MIG135E Manual

1 Safety precautions

Precautions for personal protection

 The labor should be personnel with professional qualifications or relevant knowledge and skills to
install, operate, maintain and repair the welding machine.
 The installation, inspection and repair of welding equipment must be carried out by electricians, and the
power supply of temporary construction points shall be connected by electricians.
 When working in high-altitude or narrow places, such as boxes, boilers, cabins, etc., there should be
supervisors.
 Wear personal protective equipment during work, such as protective mask, work clothes, insulating
gloves, insulating shoes, etc.
 Those who use cardiac pacemaker shall not be close to the welding machine and welding workplace in
use without the permission of the doctor.

Precautions for installation operation

Welding power shall not be used for pipe thawing, battery load or motor starting.

 Before welding, the yellow and green grounding wire in the power line must be grounded, and ensure
that the insulation of the welding cable is not damaged.
 During welding operation, don't touch the workbench, weldment, ground wire pliers, welding tongs or
welding guns and other live parts.
 For welding operation with high no-load voltage of the welding machine and operation in wet working
place, rubber insulation pad shall also be laid on the ground near the operation console.
 Don't open the machine shell and side cover during welding.
 Don't touch live electrical parts.
 Don't use cables with insufficient cross-sectional area, damaged insulation sheath or exposed conductor.
 The maintenance operation should be carried out after disconnecting the power supply for 5 minutes,
and wait until the power indicator is completely off, otherwise there is a risk of electric shock.
 Please turn off all input power when the equipment is transferred to the working place, replaced with
fuse, overhauled or not in use.

Beware of welding fumes and harmful gases

 When welding steel plates with coating or coating, harmful smoke and gas will be generated. Adequate
ventilation or exhaust facilities shall be used to keep the smoke and toxic gas away from the breathing
area. If necessary, please wear respiratory protection tools.
 When working in narrow places, such as tanks, boilers, cabins, etc., please accept the inspection of
supervisors. In order to prevent hypoxia, fully breathe and wear respiratory protective equipment.
 Keep the ventilation system of welding machine unblocked. The minimum distance between the
welding power supply and the surrounding places shall be greater than 0.5m. don't cover the air inlet
 and outlet of the equipment to ensure the smooth circulation of cooling air.

Welding sparks may cause fire or explosion

 Corresponding protective measures shall be taken in the welding area to avoid fire caused by welding
sparks.
 Please don’t carry out welding operations in degreasing, cleaning and spraying areas.
 Don't weld gas pipes, sealing grooves (boxes) and other devices with gas, otherwise it is easy to cause
explosion or fire.
 Don't weld near combustible gases or devices with combustible substances, otherwise it is easy to cause
explosion or fire.
 When not welding, ensure that any element in the welding wire circuit does not contact the workpiece
or the earth, otherwise it may cause overheating and fire.
 When the welding operation is stopped, remove the welding rod in the electric welding tongs or cut off
the welding wire in the nozzle of the welding gun.

Electromagnetic fields may be dangerous

 Those who use cardiac pacemaker shall not be close to the welding machine and welding workplace in
use without the permission of the doctor.
 It is forbidden to place or wind the welding cable on the body.
 Don't place the body between the welding wire and the workpiece cable. If the welding wire and cable
are on the right side of the body, the workpiece cable should also be placed on the right side of the body.

ARC rays may cause burns

 When welding or supervising welding, please wear protective equipment with sufficient shading.
 Protective barriers shall be set around the welding site to prevent arc light or welding spatter from
hurting others.

Avoid electromagnetic interference

 The user shall ensure that the welding power supply and other equipment in the environment will not
produce electromagnetic interference, otherwise corresponding shielding and protective measures shall
be taken.
 According to the manufacturer's recommendations, the welding power supply should be connected to
the power supply trunk line.
 Shorten the length of welding cables as far as possible to make them close to each other and close to the
ground.
 The safety of all metal components assembled by welding and their adjacent components shall be
confirmed.
 The yellow and green grounding wire in the power line must be grounded, and the workpiece and
ground wire clamp must be well connected.
 The user shall be responsible for the interference caused by welding.

The noise generated in the welding process is easy to cause hearing damage.

