Lincoln Electric Expressweld MasterMIG 250CT User Manual
Eczacıbaşı - Lincoln Electric recommend to use “ASKAYNAK” gas metal arc
welding wire for obtaining high performance from MasterMIG 250CT.
www.askaynak.com.tr
Expressweld Model : MasterMIG 250CT
Gas Metal Arc Welding Machine
USER MANUAL
GMAW (MIG/MAG)
Welding Method and Specifications
CO235%
Phase
AT - UYGUNLUK BEYANI
EU - DECLARATION of CONFORMITY
EU - KONFORMITÄTSERKLÄRUNG
Déclaration de Conformité de l'EU
KAYNAK TEKNİĞİ SANAYİ ve TİCARET A.Ş.
Şirket / Firm / Firma / Société
aşağıda modeli belirtilen kaynak makinesinin
declares that the welding machine
erklärt, daß die Bauart der Maschine
déclare que le poste de soudage
® ®
EXPRESSWELD MasterMIG 250CT
aşağıda belirtilen yönergelere uygun olduğunu
conforms to the following directives
den folgenden Bestimmungen entspricht
est conformé aux directives suivantes
2004/108/EC, 2006/95/EC
ve yine aşağıda belirtilen normlara uygun olarak tasarlandığını beyan eder.
and has been designed in compliance with the following standards
und in Überienstimmung mit den nachstehenden normen hergestellt wurde
et qu'il a été conçu en conformité avec les normes
TS EN 60974-1:2007, TS EN 60974-10:2009
Pazarlama ve Lojistik Müdürü / Marketing and Logistics Manager / Directeur de Marché et Logistiques
Sertaç ÖZEN
22.03.2010Tarih / Date / Datum / Date :
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41480 Çayırova, Kocaeli - TURKEY
1. General Safety Rules
Electromagnetic Compatibility
2. General Information, Warnings and Operation Conditions
3. Specifications
4. Technical Data
5. Front Panel Controls
6. Back Panel Controls
7. Controls in Wire Feeder System
8. Connection Diagram
9. Installation and Operation of Machine
9.1. Mains Supply
9.2. Shielding Gas Connection
9.3. Welding Torch Connection
9.4. Connecting Shielding Gas Cylinder to Welding Machine
9.5. Installing Welding Wire
10. Functions of Wire Feeder System
11. GMAW (MIG/MAG) Method
12. Environment Conditions
13. Efficient Use of Machine In Terms of Energy Consumption
14. Storage and Transportation
15. Unpacking
16. Expirty of Machine's Physical Life
17. Maintenance and Repair
18. Troubleshooting Guide
19. Failures in Welding Seams
20. Spare Part List
21. Electrical Circuit Diagram
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Table of Contents
December 2014
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41480 Çayırova, KOCAELİ
Phone: (0262) 679 78 00 Fax: (0262) 679 77 00
www.askaynak.com.tr
MANUFACTURER
Manufactured in People's Republic of China by KAYNAK
TEKNİĞİ SANAYİ ve TİCARET A.Ş.
Physical life determined by Ministry of Industry and Trade is 10 years.
(This is the period for providing spare parts required for the machine to operate.)
Expressweld MasterMIG 250CT
21. Warning and Specifications of Welding Machine
40
"Expressweld"
is the registered trademark of Kaynak Tekniği
Sanayi ve Ticaret A.Ş.
Expressweld MasterMIG 250CT
"MasterMIG"
is the registered trademark of Kaynak Tekniği
Sanayi ve Ticaret A.Ş.
Expressweld MasterMIG 250CT
Page 1
1 General Safety Rules
Expressweld MasterMIG 250CT
THIS MACHINE HAS BEEN DESIGNED FOR GMAW (MIG/
MAG). SHALL NOT BE USED FOR ANY OTHER PURPOSE.
READ AND UNDERSTAND THE INSTRUCTIONS CAREFULLY:
WARNING: This symbol indicates that the instructions within the user guide
must be followed to avoid potential serious personal injury, loss of life and
damages on machine. Protect yourself and other people.
Be sure that this machine should only operated by qualified personnel.
Be sure that all installation, operation, maintenance and repair
procedures are performed only by authorized personnel. Be sure to read
user guide carefully before operating the machine. Failure to follow the
instructions included in the user guide may cause serious injury, loss of
life and damage on machine. Please read the warnings next to the
symbols stated below. "Kaynak Tekniği Sanayi ve Ticaret A.Ş." is not
liable for any damages due to improper connection, storage conditions
and operation procedures.
