Arc TOLWDRROCM12 ROSSI 120 Amp Portable Inverter Welder User Manual

User Manual

[Revision 4.0 December 2023]

READ THIS MANUAL CAREFULLY BEFORE USE – FAILURE TO DO SO MAY RESULT IN INJURY, PROPERTY DAMAGE AND MAY

VOID WARRANTY. • KEEP THIS MANUAL FOR FUTURE REFERENCE. • Products covered by this manual may vary in appearance,

assembly, inclusions, specifications, description, and packaging.

MAG120 MK III Inverter Welder

Safety

Safety messages are designed to alert you to possible dangers or hazards that could cause death, injury or

equipment or property damage if not understood or followed. Safety messages have the following symbols:

You WILL be KILLED or

SERIOUSLY INJURED if you do

not follow instructions.

You CAN be KILLED or

SERIOUSLY INJURED if you do

not follow instructions.

You CAN be INJURED if you do

not follow instructions or equipment

damage may occur.

It is vital that you read and understand this

user manual before using the product,

including safety warnings, and any assembly

and operating instructions. Keep the manual

for future reference.

Safety precautions and recommendations

detailed here must be fully understood and

followed to reduce the risk of injury, fire,

explosion, electrical hazard, and/or property

damage.

Safety information presented here is generic

in nature – some advice may not be

applicable to every product. The term

"equipment" refers to the product, be it

electrical mains powered, battery powered or

combustion engine powered.

• Before Use - If you are not familiar with the

safe operation/handling of the equipment or

are in any way unsure of any aspect of

suitability or correct use for your

application, you should complete training

conducted by a person or organization

qualified in safe use and operation of this

equipment, including fuel/electrical handling

and safety.

• Do NOT operate the equipment in

flammable or explosive environments, such

as in the presence of flammable liquids,

gases, or dust. The equipment may create

sparks or heat that may ignite flammable

substances.

• Keep clear of moving parts.

• Equipment may be a potential source of

electric shock or injury if misused.

• Do NOT operate the equipment if it is

damaged, malfunctioning or is in an

excessively worn state.

• Do NOT allow others to use the equipment

unless they have read this manual and are

adequately trained.

• Keep packaging away from children - risk

of suffocation! Operators must use the

equipment correctly. When using the

equipment, consider conditions and pay

due care to persons and property.

General Work Area Safety

• Work areas should be clean and well it.

• Do not operate the equipment if

bystanders, animals etc are within

operating range of the equipment or the

general work area.

• If devices are provided for connecting dust

extraction / collection facilities, ensure

these are connected and used properly.

Dust collection can reduce dust-related

hazards.

General Personal Safety

• Wear appropriate protective equipment

when operating, servicing, or when in the

operating area of the equipment to help

protect from eye and ear injury, poisoning,

burns, cutting and crush injuries. Protective

equipment such as safety goggles,

respirators, non-slip safety footwear, hard

hat, hearing protection etc should be used

for appropriate equipment / conditions.

Other people nearby should also wear

appropriate personal protective equipment.

Do not wear loose clothing or jewellery,

which can be caught in moving parts. Keep

hair and clothing away from the equipment.

• Stay alert and use common sense when

operating the equipment. Do not over-

reach. Always maintain secure footing and

balance.

• Do not use the equipment if tired or under

the influence of drugs, alcohol, or

medication.

• This equipment is not intended for use by

persons with reduced physical, sensory, or

mental capabilities.

General Fuel Safety

• Petrol/fuel/gasoline is extremely flammable

– keep clear of naked flames or other

ignition sources.

• Do not spill fuel. If you spill fuel, wipe it off

the equipment immediately – if fuel gets on

your clothing, change clothing.

• Do NOT smoke near fuel or when

refuelling.

• Always shut off the engine before

refuelling.

• Do NOT refuel a hot engine.

• Open the fuel cap carefully to allow any

pressure build-up in the tank to release

slowly.

• Always refuel in well ventilated areas.

• Always check for fuel leakage. If fuel

leakage is found, do not start, or run the

engine until all leaks are fixed.

General Carbon-Monoxide Safety

• Using a combustion engine indoors CAN

KILL IN MINUTES. Engine exhaust

contains carbon-monoxide – a poison you

cannot smell or see.

