Metal Man Welding Gear FAQs

Got welding questions? Find your answers here or give us a call. Our welding experts are happy to help.


We offer a Lens Replacement Warranty that varies depending on the model.
While welding, the operator needs only a small viewing area. However, larger viewing areas are helpful for set-up and positioning. A larger viewing area also helps when the operator may not be able to view the arc straight on. If you have bi-focal glasses, you will also appreciate the extra viewing area. The other factor is cost. The price of auto-darkening helmets is mainly determined by the size of the viewing area.
It’s very important that at least one of the arc sensors gets a clear view when the arc starts. Many helmets have two arc sensors. If one is blocked by the part you’re welding, or any other obstruction, the other arc sensor is available to sense the arc. Some helmets have 4 arc sensors. Users who need to get into tight spaces often prefer 4 sensors.
The helmet uses both battery power and solar power. The battery power could be compared to a battery and starter for a car engine. Like the starter in a car, the helmet battery helps get everything up and running. The helmet then operates off the arc rays.
The helmet is auto on and auto off.
This welding helmet comes all set up to operate. The package includes the replaceable battery and also an extra outside cover lens. The cover lens is considered a consumable. It protects the electronic lens from molten metal and sparks. Over time, the lens will become pitted and your vision will be affected. If you do a considerable amount of welding, you may want to purchase the cover lens kit for replacements.
We recommend you review the shade setting recommendations in the operator’s manual. These recommendations are determined by the welding process and amperage. Use a shade that’s dark enough that you feel comfortable while welding and can still see what you are welding. We offer helmets with a wide shade range to help meet the needs of each individual user. OSHA posts recommendations for shade setting depending on the welding process and the welding amperage at www.osha.gov.
These adjustments allow you to somewhat customize how your lens reacts. Sensitivity control allows you to adjust how much light is needed to darken the lens. You can adjust your helmet to control how the lens reacts to different ambient light sources. The delay adjustment controls how quickly the lens goes back to the light state after the arc is out. High amperage welds still reflect dangerous rays after the arc has stopped. Increase the delay to keep the lens darker longer.
The unique nature of low amperage TIG welding requires a higher quality lens that can better react to the lower amperages.
Yes, any of the standard 2” x 4.25” cheater lens on the market will work. They are available in 1.0 to 2.75 diopter. See the parts page to order.
Yes, see the parts page in the manual. See the parts page to order.
Yes, we do have all replacement parts. Check the parts label on the inside of the helmet for part numbers. You can also visit our parts page.
We are available to answer any of your questions. Please call us at 888-762-4045. Our hours are 8AM - 5PM CT, Monday through Friday. Or email us at shop@metalmangear.com.