Be sure to read and understand the user guide before
operating the machine. Failure to follow the instructions stated
in the user guide may cause serious injury, loss of life and
damage on equipment.
Do not weld while you are unattentive, unattentive, tired and sleepless.
Arc welding is a safe application when necessary measures are taken to protect the
welder against potential dangers. If these measures missed or disregarded, there
may be dangers such as electric shock, exposing to high levels of fume and gas, arc
radiation, fire and explode which may cause serious injury or even death.
Note: For detailed information on safety in welding, please read ANSI Z49.1 standard.
Protective Equipments:
Welding operators should wear protective clothing to protect themselves against
burning risk. Welding burns is a frequent risk which may be caused due to splash of
welding sparks on bare skin.
Clothing used while welding may vary based on used welding method but generally it
should provide easy movements and should cover welder's body to protect against
splashes, sparks and arc radiation.
Page 2
Expressweld MasterMIG 250CT
Flame resistant clothing,
Gaiters,
Aprons,
Leather cuff gloves and capes,
Helmet used under the welding mask.
Noise:
Importance and Cleanliness of Working Environment:
Wool y clothing should be preferred due to its resistance against flame. Synthetic clothing
should not be worn since they will melt when exposed to heat.
Protective clothing should be protected from grease and oil. This kind of materials may
flare and burn uncontrolledly in an environment with oxygen.
Shirtsleeves and trouser hems should not be folded. Since sparks and melted metals
may enter into these folds. Trousers should be kept outside the work shoes and should
not be inserted into it. Otherwise melted metals and sparks may enter into shoe.
Other protective clothing used in dangerous situations are stated below:
To protect hands against burns, cuts and scratches, gloves made from flame resistant
materials such as leather must be used. In addition, to provide some insulation against
electric shock, care should be taken that the gloves made from flame resistant material
are in good condition and dry.
To protect ears against sparks and melted metals and to prevent hearing impairment due
to noise of arc welder, ear protectors should be used. When the noise in working
environment is reached to a level that disturbing the ears and causing headache, auditory
problem may occur. In such a condition immediately use your ear protectors.
Hearing impairment may not be noticed until tested and then it may be too late for
treatment.
The tidiness and cleanliness of working environment is important as the maintenance of
welder. Even the level of potential damage rises up to number of people in the
environment. Although warnings related to machine are read and necessary measures
are taken, any of the personnel tripping over a cable may cause electric shock, contact to
hot metal or falling risk for himself, you and other people.
Page 3
Expressweld MasterMIG 250CT
Electric shock risk related to welding machine divides into two categories:
Primary voltage shock (e.g. 230-460 V)
Secondary voltage shock (e.g. 20-100 V)
ELECTRIC SHOCK can kill.
All equipment, cables, hoses and gas cylinders should be kept away from busy places
such as doors, aisles and stairs. Care should be taken for the tidiness of the environment
and when welding is completed working environment should be cleaned. By this way,
both work safety and working efficiency will increase. Besides, other workers near the
welding area may step into weld pool by mistake, therefore safety guards should be
placed around the welding area during welding.
Electric shock danger is the most serious risk that operator may encounter frequently.
Contacting electrically hot parts may cause injuries, death or falling down due to electric
shock and sudden reflex. While machine is operating, do not touch to the electrode,
ground connection or live work piece connected to the machine. Insulate yourself against
electrode, grounding connection or work piece. Immediately after plugging out the power
cable, do not touch metal ends of power cable, there may be electric shock danger.
Primary electric shock is very dangerous since it is much higher than welding voltage.
When the power to the machine is open, you can encounter with primary electric
shock while your body is in contact with ground or touching a live point within the
machine. Please note that turning off the ON/OFF switch located on the machine do
not cut off the electric. To cut off the electric to the machine it is necessary to
disconnect the supply cable from connection point or to shut down the fuse of
incoming electric.
Never remove side covers of the machine and in case of failure have an authorized
technician to inspect and repair it.
Be sure to ground the machine and work piece.
While installing the machine and making ground connection, follow general electric
rules, all local laws and regulations and instructions of the manufacturer company.
Do not use uninsulated cables and pliers, replace with the new ones. Never dip the
electrode in water for cooling.
Page 4
Expressweld MasterMIG 250CT
Welding Arc and Arc Rays can burn.