• Use combustion engines OUTSIDE only,

and far away from windows, doors, and

vents.

General Equipment Use and Care

• The equipment is designed for domestic

use only.

• Handle the equipment safely and carefully.

• Before use, inspect the equipment for

misalignment or binding of moving parts,

loose components, damage, or any other

condition that may affect its operation. If

damaged, have the equipment repaired by

an authorised service centre or technician

before use.

• Prevent unintentional starting of the

equipment - ensure equipment and power

switches are in the OFF position before

connecting or moving equipment. Do not

carry equipment with hands or fingers

touching any controls. Remove any tools or

other items that are not a part of the

equipment from it before starting or

switching on.

• Do not force the equipment. Use the

correct equipment for your application.

Equipment will perform better and be safer

when used within its design and usage

parameters.

• Use the equipment and accessories etc. in

accordance with these instructions,

considering working conditions and the

work to be performed. Using the equipment

for operations different from those intended

could result in hazardous situations.

• Always keep equipment components

(engines, hoses, handles, controls, frames,

housings, guards etc) and accessories

(cutting tools, nozzles, bits etc) properly

maintained. Keep the equipment clean and,

where applicable, properly lubricated.

• Store the equipment out of reach of

children or untrained persons. To avoid

burns or fire hazards, let the equipment

cool completely before transporting or

storing. Never place or store the equipment

near flammable materials, combustible

gases, or liquids etc.

• The equipment is not weather-proof, and

should not be stored in direct sunlight, at

high ambient temperatures or locations that

are damp or humid.

• Do not clean equipment with solvents,

flammable liquids, or harsh abrasives.

• For specific equipment safety use and care,

see Equipment Safety.

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MAG120 MK III Inverter Welder

General Electrical Safety

• Inspect electrical equipment, extension

cords, power bars, and electrical fittings for

damage or wear before each use. Repair or

replace damaged equipment immediately.

• Ensure all power sources conform to

equipment voltage requirements and are

disconnected before connecting or

disconnecting equipment.

• When wiring electrically powered

equipment, follow all electrical and safety

codes.

• Always use a Residual Current Device

(RCD) (GFCI) / Earth Leakage Circuit

Breaker / Safety Switch when operating this

item (electrical items only).

• High voltage / high current power lines may

be present. Use extreme caution to avoid

contact or interference with power lines.

Electrical shock can be fatal.

General Electrical Safety

• Electrically grounded equipment must have

an approved cord and plug and be

connected to a grounded electrical outlet.

• Do NOT bypass the ON/OFF switch and

operate equipment by connecting and

disconnecting the electrical cord.

• Do NOT use equipment that has exposed

wiring, damaged switches, covers or

guards.

• Do NOT use electrical equipment in wet

conditions or in damp locations.

• Do NOT use electrical cords to lift, move or

carry equipment.

• Do NOT coil or knot electrical cords, and

ensure electrical cords are not trip hazards.

General Service Information

• The equipment must be serviced or

repaired at authorised service centres by

qualified personnel only.

• Replacement parts must be original

equipment manufacturer (OEM) to ensure

equipment safety is maintained.

• Do NOT attempt any maintenance or repair

work not described in this manual.

• After use, the equipment and components

may still be hot – allow the equipment to

cool and disconnect spark plugs and/or

electrical power sources and/or batteries

from it before adjusting, changing

accessories, or performing repair or

maintenance.

• Do NOT adjust while the equipment is

running.

• Perform service-related activities in suitable

conditions, such as a workshop.

• Replace worn, damaged or missing

warning/safety labels immediately.

Child Choking Hazard!

• WARNING: CHOKING HAZARD - CHILDREN UNDER 8 YRS. CAN CHOKE OR SUFFOCATE ON SMALL PARTS. ADULT

SUPERVISION REQUIRED.

• Carefully inspect anything a baby or child could gain access to, including this product & packaging.

• Dangers include anything of a size that could become stuck or lodged in a baby or child's airway.

• Dangers include things like raw, hard fruit and vegetable pieces, large pieces of meat, bones or sausage skins, popcorn, nuts,

hard lollies and corn chips, small magnets and batteries, coins, beads, marbles and small uninflated balloons, broken toys and smaller toys,

buttons, keys and coins. But there are also many more.