 To avoid the harm of noise to you and others, please wear specified protective equipment.
 Precautions for hoisting

 For welding power supply with strap or handle, it is forbidden to use strap or handle for lifting.
 When lifting the welding power supply with a lifting forklift, please fork it from the side and fix it well
to prevent dumping.
 When lifting the welding power supply with a crane, the cable shall be tied at the lifting ring, and the
included angle between the cable and the vertical direction φ Not more than 15 degrees.
 When lifting the welding machine equipped with gas cylinder and external wire feeder, remove the two
equipment from the power supply first. When moving the gas shielded welding machine on the ground,
the gas cylinder must be fixed with strap or chain to prevent dumping and injury.
 If the wire feeder is lifted by the lifting lug for welding, it shall be firm and insulated.

2 Overview

2.1 Product introduction

This series of welder adopts inverter technology to convert the current of 50 / 60Hz frequency into stable
welding output current, and adopts pulse width modulation (PWM) technology obtains constant current
characteristics and excellent welding process effect.
This series of welder can be used for welding carbon steel, stainless steel and other materials. Its
characteristics are as follows:
 Stable wire feeding speed.
 Small volume, light weight, high efficiency and energy saving.
 Easy arcing, stable welding process and good forming.
 Easy installation and operation.
 Equipped with voltage compensation device, when the power supply voltage changes within 15% of the
rated voltage, it can still continue to work.

2.2 Application fields

This series of welding machines are suitable for automobile and parts industry, shipbuilding, steel structure
engineering (construction site), equipment manufacturing, rail transit, boiler, interior decoration and other
fields.

Radio interference may occur during indoor use, and users should take adequate preventive
measures.

2.3 Technical parameters

Model MIG200E (V1B3) MIG135E

Power supply voltage (V) Single phase 220V ± 15% Single phase 220V ± 15%
Frequency (Hz) 50/60 50/60
No load voltage (V) 55 56
23.7(MIG)
Rated input current (A) 14
22.7(MMA)
Output current regulation 60-140(MIG)
45-90
(A) 50-120(MMA)
Output voltage (V) 17-21(MIG)
16.3-18.5
22-24.8(MMA)
Load duration 15% 20%
Power factor ≥0.62 ≥0.7
Efficiency ≥81% ≥80%
Wire feeding mechanism built-in built-in
Welding wire diameter 0.8/1.0(mm) 0.8(mm)
Insulation grade F F
Enclosure protection class IP21 IP21S
Reference net weight (kg) 5.5 4.5
Reference machine size 401*176*260(mm) 318*135*240(mm)

Note: the net weight and size of the machine in the table are only for reference. If there is any difference
with the real object, the real object shall prevail. If the machine, welding gun and ground wire clamp are
integrated at the factory, the weight of welding gun and ground wire clamp shall be included.

3. Unpacking inspection

Note: prevent dust or other impurities from entering the equipment.

1. Open the package and place the equipment on a stable and dry horizontal surface.
2. Confirm that the equipment and all its components are not damaged during transportation.
3. Confirm whether the goods are consistent with the ordered products and whether the accessory
information is consistent with the contents in the "packing list". Please refer to the attachment in the package
for the packing list.
4. Check the nameplate, warning label and serial number.

Warning label: generally pasted on the top of the machine cover. Before use, please read the warning label
on the welding power supply carefully, and don't cover, smear or tear the label.
Serial number: usually pasted on the rear panel or bottom of the machine. The serial number of the welding
machine is unique, which is particularly important when the equipment is repaired and spare parts are
ordered.
Nameplate: generally pasted on the back panel or bottom of the welding machine. The parameters in the
nameplate can be used as a reference.
Warning label

Serial number

Nameplate
Welding wire

Note: this drawing is for reference only. If the picture is inconsistent with the real object, the real object shall
prevail.
 4 Panel description

4.1 Control panel

MIG135E MIG200E (V1B3)

No. MIG135E/200E(V1B3)
Power indicator
1 After the power is turned on, the indicator light will be on when the adjustment knob is
adjusted to the position above "stand by".
Abnormal indicator
2 When the welding power supply is abnormal, the indicator light is on. When the abnormality
disappears, the indicator light goes out.
Welding current adjusting knob
Adjust the welding current. See the list below for the corresponding relationship between knob
3
gear and current. When the pointer of the adjustment knob is in the "stand by / standby"
position, the device is in standby mode.

