autres circuits électriques.
y Ne jamais placer une torche de soudage sur
une bouteille à gaz. y S’abstenir de toucher des organes mobiles
tells que des ventilateurs.
y Une électrode de soudage ne doit jamais
entrer en contact avec une bouteille. y Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
y Ne jamais souder une bouteille pressurisée −
protection.
risque d’explosion.
y Seules des personnes qualifiées sont
y Utiliser seulement des bouteilles de gaz
autorisées à enlever les portes, panneaux,
protecteur, régulateurs, tuyaux et raccords
recouvrements ou dispositifs de protection
convenables pour cette application spécifique ;
pour l’entretien.
les maintenir ainsi que les éléments associés
en bon état. y Remettre les portes, panneaux,
recouvrements ou dispositifs de protection
y Détourner votre visage du
quand l’entretien est terminé et avant de
détendeur-régulateur lorsque vous ouvrez la
rebrancher l’alimentation électrique.

Page 4
 MOVING PARTS can interference problem resulting from the
installation.
cause injury.
y If notified by the FCC about interference,
DES ORGANES stop using the equipment at once.
MOBILES peuvent y Have the installation regularly checked
provoquer des and maintained.
blessures. y Keep high-frequency source doors and
y Keep away from moving parts panels tightly shut, keep spark gaps at
correct setting, and use grounding and
y Keep away from pinch points such as drive
shielding to minimize the possibility of
rolls
interference.

y Ne pas s’approcher des organes mobiles.

y Le rayonnement haute fréquence (HF)
y Ne pas s’approcher des points de peut provoquer des interférences avec les
coincement tels que des rouleaux de équipements de radio-navigation et de
commande. communication, les services de sécurité
et les ordinateurs.
OVERUSE can cause y Demander seulement à des personnes
OVERHEATING. qualifiées familiarisées avec des
équipements électroniques de faire
L’EMPLOI EXCESSIF fonctionner l’installation.
peut SURCHAUFFER y L’utilisateur est tenu de faire corriger
L’ÉQUIPEMENT. rapidement par un electrician qualifié les
ƒ Allow cooling period; follow rated duty interférences résultant de l’installation.
cycle. y Si le FCC signale des interférences,
ƒ Reduce current or reduce duty cycle before arrêter immédiatement l’appareil.
starting to weld again. y Effectuer régulièrement le contrôle et
ƒ Do not block or filter airflow to unit l’entretien de l’installation.
y Maintenir soigneusement fermés les
portes et les panneaux des sources de
ƒ Prévoir une période de refroidissement ; haute fréquence, maintenir les éclateurs à
respecter le cycle opératoire nominal. une distance correcte et utiliser une terre
et un blindage pour réduire les
ƒ Réduire le courant ou le facteur de marche interférences éventuelles.
avant de poursuivre le soudage.

ƒ Ne pas obstruer les passages d’air du

poste. READ INSTRUCTIONS.
LIRE LES
INSTRUCTIONS.
H.F. RADIATION can ƒConsult the Owner’s
cause interference. Manual for welding safety
precautions.
LE SOUDAGE À L’ARC
ƒ Use only genuine replacement parts
risque de provoquer
des interférences.
y High-frequency (H.F.) can interfere with
ƒ Lire le manuel d’utilisation avant d’utiliser
radio navigation, safety services,
ou d’intervenir sur l’appareil.
computers, and communications
equipment. ƒ Utiliser uniquement des pièces de
y Have only qualified persons familiar with rechange.
electronic equipment perform this
installation.
y The user is responsible for having a
qualified electrician promptly correct any

Page 5
 1-3. Safety Standards
Normes de sécurité

Safety in Welding, Cutting, and Allied Processes, Code for Safety in Welding and Cutting, CSA
ANSI Standard Z49.1, from Global Engineering Standard W117.2, from Canadian Standards
Documents (phone: 1-877-413-5184, website: Association, Standards Sales, 178 Rexdale
www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3
(phone: 800−463−6727 or in Toronto
416−747−4044, website:
www.csa−international.org).