• Pay particular attention to accessories, nuts, bolts, screws, washers, caps, covers, loose parts, parts that could be removed or break off, pieces

of packaging, staples, tape etc.

• In the case of any doubt, secure the item of concern in an appropriate manner, or completely remove the possibility of access by a baby or child.

Inverter Welder Safety

• WARNING! READ ALL SAFETY WARNINGS, INSTRUCTIONS, ILLUSTRATIONS AND SPECIFICATIONS PROVIDED WITH THIS

MACHINE. FAILURE TO FOLLOW ALL INSTRUCTIONS LISTED BELOW MAY RESULT IN ELECTRIC SHOCK, FIRE AND/OR SERIOUS

INJURY. ONLY QUALIFIED PERSONS SHOULD INSTALL, OPERATE, MAINTAIN, AND REPAIR THIS UNIT.

Electric Shock

• Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on.

Incorrectly installed or improperly grounded equipment is a hazard.

• Insulate yourself from work and ground using dry insulating mats or covers, big enough to prevent any physical contact with the work or ground.

• Do not connect more than one electrode or work cables to any single weld output terminal.

• Always verify the supply ground – check and be sure that input power cord-ground wire is properly connected to ground terminal in disconnect

box or that cord plug is connected to a properly grounded receptacle outlet.

Fumes and Gases

• Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do

not breathe the fumes.

• Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is

well ventilated, Wear an air-supplied respirator if necessary.

Arc Rays

• Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks may fly

off from the weld.

• Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching.

• Wear approved safety goggles with side shields under your helmet.

Additional Safety Reminders

• Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.

• Hot parts can cause severe burns. Do not touch hot parts bare handed. Wait for the cooling period before working on gun or torch.

• Moving parts can cause injury. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in

place.

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MAG120 MK III Inverter Welder

• High-frequency due to welding can cause interference. It can interfere with radio navigation, safety services, sensors computers, and/or

communications equipment.

• Electro-static discharge can damage printed circuit boards. Put on grounded wrist strap before handling boards or parts.

• Welding wire can cause injury. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or

any metal when threading welding wire.

• This welding machine is only for MMA and gas-less flux-cored welding; This machine cannot connect to a spool gun which is recommended for

other materials.

• Do not weld or heat Aluminium, as it requires shielding gas, and this machine is a gas-less welding machine. Likewise, do not weld lead, zinc,

cadmium, mercury, beryllium, cobalt, manganese, copper, silver, barium, chromium, vanadium, nickel, or similar metals without seeking

professional advice and inspection on the ventilation of the welding area. These metals produce extremely toxic fumes which can cause

discomfort, illness and death.

• Do not, in any manner, come into physical contact with any part of the welding current circuit, which includes:

• Workpiece or any conductive material in contact with it.

• Ground clamp.

• Electrode or Welding Flux-cored Wire.

• Any metal parts on the electrode holder or MAG Gun.

• All the equipment should be kept in good working condition, inspected and, when defective, promptly repaired or withdrawn from service.

• Training should be sought out in the safe use of this equipment, the processes and the emergencies.

• WARNING! THE PRODUCT MUST BE FULLY ASSEMBLED BEFORE OPERATION! DO NOT USE A PRODUCT THAT IS ONLY PARTLY

ASSEMBLED OR ASSEMBLED WITH DAMAGED PARTS! FOLLOW THE ASSEMBLY INSTRUCTIONS STEP-BY-STEP.

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MAG120 MK III Inverter Welder

Safety Symbols

The product may have safety warning labels attached to it, explained below. Understand the symbols on your

product and their meanings. If any stickers become unreadable, unattached etc., replace them.

Flammable Material Hazard

Flammable liquids, gases, or

substances etc may present.

Avoid ignition sources and open

flames. Danger of fire.

Read User Manual

Read and fully understand

product safety warnings,

operation, procedures etc before

using the product.

Use Hand Protection

Wear appropriate hand protection

and take due care as the product

or use of the product may present

hand hazards.

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be fatal.

Electrocution / Electrical Shock

Hazard

High voltage or high current

electricity may be present or

required by the product. Take

due care when handling electrical

products, cables, plugs and

leads. Electrical shock can be

fatal.