Yes. With the advancement of inverter technology and the efficiency of that technology, MIG and Flux Core welding can be done with great success on typical 120V, 20A household power. Metal Man 120V wire welders such as the Flux Core 135T, Flux Core 130i, MP 140T and the Multiprocess 141 all run off 120V, 20A circuits and can weld up to 3/16” steel.
Yes. You need to make certain you have a large enough generator. The Metal Man 120V welders require a 20 Amp breaker. Make certain your generator has a 20-amp breaker. You also need to make certain your generator is capable of the total wattage needed. Volts x Amps = Watts. 120V x 20A = 2400 watts. If your generator has an automatic idle control, disengage that control to avoid power spikes that may damage your welder. See our blog post for more information.
Yes. An extension cord should never be used as a permanent solution, but in a pinch an extension cord could be a good temporary solution. Special care should be taken to make certain you size your extension cord correctly. The size of the cord and the length of the cord are all factors. Most extension cord packaging will state the voltage and amperage the cord is designed to handle. We suggest contacting a qualified electrician if there are any doubts. See our blog post for more information.
Yes. A dedicated circuit means that no other electrical devices are connected to a circuit. Typical household power in construction today is 120V, 20A service. Welders will use all that power if welding at the top end of the welder. If your refrigerator kicks in while welding on the same circuit, it is likely the circuit breaker with “blow.”
No. This could damage the equipment and could be dangerous for the operator. Exceptions would be for equipment that is designed to run off both 120V power and 230V Power.
No. This could damage the equipment and could be dangerous for the operator. Exceptions would be for equipment that is designed to run off both 120V power and 230V Power.
Typically, not. There are some welders on the market that allow you to upgrade your flux core welder with the needed gas plumbing that allows you to MIG weld. Metal Man flux core welders such as the Flux Core 135T and the Flux Core 130i do not have these costly upgrades.
Typically, yes. Flux core generally requires the polarity to be DCEN or electrode negative. MIG welding is usually done DCEP or Electrode positive. If your wire welder has the capability to change the polarity, and your welder is capability of MIG welding, it is also capable of flux core welding. Metal Man models that are capable of both MIG welding and flux core welding are the MP-140T, Multiprocess 141, MIG 180DVT, and the Multiprocess 220iDV.
Maybe. Multiprocess welders such as the Metal Man MP 140T, Multiprocess 141, and the Multiprocess 220iDV have an optional TIG torch ACTT1. It will allow you TIG weld certain materials. TIG welding on these units are limited to steel and stainless steel because they only provide DC output. TIG welding of Aluminum requires units with AC output, High Frequency and either a foot pedal or fingertip control.
The duty cycle needed really depends on your individual situation. Duty Cycle is not to be confused with thermal overload. With thermal overload, your machine will stop welding when the inside of the welder gets too hot. This could vary depending on how hot of a day it is. Duty cycle is a total amount of time in a 10 min period that you should not exceed to maintain the long-term integrity of your welder. For example, a 40% duty cycle means you can have the arc on for 4 minutes out of 10. Four minutes of welding is a lot of welding. Every time you stop the arc to set up or to reposition, counts toward the recovery time of your welder. If you estimate that you can weld one inch in 10 seconds, that means you should be able to weld about 2 feet worth of weld with 4 minutes of constant welding. Spread that welding out over 10 minutes if your welder has a 40% duty cycle.
Maybe. Any MIG welder has the electrical power and the plumbing needed to deliver the right shielding gas needed for MIG welding aluminum. The trouble is getting that soft wire to feed correctly to the weld. When aluminum wire gets hot, it will expand and loose its stiffness. These issues cause aluminum wire feeding nightmares. A spool gun is the only wise choice. Check to see if a spoolgun is available for your welder. It puts the spool of wire right on the MIG gun. The wire now only needs to feed consistently for a few inches rather than 10 ft. Metal Man models MP-140T, Multiprocess 141 and Multiprocess 220iDV all accept the EZFSG2 for MIG welding hard to feed wires such as aluminum.
A good start is to familiarize yourself with the basics in the Owner’s Manual. It will cover set up and basic welding skills. Most welders will have a set-up guide on the wire compartment door. It will help you get starting settings depending on the wire, material welding, type of shielding gas and process. From there, it takes arc on time. Practice on scrap to help build your confidence. If you need more assistance, feel free to call our welder helpline or email us.
That depends. Generally, we think most people will do well with .030 wire. In fact, Metal Man wire welders all come with contact tips for .030 wire. It just works well. Some people like to use .023 wire for the thinnest of materials. Others like to use .035 for maximum output and value per pound of wire. It is all a personal preference, but we like .030 wire.
If you are MIG welding or TIG welding, we give generally guidance to set the flow of gas at 20 cubic feet per hour. This is for average conditions. More or less will be needed depending on your shop conditions such as wind. Then you have to plan on how much welding you will be doing and how often you will need to go to your local welding gas store to refill. Consider this estimate: If you are able to weld 1 inch in 10 seconds, that means you can weld 360 inches, or 30 feet in one hour of arc time. That is a lot of welding. The size of bottle you would want to buy will depend on how often you are willing to bring your bottle in for a refill exchange.

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