Safety in Welding, Cutting, and Allied Processes, Code for Safety in Welding and Cutting, CSA
ANSI Standard Z49.1, de Global Engineering Standard W117.2, de Canadian Standards
Documents (téléphone : 1-877-413-5184, site Association, Standards Sales, 178 Rexdale
Internet : www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3
(téléphone : 800-463-6727 ou à Toronto
416-747-4044, site Internet :
www.csa-international.org).

1-4. EMF Information

EMF Information

Considerations About Welding And The Effects 1. Keep cables close together by twisting or
Of Low Frequency Electric And Magnetic Fields taping them.

Welding current, as it flows through welding 2. Arrange cables to one side and away from the
cables, will cause electro- magnetic fields. There operator.
has been and still is some concern about such
fields. However, after examining more than 500 3. Do not coil or drape cables around your body.
studies spanning 17 years of research, a special
blue ribbon committee of the National Research 4. Keep welding power source and cables as far
Council concluded that: “The body of evidence, in away from operator as practical.
the committee’s judgment, has not demonstrated
that exposure to power- frequency electric and 5. Connect work clamp to work piece as close to
magnetic fields is a human-health hazard.” the weld as possible.
However, studies are still going forth and
evidence continues to be examined. Until the About Pacemakers:
final conclusions of the research are reached,
you may wish to minimize your exposure to
Pacemaker wearers consult your doctor first. If
electromagnetic fields when welding or cutting. cleared by your doctor, then following the above
procedures is recommended
To reduce magnetic fields in the workplace, use
the following procedures:

Considérations sur le soudage et les effets de 1. Maintenir les câbles ensemble en les tordant ou
basse fréquence et des champs magnétiques et en les enveloppant.
électriques.
2. Disposer les câbles d’un côté et à distance de
Le courant de soudage, pendant son passage dans l’opérateur.
les câbles de soudage, causera des champs
électromagnétiques. Il y a eu et il y a encore un 3. Ne pas courber pas et ne pas entourer pas les
certain souci à propos de tels champs. Cependant, câbles autour de votre corps.
après avoir examine plus de 500 études qui ont été
faites pendant une période de recherché de 17 ans, 4. Garder le poste de soudage et les câbles le plus
un comité spécial ruban bleu du National Research loin possible de vous.
Council a conclu : « L’accumulation de preuves,
suivant le jugement du comité, n’a pas démontré 5. Connecter la pince sur la pièce aussi près que
que l’exposition aux champs magnétiques et possible de la soudure.
champs électriques à haute fréquence représente
un risque à la santé humaine ». Toutefois, des En ce qui concer ne les sti mulateurs
études sont toujours en cours et les preuves cardiaques
continuent à être examinées. En attendant que les
conclusions finales de la recherché soient établies, Les porteurs de stimulateur cardiaque doivent
il vous serait souhaitable de réduire votre
consulter leur médecin avant de souder ou
exposition aux champs électromagnétiques
d’approcher des opérations de soudage. Si le
pendant le soudage ou le coupage. médecin approuve, il est recommandé de suivre les
procédures précédentes
Pour réduire les champs magnétiques sur le poste
de travail, appliquer les procédures suivantes :

Page 6
 SECTION 2 INSTALLATIONS
2-1. Welding power source specifications

Type MIGSONIC145

Power supply 115V/60Hz 230V/60Hz

Phase 1

Input current @ Maximum output 20 21

Rated input (Kva) 2.3 4.8

Open circuit voltage(v) 44 44

Amperage range(A) 40-110 40-180

Welding voltage(V) 16-18.5 16-21.3

Rated Duty cycle (%) 60 60

Rated welding current(A) 90 145

Wire feed speed(IPM) 31-590 (0.8-15 m/min)

Dimension(HxWxD)(CM) 52 x25.5 x51

Weight(KG) 20

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

CAUTION
WELDING LONGER THAN RATED DUTY CYCLE CAN DAMAGE GUN AND VOID
WARRANTY.