Toxic Fumes / Dust Hazard

Using the product or by-products

from use may produce fumes,

smoke or particles that could be

harmful if inhaled. Wear

appropriate breathing protection

and have adequate ventilation.

Explosive Material Hazard

Combustible liquids, gases, or

substances etc may be present.

Avoid ignition sources and open

flames. Danger of explosion.

Cutting / Amputation Hazard

The product may have blades,

edges or mechanical devices that

can cause severe cut injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Crush Hazard

The product may have blades,

edges or mechanical devices that

can cause severe crush injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Single Operator Only

The product must be operated by

a single person only. More than

one person operating the product

may introduce additional hazards.

Use Face Protection

Wear appropriate full-face

protection and take due care as

the product or use of the product

may present face and eye

hazards.

Use Foot Protection

Wear appropriate foot protection

and take due care as the product

or use of the product may present

foot hazards.

Use Eye / Ear / Head Protection

Wear appropriate eye and / or

ear and / or head protection and

take due care as the product or

use of the product may present

eye, hearing, and head hazards.

Running Hazard

Do not run on or near the product

as doing so may present a fall

hazard.

Diving Hazard

Do not dive into the product as

doing so may present a neck /

head injury hazard.

Adult Supervision Required

Always supervise children and

other users of a product to

prevent drowning or injury.

Skin Penetration / Puncture

Hazard

The product may produce

pressure, emit liquids or objects

that can cause severe injury to

fingers, limbs, blood etc. Take

due care when handling and

using the product.

Hot Surface Hazard

Be aware that the product may

produce high temperatures and

hot surfaces that can cause burn

injuries.

Flying Debris Hazard

Be aware that the product or use

of the product may present

hazards produced by flying

debris. Wear appropriate clothing

and protective devices.

Moving Parts Hazard

Be aware that the product

contains or uses mechanical

devices that move or rotate.

Always wait for moving parts to

stop fully before handling the

product, adjusting, maintenance

etc.

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MAG120 MK III Inverter Welder

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be fatal.

Pull Hazard

Be aware that the product

contains or uses mechanical

devices that can pull in objects

and can cause severe injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Slope / Fall Injury Hazard

Be aware that using the product

on sloping surfaces or in slippery

conditions may present additional

dangers from falls and contact

with blades, moving parts, hot

surfaces etc.

"Slam Dunk" Warning

Do NOT attempt "slam dunk"

manoeuvres as this may result in

severe injury due to falling,

product breakage or collapse etc.

Electrocution / Electrical Shock

Hazard - Outdoor

High voltage or high current

electricity may be present or

required by the product. Do NOT

use in rain, damp, or wet

conditions. Electrical shock can

be fatal.

Electrocution / Electrical Shock

Hazard - Disconnect

High voltage or high current

electricity may be present or

required by the product. Always

disconnect the product from the

electrical supply before handling

the product, adjusting,

maintenance etc.

Power Line Electrocution

Hazard

High voltage / high current power

lines may be present. Use

extreme caution to avoid contact

or interference with power lines.

Electrical shock can be fatal.

"Kick-Back" Hazard

High level of "kick-back" hazard

that can cause the machine to

suddenly rotate towards operator.

Kick-back injury can be fatal.

Winch Operator Position

Hazard

Do NOT stand between winch

and load. Do NOT use winch to

move people.

Winch Lift Hazard

Do NOT LIFT load vertically. Use

machine to PULL only.

Cable Hazard

Ensure that load bearing cable is

not kinked or knotted.

Winch Cable Hazard

Ensure that there is a minimum

number of cable coils on

winching mechanism.

Winch Hook Hazard

Carry hook to load – do NOT

throw or run.

Flash / Blinding Hazard

Wear appropriate eye protection

for welding. Direct exposure to

weld arcs may cause permanent

eye injury.

Laser Hazard

Laser may be in use – do NOT

look directly at laser or allow

others to.

Choking Hazard

Children under 8 yrs. Can choke

or suffocate on small parts. Adult

supervision required.