Never simultaneously touch electrically "hot" parts of electrode holders connected to two
separate welders, because voltage between the two can be the total of the open circuit
voltage of both welders.
When working above floor level, use a safety belt to protect yourself from a fall should you
get a shock.
In semi-automatic or automatic welding, welding wire, electrode reel, welding head,
nozzle or torch are also electrically “hot”.
Always be sure the work cable makes a good electrical connection with the metal being
welded. The connection should be as close as possible to the area being welded.
While the welder is electrically hot, do not insert your hand or any other object inside it.
Use a shield with proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding. Skin should be protected by
clothing made from flame resistance material. Protect other nearby personnel with
suitable, non-flammable screening and/or warn them not to watch welding arc nor expose
themselves to the arc rays or to hot spatter or metal.
When eyes are exposed to UV rays even for a short time, also called as “Getting Welder's
Flash”, it may cause burns in your eyes. Getting Welder's Flash may not be noticed after
hours of exposing, but it is too irritating as well as may cause transient blindness. Normally
getting welder's flash is a temporary situation, but exposing eyes to UV rays for a long time
and frequently may cause permanent damage on eyes. As a protection measure besides
not to watch arc rays, also using welding goggles having proper filter is necessary.
As a rule, welding should start with a dark colored protective filter then should continue
with a lighter colored filter sufficient to see the area being welded providing that not to fall
under the minimum level. Welding masks protect head, face, ears and neck against
electric shock risk, heat, sparks and fire.
Page 5
Expressweld MasterMIG 250CT
GASES and FUMES can be dangerous.
When welding with electrodes which require special ventilation such as stainless or hard
facing or on lead or cadmium plated steel and other metals or coatings which produce
highly toxic fumes, keep exposure as low as possible and keep the exposure level under
“Minimum Limit Values” using local exhaust or mechanical ventilation. In confined spaces
or in some circumstances, a respirator may be required even outdoors. Additional
precautions are also required when welding on galvanized steel.
Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent
vapors to form a highly toxic gas, and other irritating products.
Welding may cause fumes and gases that are injurious to health. Always enough
ventilation should be used or fumes and gases should be exhausted from breathing
place.
Generally in welding applications; temporary effects for short time can be seen such as
face and skin burning, dizziness, nausea and fever based on exposure period and
amount of fume. Long time fume exposure may cause iron loading and dysfunctions in
lungs. Bronchitis and pulmonary fibrosis are primary effects occurred.
Some electrodes may include alloys that entail special ventilation. Label of these
products that entails special ventilation should not be ignored and gProduct Safety
Information Form h reports should be read carefully. When welding on this kind of
materials it may be necessary to use gas mask.
Keeping your head out of fume clouds is the easiest way for protection against toxic fumes
and gases.
Avoid breathing these fumes and gases, air circulation or mechanical ventilation
equipments should be used and if the ventilation is not enough gas mask should be used.
Page 6
Expressweld MasterMIG 250CT
WELDING and CUTTING SPARKS can cause fire or
explosion.
Where compressed gases are to be used at the job site, special precautions should be
used to prevent hazardous situations.
Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken
to insure that such procedures will not cause flammable or toxic vapors from substances
inside. Tanks, drums or containers can cause an explosion even though they have been
cleaned. For information, read “Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from American Welding Society.
Connect work cable to the piece being welded as close as possible. Work cables
connected to the building framework or other locations away from the welding area
increase the possibility of the welding current passing through lifting chains, crane cables
or other alternate circuits. This can create fire hazards or overheat lifting chains or cables
until they fail.
Keep away fire hazards from welding area and have a fire extinguisher readily available.
Remember that welding sparks and hot materials from welding operation can easily go
through small cracks and openings to adjacent areas. Until ensuring that precautions are
used to fully clean flammable and toxic gases, never weld any tanks, drums, containers or
material. Never operate welder in places that flammable gases, vapors or liquid fuels
exist.
Always keep in mind the fire risk due to high temperatures in arc welding. Welding arc
temperature may increase up to 5000 ‹C, but generally this temperature is not the only
fire reason. Fire risk may be occurred due to sparks or melted metals splashed around.
These metals may splash up to ten meters away. Therefore keep inflammable materials
away from welding area. Also make sure that your work piece do not contact with any
material that may flare when heated. Material, that may flare with contact are divided into
three categories as liquids (fuel, oil, paint, thinner etc.), solids (wood, cartoon, paper etc.)
and gases (acetylene, hydrogen etc.).