See the table below for the corresponding relationship between the adjustment knob gear and current of
MIG135E.
Gear Electric current Gear Electric current Gear Electric current
1 45-60A 4 70-75A 7 85-90A
2 60-65A 5 75-80A 8 90-95A
3 65-70A 6 80-85A 9 95-100A

4.2 I/O panel

MIG 200E (v1b3) rear panel

Electric wire
 MIG 135E rear panel

Input joint Electri

c

Note: the power cord access methods of different versions of machines are different. Please refer to the real
object.

5 Installation operation

5.1 Installation steps

MIG 135E cables are connected when leaving the factory.

MIG 200E (v1b3) cable connection diagram
Airless self shielded welding manual welding (DC reverse connection)
Input power Input power

Ground wire pliers Ground wire pliers

welding torch workpiece

workpiece Ground wire pliers

Note: the above pictures are for reference only. If the pictures are inconsistent with the real object, the real
object shall prevail.

Description of operation steps

1) Connect the cable according to the schematic diagram. If the welding gun and ground wire pliers are
already connected when leaving the factory, skip this step.
2) Install the welding wire reel on the shaft frame in the power supply, and select different wire feeding slot
positions according to the diameter of the welding wire.
3) Loosen the pressure arm, send the welding wire into the wire feeding pipe through the groove of the wire
guide wheel, press the pressure arm to make the wire pressing wheel press the welding wire to ensure that
the welding wire does not slide, but the pressure should not be too large to prevent the deformation of the
welding wire from affecting the wire feeding. The welding wire coil shall be rotated clockwise to release the
welding wire. In order to prevent the welding wire from loosening, the head of the new welding wire reel is
often threaded into the fixing hole on the edge of the welding wire reel. In order to prevent the bent welding
wire from being stuck during normal use, please cut this part of the welding wire.

4) According to the input voltage and current of the welding machine, connect the appropriate power line to
the distribution box with corresponding capacity. don't connect the wrong voltage, and ensure that the error
of power supply voltage is within the allowable range.
Note: this step must be operated by electrician!
Attachment: specifications of relevant devices
Model MIG200E MIG135E
Cable Input side ≥1.5mm 2
≥1.3mm2
Output side ≥10mm2 ≥10mm2
Ground wire ≥1.5mm2 ≥1.3mm2
welding torch It is recommended to use welding gun It is recommended to use welding gun
with specification ≥ 200A with specification ≥ 100A
5) If the machine is equipped with harness, please refer to the following figure for installation.

5.2 Welding operation

Connect the power cord of the welding machine. The yellow and green grounding wire of the power line
must be effectively grounded.
Don't connect the wrong voltage and ensure that the error of power supply voltage is within the allowable
range. Our welder is equipped with power supply voltage compensation device. When the power supply
voltage changes within 15% of the rated voltage, it can still continue to work.
Operation instructions for airless self shielded welding
Operation steps Explain
1 power on Turn the power switch on the rear panel of the welding machine to the "on"
position, and the power indicator will be on.
Note: for models without power switch, the power indicator will be on after the
power is turned on.
2 select welding mode Turn the change-over switch on the clapboard in the machine to the "airless self
shielded welding" position.
Note: this step is applicable to mig200e (v1b3) model with manual welding.
3. Set the welding Set the welding voltage, welding current or wire feeding speed through the
voltage, welding current adjusting knob of the panel.
or wire feeding speed Note: the adjustable parameters are different for different machines. Please refer
to the panel display.
4 wire inspection Press and hold the welding gun switch, and the equipment starts to feed wire at
the speed of 8m / min. Release the welding gun switch and stop wire feeding.
5 start welding After setting, the welding operation can be carried out.

Manual welding operation instructions

MIG200E (V1B3) has the function of manual welding, and its operation steps are as follows.
Operation steps explain
1 power on After the power is turned on, the power indicator is on.
2 select welding mode Turn the change-over switch on the clapboard in the machine to the "manual
welding" position.
3 set welding current Set the welding current through the adjusting knob on the panel.
4 start welding After setting, the welding operation can be carried out.