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MAG120 MK III Inverter Welder

Table of Contents

Safety ............................................................................................................................................................. 2

Safety Symbols ........................................................................................................................................................... 5

Parts Identification ....................................................................................................................................... 8

Assembly ....................................................................................................................................................... 9

MMA Assembly ........................................................................................................................................................... 9

MAG Assembly ......................................................................................................................................................... 10

MAG Connection ...................................................................................................................................................... 12

Operation ..................................................................................................................................................... 14

Control Panel ............................................................................................................................................................ 14

Product Description .................................................................................................................................................. 14

Parameters ............................................................................................................................................................... 15

Current Setting ................................................................................................................................................... 15

Arc Length .......................................................................................................................................................... 15

Travel Angle ....................................................................................................................................................... 15

Travel Speed ...................................................................................................................................................... 15

General Operation .................................................................................................................................................... 15

MMA Welding ..................................................................................................................................................... 15

MAG Welding ..................................................................................................................................................... 16

Storage and Maintenance .......................................................................................................................... 18

Troubleshooting ......................................................................................................................................... 19

MMA Welding ........................................................................................................................................................... 19

MAG Welding ............................................................................................................................................................ 20

Specifications ............................................................................................................................................. 21

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MAG120 MK III Inverter Welder

Parts Identification

No. Name

1 (-) Earth clamp socket

2



(+) Electrode holder socket (MMA)



Earth clamp socket (MAG)

3 MAG torch

4 Current Adjustment Knob

5 Overheating LED indicator

6 LED display

7

Function select button

8

ARC/MMA LED indicator

9

Gasless MAG LED indicator

10 TIG LED indicator

11 Wire feed rate knob

12 ON/OFF switch

13

Power cable (not shown)

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MAG120 MK III Inverter Welder

Assembly

MMA Assembly

1. Connect the welding tongs (grounding clamp and electrode holder) correctly. First, make sure that the cable,

welding tongs, and quick plugs are connected securely.

2. Connect the electrode holder in the quick socket with the ‘+’ polarity, and then tighten it; suitable electrode is

connected to the holder.

3. Connect the grounding clamp into quick socket with the ‘-‘ polarity, and then tighten it; connect the grounding

clamp to the workpiece.

Accessories:

•

1.8m-cable 14mm² 200A Electrode Holder

•

1.5m-cable 14mm² 300A Earth Clamp

•

0.5Kg 0.8mm flux cored wire

•

2m MAG Torch

•

Steel brush

•

2pcs 0.8mm tips. 2pcs nozzles

•

1pc. little wrench

•

1pc. belt

•

Welding Glass

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MAG120 MK III Inverter Welder

MAG Assembly

1. Unlock the panel cover to access the inner compartment for MAG Gasless usage to feed the flux cored wire.

2. Set the wire reel in the spring holder and insert the snap pin.

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MAG120 MK III Inverter Welder

3. Turn the adjustment knob of the pressure arm anti-clockwise to loosen it.

4. Lower the pressure arm to raise the roller retainer to feed wire through the drive roll.

5. While turning the wire reel anti-clockwise, pass the end of the wire through the guide tube.

6. Guide the wire to the correct roller groove (according to its size). Push it through to the inlet tube of the torch.

NOTE: The placement of the reel should be such that the wire comes off the spool, it will look like the illustration

above. The wire should unspool from the bottom, and the spool will rotate in an anti-clockwise manner.

7. Wire from reel to the drive should relax with a slight curve after feeding, it should not be a tight line.

8. Place the retainer back and pull up the pressure arm back to position and turn the knob clockwise.

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MAG120 MK III Inverter Welder

9. For proper tension, align tops of the screw and nut together on the knob of pressure arm.

The drive roll pressure should not be too much nor too less. Too little pressure, the roll can slip, and

feed can be erratic. Too much pressure, the wire can be crushed and cause wire feeding problems and

welder damage.

10. Connect the plug to power for inspection of proper wire feed.

11. Pull the trigger on the MAG gun to feed wire through the gun assembly. The panel should be open (as of

now) so that you can inspect the wire feeding process.

12. Keep the gun straight. When feeding a new wire through the liner, make sure the wire is cut cleanly (no burrs

or angles) and that at least 1” from the end is straight (no curves). Cut off the excess wire that extends past

the end of the nozzle. The nozzle can be loosened to see a vivid wire movement through the contact tip.

