A) When you tried to run the welder, was it set at 110 or 220?
B) If you used the 220 setting, did you have 220 wiring to the welder plug...did you have a red wire, a black wire, a white wire and an uninsulated wire to the plug?
C) If you were trying to run at 220 are you coming off a 220 breaker in your box (basically just two normal breakers hooked in tandem)? What is the amperage of the 220 breaker and what size wiring are you using to your plug? Also, how much amperage do you have running into your main fuse box and what is the rating on the main fuse (breaker)?
D) If you were trying 220, does the plug wire coming out of your welder and going into the plug have 4 wires (one wire to the blue neutral on our welder, one to the green/yellow ground, and two live conductors connected to two brown wires in you welder?
E) If you had the welder set at 110 for your fatal test run, what size breaker are you running from in your fuse box and what size wire do you have from your fuse box to the plug?
F) If you were set at 110, how were you wired from your welder to your plug?
Again, pics would help - and a detailed description of how your breaker box and your wiring is set up (sizes etc.).