Page 7
2-2. Connection diagram
MIGSONIC145 (115v input)

Gauge

Cylinder

Power
Cord

To 115 volt, 20 ampere

individual branch circuit

Torch

Figure 2.1

Page 8
MigSonic145(208/230V input)

Gauge

Cylinder

Power
Cord

Torch

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
Process Polarity
Cable To Gun Cable To Work

GMAW－Solid wire DCEP – Reverse Connect to positive(+) output Connect to negative(-)output

with shielding gas polarity terminal terminal

FCAW – Self-shielding DCEN－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 resistance of circuit which is connected to the network. The
resistance must be higher than 2.5M Ω; 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 Ф8 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:

Figure 2.5

8 in (200mm) wire spool:

Figure 2.6

Commission the machine after the machine is installed and tested:

‘ Release the pressure roller in 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 Á

L’ALIMENTATION DOIT ÉTRE CONFORME AUX CODES D’ ÉLECTRICITÉ
PERTINENTS

Use 115 volt single phase input, 20 ampere individual branch circuit protected by
time-delay fuses or circuit breaker is required.

Extension cord: 14 AWG

Extension length: 8m with 14AWG, 12 AWG for up to 10 m.

Page 12
MigSonic145

Input voltage(V) 230

Frequency(Hz) 60

Input Amperes at rated output(A) 24

Max recommended standard fuse Rating in Amperes

Circuit breaker, time delay 25

Normal operation 35

Min input conductor size in AWG 14

Min Grounding conductor Size in AWG 14

Table 2.3

2-8. Extension Cable Selection Chart

CAUTION
USE SHORTEST CABLE POSSIBLE

Input Conductor Size in Maximum Cord Length allowed in Ft(M)

AWG (mm2)

115V 230V

14(2.08) 23(7) 56(17)

12(3.31) 29(9) 90(27)

10(5.26) 43(13) 131(40)

8(8.36) 72(22) 160(50)

6(13.29) 105(32) 243(74)

Table 2.2

Page 13
 SECTION 3 OPERATION

3-1 Front panel Layout 3 1

2

Figure 3.1

1. Power indicator 5. Control receptacle

2. welding current adjust knob 6. Earth clamp

3. Over-heat protection indicator 7. Main switch

4. Torch terminal 8. Voltage adjust knob

Page 14
3-2 Operation
3-2.1 Check the connection of work piece, earth cable, welding torch, wire feeder,
gas cylinder, regulator and hose, make sure they are firm and reliable.

3-2.2 Install the wire spool to the wire spool spin, select correct feeding roller and tip
according to the wire diameter. Manually put wire into liner. Set back the
pressure roller with proper pressure.

3-2.3 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)

3-2.4 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.

3-2.5 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.

3-2.6 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.

3-2.7 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
Adjust(S)

Figure 3.2

3-2.8 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
Wire feed speed 200/19 ∅ Voltage “V”
- : setting not recommended
The setting in the following chart is just for start only and can be fine tune during welding.

MIGSONIC145

Material Steel Stainless steel

ER308,ER308L,ER
Wire type Solid ER70S-6(DCEP) Flux core E71T-1(DCEN)
308LSi(DCEP)
Wire size (in) 0.023” 0.035” 0.030” 0.035” 0.023” 0.035”
(mm) 0.6 0.9 0.8 0.9mm 0.6 0.9
3/16” (4.8mm) - - - 250/19.5 - -
1/8” (3.2mm) 310/21 280/19.5 280/19.5 250/19.5 320/21.5 300/21
14ga. (2.0mm) 200/18.5 160/18.5 120/18.5 100/18.5 230/21 210/20
16ga. (1.6mm) 120/17.5 100/17.5 80/17.5 70/17.5 120/19 110/18
18ga. (1.2mm) 80/17.5 70/17 50/17.5 45/17 100/17.5 90/16.5
20ga. (0.9mm) 60/16 50/15.5 - - 80/16.5 80/16
22ga. (0.8mm) 50/15 40/14 - - - -
24ga. (0.6mm) 40/13 35/13 - - - -