13. Check if the drive roll is slipping on the wire and increase pressure on the pressure arm adjustment knob, if

necessary.

NOTE: When the drive pressure is set correctly, there should be no slippage between the wire and the

drive roller. If obstruction occurs along the feed path, the wire should then slip on the drive roller. This can be

checked by squeezing the wire between two fingers with moderate force as it comes out of the gun. If this stops

the wire from feeding, increase pressure until the wire feeds through your fingers without issue.

MAG Connection

1. For MAG, Connect the grounding clamp into quick socket with the polarity of ‘+’ (unlike in the MMA) tighten it

securely.

2. Connect the grounding clamp to the workpiece.

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MAG120 MK III Inverter Welder

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MAG120 MK III Inverter Welder

Operation

Control Panel

1. Current (Amperage) Display: Displays the

Current

2. Mode Indicator Lights

3. Amperage (Current) Adjustment

4. Mode Toggle Switch

5. Wire Speed Adjustment

6. Positive connection

7. 2 Pin Female Connector

8. Negative (Earth) Connector

Product Description

MAG120 MK III Inverter Welder functions both as Gas-less Flux-cored MAG (Metal Active Gas) and MMA

(Manual Metal Arc) Machine.

•

MAG with Flux cored arc welding uses heat generated by an electric arc to fuse base metal in the weld

joint area. This arc is struck between the metallic workpiece and the continuously fed tubular cored

consumable filler wire, with both the wire and the metallic workpiece melting together to form a weld joint.

This welding works well with most carbon steels, cast iron, stainless steel, and hard facing /surfacing alloys.

However, non-ferrous exotic metals, like aluminium cannot be welded using this welding technique.

•

In Manual Metal Arc Welding (MMA) with consumable, flux-covered electrode and a ground clamp, a short-

circuit is initially made on the weld piece. An electric arc forms between electrode and workpiece, which

heats up enough to melt both. As the electrode melts, the flux coating on the electrode develops gas and

slag, which help protect the weld pool. The gas keeps air and other pollutants away, while slag forms on top

of the weld pool to protect the weld seam.

•

The machine uses a high performance IGBT Technology. This Technology is very useful as it gives

power that can be used for different welding processes.

− Hot Start provides excellent arc ignition without the electrode sticking and avoids any metallurgical

default in the weld.

− Anti-sticking feature minimises the short circuit current in the event of the electrode sticking to the work

piece.

1

2

3

4

5

6

7

8

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MAG120 MK III Inverter Welder

− VRD (Voltage Reduction Device) in-built function provides an additional measure of safety.

− In-built arc force improves the weld performance on the specified size of electrodes to be used, making

the job easier.

Parameters

Current Setting

The correct current, or amperage setting primarily depends on the diameter and the type of electrode selected.

Select an amperage based on the material thickness and welding position (about 15 % less heat for overhead

work compared to a flat weld).

The wire feed rate is adjusted by the Feed rate knob.

Arc Length

The correct arc length varies with each electrode and application. As a good starting point, arc length should not

exceed the diameter of the metal portion of the electrode. Excessively long arcs (too much voltage) produce

spatter, low deposition rates, undercuts and sometimes porosity. Length of arc is regulated by holding

electrode tip at a suitable distance from welding piece.

Travel Angle

Hold the rod perpendicular to the joint and tilt the top of the electrode in the direction of travel approximately 5 to

15°. For welding vertical up, use a forehand technique and tilt the top of the rod 15° away from the direction of

travel.

Travel Speed

The proper travel speed produces a weld bead with the desired contour (or crown), width and appearance. Slow

travel speeds produce a wide, convex bead with shallow penetration. Excessively high travel speeds also

decrease penetration, create a narrow and/or highly crowned bead, and possibly undercuts.

General Operation

NOTE: It is recommended that you try welding and check the rate of welding current first on something other

than the actual work piece. You can start welding after having made the necessary selections.

The MMA/ MAG Switch (1) is used to switch between the two welding operations: MMA and MAG Gasless

welding.

MMA Welding

1. Always secure the earth cable clamp directly on the welding piece.

2. Turn the power switch to ‘ON’ position. Cooling fan inside the machine should begin to work once welding

starts.