6 Welding Machine Environment

6.1 External environment

Note: the welding power supply cannot be used in the open air, rain or snow.
The recommended external environment for welding is as follows:
 Please place the welding power supply in a horizontal position. The inclination of welding power supply
shall not exceed 10 °.
 The environment where the equipment is stored needs to be clean and protected by sand and dust.
The dust, acid, corrosive gas or substances in the surrounding air shall not exceed the normal content, except
those produced by the welding process.
 The storage environment of the equipment needs to be dry, and the requirements of air relative humidity
are as follows:
Not more than 50% at 40 ℃; Not more than 90% at 20 ℃
 There shall be no heat source, fire source and welding spatter around the environment where the
equipment is placed. Ambient temperature requirements are as follows:
During welding: - 10 ℃ ~ + 40 ℃; During transportation and storage: - 20 ℃ ~ + 55 ℃.
 The altitude shall not exceed 1000m.
6.2 Welding system and power grid

This series of welding power supply is applicable to the power supply system with input voltage of
single-phase AC220V ± 15%.

7 Daily maintenance and overhaul

7.1 Routine maintenance

 Clean the welding machine regularly with dry low-pressure compressed air. It is recommended to clean
it once or twice every six months. If the welding machine is used in the environment with heavy smoke
and serious air pollution, it should be cleaned once a month.
 Regularly check whether the plug, cable, electrode holder, negative electrode and internal circuit of the
welding machine are connected reliably.
 Avoid water or steam entering the inside of the welding machine. If this happens, please dry the inside
of the welding machine. After that, use a megger to measure the insulation of the welding machine
(including between the connecting nodes and between the connecting points and the casing). The
welding operation can be continued only after confirming that there is no abnormality.
 If the welding machine is not used for a long time, it shall be sealed back in the original packing box
and placed in a dry environment without direct sunlight

7.2 Daily maintenance

Warning:
Unless there are special needs, the maintenance must be carried out on the premise of cutting off the power
supply of the distribution box and ensuring safety. Failure to observe the above principles may lead to major
accidents related to personal safety such as electric shock and burn.
In order to give full play to the performance of the machine and ensure safe operation every day, daily
maintenance is very key.
During routine maintenance, the following parts shall be checked in turn, focusing on the wear, deformation
and blockage of air holes of various parts in the welding gun and wire feeding device. Some parts shall be
descaled and replaced when necessary. When replacing parts, in order to maintain the performance of the
original machine, please be sure to use the pure parts of our welder.