Table 3.1

Page 16
 SECTION 4 TROUBLE SHOOTING

No. Problem Cause Solution

1 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

2 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

3 No gas flow out Gas pressure not Check gas

after pushing the enough pressure
gun trigger
Poor gas hose Check gas
connection 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
 passage

Torch gas hose problem Check and

repair torch
cable

Control circuit failure Replace circuit

board

Control transformer Replace

failure transformer

4 Failure of arc to ignite or does not Fuse melt or poor Check and
ignite properly contact repair

Main power switch Check, repair,

failure replace

Control circuit board Check and

failure repair the circiut
board

Welding cable broken or Check the

poor contact connection

Gun trigger wire broken Replace cable

Gun cable broken Replace cable

Voltage adjustment knob Check, repair,

failure or poor contact replace

Control transformer Check, repair,

failure replace

Main transformer failure Check, repair,

or poor contact replace

5 Unstable arc Gas hose not installed Connect the gas

properly, gas mixed by hose firmly
air

Gas not pure Changes gas

Page 18
 Wire liner or gun cable Check, repair,
broken and leak cause replace
insufficient gas volume.

Wire pressure not setup Adjust pressure

properly

Wire feed speed not See No.9

stable

Control circuit failure Check, repair,

replace circuit
board

Gas heating failure Check 20A

Fuse, repair,
replace

the work piece surface Clean the

contaminated by oil workpiece
surface

Poor contact inside the Check, repair,

gun replace

6 Arc ignited but the wire does not Rectifier tube failure Check, replace
melt
Output reactor failure Check, replace

Output capacitor failure Check, replace

7 Wire does not feed while the feed Wire pressure not proper Adjust pressure
roller is rotating
Wire liner or contact tip Check, repair,
jammed replace

Used wrong groove at Use the right

the feeding roller groove

8 Can not stop the gas Solenoid valve Check, repair,

contaminated replace solenoid

Contactor failure Check, replace

the contactor

Page 19
 Control board failure Check, repair,
replace

9 Wire feeding not stable Wire out of feeding roller Put wire back
groove

Wire feed pressure not Adjust pressure

set properly

Feeding roller deformed Check and

replace

Pressure roller deformed Check and

replace

Feeding motor failure Check and

replace

Current adjust potential Check and

meter failure replace

Circuit board plug socket Check and

not properly contacted repair or replace

Control circuit failure Check and

repair or replace

Welding hose deformed Check and

replace

Input voltage fluctuated Use under rated

input voltage

10 Power supply switch jump Rectifier short circuit Check and

replace

Main transformer short Check and

circuit replace

Control transformer Check and

short circuit replace

Solenoid valve short Check and

circuit replace

Page 20
 Cooling fan short circuit Check and
replace

11 Overheat light on Work excess the rate Use under rate

duty circle duty circle

Input voltage is too high Use under rate

input voltage

Table 4.1

Page 21
 SECTION 5 MAINTENANCE

5.1. Maintenance
Periodic maintenance is necessary for keeping the machine work properly.

CAUTION
DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH
BEFORE START OF MAINTENANCE.

Regular Check and Inspection 6 Month Routine Maintenance

• Clean spatter inside the nozzle when • Blow out with dry clean pressure air or
continuously use the machine. vacuum inside machine, especially
transformer coil and power component.
• 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. necessary.

• Check if the fan rotates properly and if • Check and clean the oil or other
there is air venting out from back of the contamination in the feeding roller and
machine feeding tube. If the V grooves have worn
out change feeding roller immediately to
• Pay Attention to the abnormal vibration, avoid slipping or unstable feeding
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?

• Check the cover grounded properly

Table 5.1

Page 22
5.2. Safety precaution
5.2.1. 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.

5.2.2. Do not weld near flammable, explosive materials or gases.

5.2.3. Gas cylinder must be located at a safe and steady place to avoid injury
others.

5.2.4. Keep finger, hair and clothing away from the rotating fan.

5.2.5. The power source must be grounded when welding.

5.2.6. Welding machine should not work in a flammable and toxic environment,
avoid moisture, rain, and do not directly expose to sun.