Inspect the welding area. If there are systems operating with fuel or hydraulic oil and if you
cannot move welding area or system, place fire-resistant protecting screen between
them.
Page 7
Expressweld MasterMIG 250CT
FIRE DANGER may cause accidents.
If you are working above floor level or on stairway, make sure there is no flammable or
explosive material below. Also please remember that slag and sparks may splash on
people around.
Special precautions should be used when welding in dusty environment. Dust particles
may burn and may cause sudden fire or explosion. If you don't have information about the
inflammableness and fugacity of the dust in the environment, do not start welding or
cutting until it is inspected and approved by expert and authorized person.
Before starting to the welding procedure, please check if there is any flammable or selfignition under heat coating on the surface of your work piece.
When you have a break in welding process, please make sure that the electrode holder
do not contact to the ground or work piece.
If you are welding within ten meters to the place where flammable materials located, have
a observor near you. This observer should watch where the sparks and splashes go and
should access easily to the fire extinguishers when necessary. After welding process,
please check if there is any fume around for half an hour with the observer.
As in other emergency situations, first rule is not to panic in situations where welding
accidents happen. According to the size of the fire, to warn the others activate the fire
alarm, inform fire station, shut down the plasma cutting machine and leave the building
from fire exits as soon as possible.
To prevent the risk for every kind of arc glare and fire, never leave the welding torch on
welding desk or any surface in contact with work clamp.
Never refuel near to the welding arc or if there is any engine operating in the surrounding
area. Stop the engine and allow it to cool before refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts and igniting. While refilling the tank, do not
spill fuel around.
Page 8
Expressweld MasterMIG 250CT
Use only compressed gas cylinders containing the correct shielding gas for the process
used and properly operating regulators designed for the gas and pressure used. All
hoses, fittings, etc. should be suitable for the welding application and maintained in
good condition with a proper installation.
Always keep cylinders in an upright position securely chained to an undercarriage or
fixed support.
Carefully choose the locations of the cylinders:
Cylinders should be kept away from areas where they may be struck or subjected
to physical damage.
Cylinders should be located to a safe distance from arc welding or cutting
operations and any other source of heat, sparks or flame.
Never allow the electrode, electrode holder or any other electrically “hot” parts to touch
a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the
Valve protection caps should always be in place and hand tight except when the
cylinder is in use or connected for use (including the transportation of the cylinder).
CYLINDER may explode if damaged.
MOVING PARTS may hurt your hands.
cylinder valve.
Always keep all safety guards, coverings and equipments in place and maintain in good
condition. Always keep your hands, hair, clothing and tools away from V-belt, gears, fans
and all other moving parts when starting, operating or repairing the equipment.
In some cases, it may be necessary to remove safety guards to perform required
maintenance. Remove the guards only when necessary and replace them when the
maintenance requiring their removal is complete. Always use the greatest care when
working near moving parts.
Never put your hands near to the cooling fan while it is operating.
To prevent accidentally starting gasoline engines while turning the engine or welding
generator during maintenance work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Page 9
Expressweld MasterMIG 250CT
For electrically powered equipment.
WELDED HOT material may cause burns.
ELECTRIC and MAGNETIC fields may
be hazardous on human health.
Compliance with CE NORMS,
SAFETY USAGE.
Turn off input power using the disconnect switch at the fuse box before working on the
equipment. Install equipment in accordance with local codes in force.
GROUNDING: Power cables should be connected to a well grounded plug for your
safety and proper operation of the equipment.
Periodically inspect the conditions of electrode cables, supply cables and cables
connected to the equipment. If you notice any improper situation, immediately replace
damaged parts with the new ones. To prevent the risk for every kind of arc glare and fire,
never leave the electrode holder on welding desk or any surface in contact with work
clamp.
High amounts of heat may be produced from welding process. Hot surfaces and material
may cause serious burns. While touching or moving this kind of material, always wear
gloves.
Electric current flowing through any conductor causes electromagnetic fields. This
electromagnetic field may interfere with devices such as pacemaker. Welders having a
pacemaker shall consult their physician before operating this equipment. Exposure to
electric and magnetic fields may have other health effects which are not known yet (For
detailed information, refer to Page 12).
This machine has been manufactured as per “European Instructions”.
This machine is suitable for welding in environments where there is high electric shock
risk.
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