Diameter of welding rod (mm) φ1.6 φ2.0 φ2.5 φ3.2

Welding current (A) 20-60 60-100 80-120 120-140

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MAG120 MK III Inverter Welder

3. Clamp the welding rod on the electrode holder, the machine is in the manual welding mode and in a standby

state.

4. In accordance with the thickness of welding workpiece, diameter of welding rod, working position and

technology needs, ensure that you adjust to a suitable welding current with the adjustment knob (2) (See

Parameters). If the current is too high, intensified splashing occurs and if it’s too low, the melted welding

stick becomes a fluid and drips transfer or would not proceed smoothly.

For beginners, the first difficulty is priming the arc. For best results proceed as follows:

1. Test the current intensity and the electrode on a piece of scrap material. Hold the electrode approx. 2cm

above the start of the joint. Touch the workpiece with the electrode and stroke it repeatedly on-off the

workpiece to start the arc.

2. Watch the arc only through the face shield and keep the arc length approximately 1–1.5 times the

diameter of the electrode.

3. Hold the electrode at an angle approximately 70° – 80°.

4. Wait until the joint has cooled completely before removing the slag. If you wish to continue welding a joint

after taking a break, the slag at the end of the joint must be removed first. Prime the arc in the joint and melt

the electrode at the point where the two joints meet.

MAG Welding

Welding current of this machine is proportional to the Wire feed speed. This also matches the voltage with its

semi auto-voltage matching.

1. Ensure the ground clamp has a good connection to the workpiece and is connected on clean, bare metal.

2. Place the MAG gun (3) on the joint you want to weld. The distance between the gun and the workpiece

should be about 6mm-12mm Lower your face shield and press the gun trigger to start the arc. When the arc

has struck, move the nozzle along the joint. Pull the trigger while in contact with the workpiece. The

machine does not arc unless the trigger is pulled.

3. The gun should bisect the angle of the two workpieces to form the weld work angle. The torch in relation to

its movement is torch angle.

For an angle joint: the angle between the weld gun and the workpiece should be around 45°.

For a butt joint: the angle between the weld gun and the workpiece should be around 90°.

4. The torch can be pulled or pushed, can be moved in a straight line (stringer bead), or in small overlapping

arcs (weave pattern).

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MAG120 MK III Inverter Welder

A weave is better for thicker materials that require more heat.

A stringer is best for very thin material that cannot take much heat.

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MAG120 MK III Inverter Welder

Storage and Maintenance

Storage

Store the equipment and accessories out of children’s reach in a dark and dry place at above freezing

temperatures. The ideal storage temperature is between 5°C and 30°C. Store the electric machine in its original

packaging.

Maintenance

NOTE: All the maintenance work must be conducted under the condition of complete power shut down; please

make sure that the welder is turned OFF and the power plug is pulled out.

•

Regularly remove dust on the welding machine with dry compressed air. When use it in heavy fume and

polluted air, do this job at least once a month. Compressed air should drop down to the required pressure to

prevent damaging the small parts and units in machine.

•

Avoid water or moisture getting into the welding machine. If this happens, blow-dry the welding machine

immediately, then measure the insulation with insulation resistance meter, it can only be used when the

measuring result is accepted.

•

If the welding machine will not be used for an extended period, it should be placed into the original

packaging and stored in a dry, cool place.

•

Any improper or incorrect operation may cause the welder’s failure and damage. Routine maintenance on

power control switch, grounding device, welding electrode holder, coupling device and set screws should be

performed on a regular basis.

•

Measure the welder’s insulation resistance with an insulation resistance meter.

NOTE: Repairing welding equipment should be carried out by a qualified technician or service centre using

original spare parts. This ensures the safety of the device as well as yourself.

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MAG120 MK III Inverter Welder

Troubleshooting

NOTE: The following operations must be performed by qualified technicians. Before maintenance, please

contact a technician or service centre for assistance.

MMA Welding

Problem Possible Causes and Solutions

Meter doesn’t display, fan doesn’t

work, no welding output.



Make sure power switch is ON.



Make sure the power source connecting to the input cable is working

well.

Meter is normal, fan is working, no

welding output.