5.2.7. Periodically maintain the machine and clean the dust inside.

Page 23
 SECTION 6 ELECTRICAL DIAGRAMS

1
4 2

1
2

CN102-103
S25VB 3
4
POWER SWITCH
3

1 1
5
2 2
6
Port 3 3
1

7 CN107
4 4
8 CN203
5 5
INPUT 115V/230V 9
10
6 6
S2 7 7
4 2
MIG 145 inverter board
Port 8

MIG 145 capacitor board

9

S25VB
3

CN106 CN101 CN202

CN204

1
2
3

1
2
3

1
2
3
4

1
2
3
4
5
6
7
Voltage regulator
2W10K
the input side of transformer
3
2
1

3
2
1

1
2
3

3
2
1
4
3
Current regulator
1
CN104 CN303 CN101 CN118 CN114 2 Port
+
2W1K 1
2 CN111
3

MIG 145 rectifier of board OUT

protect LED 1
2 CN107
MIG 145 control board
3 1
CN110
2 2
CN301 Port
-
1 3
1
POWER LED 2
CN117
CN106 CN105 115 CN308 CN302 CN318
1
2
3

1
2

1
2

1
2

1
2
3
4

1
2
2W10K 3

BURN BACK reg ulator DC 24V

FAN
M
+

-
A

Solenoid thermostat Feed motor gun torch

Figure 6.1

Page 24
 NOTES
WELDKING™ MIGSONIC145

Page 25
 SECTION 7 PARTS LIST

Item Order No. Description Note Quantity

1 Y0161001 Potentiometer WH118 2W 1K carbon film 1

2 Y0161002 Potentiometer WH118 2W 10K carbon film 2

3 B0103030 MIG-200C Control PCB MIG200-KZ-B 1

4 B0100025 MIG-145C Inverter PCB MIG-145C 1

5 Y0701015 Mosfet FMH23N50E 8

6 Y1602003 Solenoid Valve VZCT-2.5 DC24V(copper 1

base∅6)

7 Y2515009 Gas inlet Connector(Export)-01-A1 1

8 Y0311013 MIG-145C reactor DKQ-002 1

9 Y0108121 Ignition resistance 9T 0.5Ω 1

10 Y2516002 Wire feed motor MIG-145(US) 1

11 B0101044 DVI-200 Capacitor PCB DVI200-DR 1

(new)

12 B0102029 MIG-145C rectifier PCB MIG-145C rectifier PCB 1

13 Y0401040 Rectifier D92-02 8

14 Y1801001/2 ARC-160C Heat sink WJJ-031/032 2

15 Y2517037 Circuit breaker KuoYuH-25A/AC250V 1

16 Y1301004 Fan 12038 DC24V 1

17 Y2517036 Spool holder 1Kg/5Kg 1

18 Y2508007 Knob RN-110Z（black/red） 3

19 Y2517034 Plastic wiring terminal Plastic control connector 1

20 Y0401006 luminescent diode ∅5 yellow 1

21 Y0401005 luminescent diode ∅5 red 1

22 Y1101001 Toggle switch R210-C5L-BR(25A) 1

23 Y2517038 Control receptacle AANWAN-4 hole 1

24 B0201050 Earth clamp 005 10mm, 2/3m 1

Table 7.1

Page 26
 2 3 4 5 6
1 7

16

15

13
9 14
8
10 11 12

Figure 7.1

Page 27
 18

20

21

22

23

24

Figure 7.2

Page 28
 17 18
19

Figure 7.3

Page 29
Wire feeder (HANWAN-4D/24V) , Order No. 2611017

Figure 7.4

ITEM DESCRIPTION ORDER NO. QUANTITY

1 Clamp 200A(Black) 2301006 1

1 Electric Machinery 26110171 1

2 Gearbox 26110172 1

3 #18 Bracket 26110173 1

4 Roller(0.6/0.8mm)(.023/.030) Y2517047 1

5 #18 Pressure shell components 26110175 1

6 #6 Pressure 26110176 1

Page 30
 WeldKingTM NT1 Mig Torch, Order No. 07000403

Figure 7.5

Nozzles

ITEM DESCRIPTION ORDER NO.