Welding power supply

Position Maintenance focus remarks

Operation 1.Operation,conversion and installation of -
control board switches.
Cooling fan 1. Check whether there is wind and whether the If there is no fan rotation sound or
sound is normal. abnormal sound, internal maintenance
is required.
Power part 1.Whether there is abnormal vibration and -
buzzer during power on.
2. Whether there is peculiar smell when
powered on.
3. Whether there are signs of discoloration and
 other heating on the appearance.
Peripheral 1. Whether the air supply pipeline is damaged
and the connection is loose.
2. Whether the shell and other fastening parts
are loose.
Injector Whether the installation is firm and whether the
front end is deformed.
Whether spatter is attached.
Conductive Whether the installation is firm.
nozzle
End damage, hole wear and blockage.
Wire feeding Check the size of the protruding part of the wire
hose feed pipe. If it is less than 6mm, it shall be
replaced.
Whether the diameter of welding wire is
consistent with the inner diameter of wire
feeding pipe.
Local bending and elongation. It is the cause of
poor wire feeding and unstable arc.
Dirt in wire feed pipe and blockage of welding
wire coating residue.
Breakage of wire feed pipe. Wear of O-ring.
Gas diverter Forget to insert or plug the hole, or purchase
from other sources
Wire feeder
Position Maintenance focus
Press Whether the pressure handle is adjusted to the
handle appropriate pressure indication line.
(special attention: it is strictly prohibited to Ф
Welding wire below 1.2mm (damaged)
-
Become the cause of pores.
This is the reason for the burning of
the welding gun. (the effective method
is to use splash proof agent).
Become the cause of welding gun
thread damage.
Become the cause of unstable or
broken arc.
If the size of the protruding part is too
small, the arc will be unstable. (when
replacing the wire feed pipe, please
note that it is better to make the size of
the protruding part slightly longer than
the specified one).
Mismatch is the cause of arc
instability. Please use a suitable wire
feed tube.
Please replace it.
It can lead to poor wire feeding and
unstable arc. (wipe with kerosene or
replace with a new wire feed pipe).
Can cause splashing.
1. If the heat shrinkable tube is
damaged, a new wire feeding tube
needs to be replaced.
2. The O-ring is worn and needs to be
replaced with a new one.
Assembly of components purchased by
the manufacturer. Welding defects
(splash, etc.) caused by poor gas
protection, burning loss of welding
gun body (arc in the body), etc. please
handle them correctly.
remarks
Lead to unstable wire feeding and arc.
Wire Whether cutting powder and waste chips are
guide accumulated at the mouth of wire guide pipe and the
tube edge of wire feeding wheel.
Whether the diameter of welding wire is consistent
with the inner diameter of wire guide tube.
Check whether the interface center of the wire guide
tube is consistent with the center of the wire feeding
wheel groove. (visual inspection)
Wire 1. Whether the diameter of welding wire is
feeding consistent with the nominal diameter of wire
wheel feeding wheel.
2. Check whether the groove of wire feeder is
blocked.
Pressure Check the stability of rotation and the grinding of
wheel welding wire pressure surface.
Cable type
position Maintenance focus
Welding gun 1. Whether the welding torch cable is bent
cable too much.
2. Check whether the metal connection part
of the quick plug is loose.
Output cable 1. Abrasion and damage of cable insulation.
2. Exposure (insulation damage) and
looseness at cable joints (cables at welding
power terminals and base metal
connections).
Input cable 1. Whether the input and output terminals
of the input protection facilities of the
distribution box are firmly connected.
2. Whether the wire connection of the safety
device is reliable.
3. Check whether the cable at the connection
of input terminal of welding power supply is
firm.
4. Whether the insulation of the input cable
is worn or damaged during wiring to expose
the conductor.
ground wire 1. Check whether the grounding wire for
welding power supply is open circuit and
whether the connection is firm.
2. Whether the ground wire for base metal
grounding is open circuit and whether the
connection is firm.
Remove the powder scraps and check
the causes And eradicate it.
In case of mismatch, the arc is unstable
or generate cutting powder and waste.
Dislocation will lead to the generation
of cutting powder and unstable arc.
1.It leads to powder cutting of welding
wire, blockage of wire feed pipe and
instability of arc.
2. In case of any abnormality, replace it
with a new one.
Lead to poor wire feeding and unstable
arc.
remarks
1. Cause poor wire feeding.
2. Cable bending wire feeding is too easy
to lead. Unstable arcing.
In order to ensure personal safety and
stable welding, please take appropriate
maintenance methods according to the
conditions of the workplace.
 Daily maintenance
General and simple
 Regular maintenance
Thorough and meticulous
In order to prevent electric leakage
accidents and ensure safety, please carry
out daily maintenance.
 8 Troubleshooting

Personnel with professional qualifications or relevant knowledge and skills are invited to carry out the
following maintenance operations on the welding machine.

The machine failure or damage caused by non professional operation or failure to operate in accordance with
the relevant requirements in this manual and relevant standards and regulations is not within the scope of our
warranty.
Fault Exclude
The power indicator is not on 1. Confirm that the power switch is closed.
Fan does not rotate 2. The power supply connected to the input cable is energized.
No welding output 3. Confirm that there is no phase loss in the power supply.
The power indicator is not on The auxiliary power supply on the control board fails (contact the
The fan rotates normally dealer or manufacturer).
No welding output
The abnormal indicator light is on 1. IGBT is damaged.
The fan rotates normally 2. Quickly recover the damage of rectifier tube.
3. The control board is faulty.
The fan rotates normally 1. Check whether all kinds of patch cords in the machine have poor
The power indicator is on contact.
No welding output 2. The control wire on the welding gun is broken or the microswitch is
damaged.
3. The control circuit is damaged (contact the dealer or manufacturer).

Note: for the machine with the label of "fan sleep function", the fan does not work after startup. When the
temperature in standby exceeds the limit value, the fan starts to work. When the temperature drops below the
limit value, the fan stops working. For machines without "fan sleep function" label, the fan starts to work
after startup and stops working after shutdown.

If it still cannot work normally after the above maintenance, please contact the local dealer or the
after-sales service department of Lucosy Welding Industry Co., Ltd.

Manufacturer: Shanghai Lucosy Technology Co., Ltd.

Tel:+8615801924199
Email: sales1@lucosy.com
Web: www.lucosy.com
Address: CN,Shanghai,Shanghai,Room Jt2776, Floor 2, No. 5358, Huyi Highway