Check if connector of output terminal is broken or damaged.



Check if the control board is damaged (Connect with an authorised

service centre or a qualified technician).

QC indicator is ON, fan is working,

meter is normal.



IGBT is damaged.



Quick recovery rectifier is damaged.



Control board is broken.



The feedback circuit is faulty.

Too much spatter.

Output terminal polarity connection is wrong. So please change the polarity

Erratic welding output current or

out of control of potentiometer.



The potentiometer is damaged.



Check if all the connectors are not connected well, especially the plugs.

Power switch doesn’t work.



Power switch is broken.



Rectifier bridge is broken, Replace it.



Check if there is any short circuit of the inner machine.

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MAG120 MK III Inverter Welder

MAG Welding

Problem Possible Cause Solution

Wire feeds, but no arc.



Poor grounding/ground

connection.



Trigger not pulled while wire is in

contact with the workpiece.



Check connections; tighten ground

cable.



Press the trigger while in contact with

the workpiece.

Arc works, but not feeding

wire.



Insufficient or excessive pressure

on the drive roller.



Wire reel/spool is empty.



Adjust the drive pressure.



Check if wire is in place and replace, if

necessary.

No arc or wire feed.



Exceeded duty cycle (>60%);

Thermal protector engaged.



Insufficient air flow/ Overheat.



Circuit breaker has been tripped.



Allow it to cool at least 10 minutes with

machine ON.



Check the vents on all sides of the

machine for any obstacles.



Make sure circuit breaker has been

reset.

Poor quality welds.

Gun moved over workpiece too quickly

/ slowly.

Move the gun in a steady manner.

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MAG120 MK III Inverter Welder

Specifications

Voltage 220-240V (15A Plug)

Output Current Range 35 - 120 Amps

Protection Class IP21

Duty Cycle 40% @ 120A, 60% @ 60A

No-Load Power 40W (65 - 70V)

Power Factor COS 0.85

Flux-core Wire Auto-feed 0.6-0.8mm

Welding Electrodes (Rod /Stick) 1.6mm – 4.0mm

Generator Recommended 4.2kW

Input voltage 240V AC

Power Plug 15A Australian Approved

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Some experts believe that the incorrect or prolonged use of almost any

product may cause serious injury or death. To help reduce your risk of

serious injury or death, refer to the information below. For more information,

see www.datastreamserver.com/safety



Consult all documentation, packaging,

and product labelling before use. Note

that some products feature

documentation available online. It is

recommended to print and retain the

documentation.



Before each use, check the product for

loose/broken/damaged/missing parts,

wear, or leaks (if applicable). Never use a

product with

loose/broken/damaged/missing parts,

wear, or leaks.



Products must be inspected and serviced

(if applicable) by a qualified technician

every 6 months. This is based on

average residential use by persons of

average size and strength, and on a

property of average metropolitan size.

Use beyond these recommendations may

require more frequent

inspections/servicing.



Ensure that all users of the product have

completed a suitable industry recognised

training course before being allowed

access to the product.



The product has been supplied by a general merchandise

retailer that may not be familiar with your specific

application or description of application. Be sure to attain

third-party approval from a qualified specialist for your

application before use, regardless of any assurances from

the retailer or its representatives.



This product is not intended for use where fail-safe

operation is required. As with any product (for example,

automobile, computer, toaster), there is the possibility of

technical issues that may require the repair or

replacement of parts, or the product itself. If the possibility

of such failure and the associated time it may take to

rectify could in any way inconvenience the user, business,

or employee, or financially affect the user, business, or

employee, then the product is not suitable for your

requirements. This product is not intended for use where

incorrect operation or a failure of any kind, including but

not limited to, a condition requiring product return,

replacement, parts replacement, or service by a

technician may cause financial loss, loss of employee

time or an inconvenience requiring compensation.



If this product has been purchased in error when

considering the information presented here, contact the

retailer directly for details of their returns policy, if

required.

diagrams, or images may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying, scanning, or recording, or any information storage and retrieval system,

without express permission or consent from the publisher.

Arc TOLWDRROCM12 ROSSI 120 Amp Portable Inverter Welder

Product's Documents

Product manual

Specifications

ROSSI TOLWDRROCM12 Questions and Answers