1 Nozzle Self Insulated 21-37 A
2 Nozzle Self Insulated 21-50* A
3 Nozzle Self Insulated 21-62 A
4 Nozzle Self Insulated 21-37F A
5 Nozzle Self Insulated 21-50F A
6 Nozzle Self Insulated 21-62F A
7 Nozzle Self Shielding LA8201 B

Contact Tips

ITEM DESCRIPTION ORDER NO.

1 Contact Tip 0.023”/0.6mm Ecu 11-23 C

Page 31
 2 Contact Tip 0.030”/0.8mm Ecu 11-30* C
3 Contact Tip 0.035”/0.9mm Ecu 11-35 C
4 Contact Tip 0.040”/1.0mm Ecu 11-40 C
5 Contact Tip 0.045”/1.2mm Ecu 11-45 C

Liners

ITEM DESCRIPTION ORDER NO.

1 Steel Liner 0.030”-0.035”/0.8-0.9mm X15ft D
2 Teflon Liner 0.030”-0.035”/0.8-0.9mm X15ft 42T-3035-15 D

* Default

Component

ITEM DESCRIPTION PART No. QTY

1 Gun ＆Cable Assembly 2011008 1

2 Gun Handle (Left ＆Right) 2011009 1

3 Trigger Assembly 2011010 1

4 Hook 2011011 1

5 Locking Nut 2011012 1

6 Gas Diffuser 51 1

7 Contact Tip.030 See above 1

8 Gas Nozzle See above 1

9 Control Assembly 2011059 1

10 Control Wire Cord 2011016 1

11 Cable Boot 2011017 1

12 Liner 0.6-0.8 / 10FT See above 1

Page 32
 NOTES
WELDKING™ MIGSONIC145

Page 33
 SECTION 8 WARRANTY POLICY
Malo Welding Products Ltd., Warranty Policy
Effective August 1st, 2004, revision at April 1st, 2011
LIMITED WARRANTY - Subject to the terms and COMMERCIAL/INDUSTRIAL USE AND PERSONS
conditions below, Malo Welding Products TRAINED AND EXPERIENCED IN THE USE AND
Ltd.(WELDKING™ ) endeavors to provide high MAINTENANCE OF WELDING/PLASMA CUTTING
quality products and product support to its EQUIPMENT.
customers and therefore backs up all of its new
products purchased from Malo Welding Products In the event of a warranty claim covered by this
Ltd.(WELDKING™ ) or any authorized Malo Welding warranty, the exclusive remedies shall be, at Malo
Products Ltd.(WELDKING™ ) distributor/service Welding Products Ltd.(WELDKING™ )'s option: (1)
center after the effective date of this limited warranty repair; or (2) replacement; or, where authorized in
and is free of defects in material and workmanship at writing by Malo Welding Products
the time it is shipped. THERE ARE NO Ltd.(WELDKING™ ), in appropriate cases, (3) the
WARRANTIES WHICH EXTEND BEYOND THE reasonable cost of repair or replacement at an
FACE OF THE MALO WELDING PRODUCTS authorized service station; or (4) payment of or credit
LTD.(WELDKING™ ) WARRANTY. MALO for the purchase price (less reasonable depreciation
WELDING PRODUCTS LTD.(WELDKING™ ) based upon actual use) upon return of the goods at
DISCLAIMS ALL OTHER WARRANTIES, customer's risk and expense. No compensation or
EXPRESS OR IMPLIED, REGARDING THE reimbursement for transportation costs of any kind
PRODUCTS, INCLUDING ANY IMPLIED will be allowed.
WARRANTIES OF MERCHANTABILITY, FITNESS LIMITATION OF DAMAGES: THE REMEDY OF
FOR A PARTICULAR PURPOSE OR REPLACEMENT OR REPAIR OF ANY DEFECTIVE
NONINFRINGEMENT. IN THE UNITED STATES, GOODS SHALL BE THE EXCLUSIVE REMEDY
SOME STATES DO NOT ALLOW THE EXCLUSION UNDER ANY WARRANTY MADE BY MALO
OF THE IMPLIED WARRANTIES, SO THE ABOVE WELDING PRODUCTS LTD.(WELDKING™ ),
EXCLUSION MAY NOT APPLY TO YOU. WHETHER EXPRESS OR IMPLIED. IN NO EVENT
Malo Welding Products Ltd.(WELDKING™ ) shall SHALL MALO WELDING PRODUCTS
honor warranty claims on warranted equipment LTD.(WELDKING™ ) BE LIABLE FOR ANY
listed below in the event of such a failure within the INCIDENTAL OR CONSEQUENTIAL DAMAGES,
warranty time periods. All warranty time periods start PROPERTY DAMAGES, OR PERSONAL
on the date that the equipment was delivered to the INJURIES.
original retail purchaser, or one year after the ANY EXPRESS WARRANTY NOT PROVIDED
equipment is sent to a North American distributor. HEREIN AND ANY IMPLIED WARRANTY,
(1) 3 Years - Parts and Labor GUARANTY OR REPRESENTATION AS TO
PERFORMANCE, AND ANY REMEDY FOR
Power Sources BREACH OF CONTRACT TORT OR ANY OTHER
LEGAL THEORY WHICH, BUT FOR THIS
Wire Feeders PROVISION, MIGHT ARISE BY IMPLICATION,
(2) 90 Days - Parts (No Labor) OPERATION OF LAW, CUSTOM OF TRADE OR
COURSE OF DEALING, INCLUDING ANY IMPLIED
Guns WARRANTY OF MERCHANTABILITY OR FITNESS
Remote Controls FOR PARTICULAR PURPOSE, WITH RESPECT
TO ANY AND ALL EQUIPMENT FURNISHED BY
Accessory Kits MALO WELDING PRODUCTS LTD.(WELDKING™ ),
IS EXCLUDED AND DISCLAIMED BY MALO
Replacement Parts (No labor)
WELDING PRODUCTS LTD.(WELDKING™ ).
Malo Welding Products Ltd.(WELDKING™ )'s limited
If any provision or portion of this limited warranty
Warranty shall not apply to:
policy is found to be unenforceable, then the
(1) Consumable components; such as contact tips, remaining provisions and portions shall remain valid
cutting nozzles, contactors, brushes, slip rings, and enforceable. If any provision or portion of this
relays or parts that fail due to normal wear. limited warranty policy is found to be limited by law,
then that provision or portion shall be construed to
(2) All limited warranties are void for, and Malo make it effective within the bounds of law.
Welding Products Ltd.(WeldKing™ ) does not
warrant in any way, any product that evidences To obtain warranty service you must active your
misapplication, improper installation, abuse, lack of product(s)'s warranty online at weldking.com or mail
maintenance, negligence in use or care, abnormal the product registration card included in the package
use, alteration of design, use of incompatible or to Malo Welding Products Ltd.(WELDKING™ ) right
corrosive chemicals, and/or servicing, installation of after the purchase. When there is a warranty issue,
parts, or repairs by anyone other than Malo Welding return the defective welding machine or plasma
Products Ltd.(WELDKING™ ) or a Malo Welding cutting machine along with proof of purchase to any
Products Ltd.(WELDKING™ ) authorized distributor WeldKing™ Authorized Warranty Depot. For the
or service center. Malo Welding Products location of the nearest WeldKing™ Authorized
Ltd.(WELDKING™ ) may make changes in products Warranty depot or for service information in the
it manufactures and markets at any time; these United States or Canada, please telephone toll free:
changes are made without obligation to change, 1-866-686-5088 or visit www. weldking.com (USA &
retrofit, or upgrade any product previously sold or Canada).available, but may vary from province to
manufactured. province
MALO WELDING PRODUCTS
LTD.(WELDKING™ )'S PRODUCTS ARE FOR

Page 34
 SECTION 9 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 0H3

Tel: 1 866 686 5088

Fax: 1 866 686 5090

www.malowelding.com

Printed September 13, 2010