ESAB MIG C250i User manual

MIG C250i
Instruction manual
Welding Power Source

MIG C250i
Instruction manual
For
Installation, Operation & General maintenance

1
SAFETY
Precautions for installation
Beware of electric shock!
Install grounding device according to application standard.
Do not touch live parts with naked skin, wet gloves or wet clothes.
Be sure you are insulated from ground and work piece.
Cover the cover plate of the machine before power on to avoid an
electric shock.
Confirm the safety of your working position.
Beware of fire hazard!
Please install the machine on non-combustible materials to avoid
a fire.
Make ensure there are no inflammables near the welding position
to avoid a fire.
Beware of explosion!
Do not install the machine in an environment with explosive gas
to avoid an explosion.
Replacing the components can be dangerous.
Only professionals can replace the components of the machine.
Make sure the connecting wires inside the machine are correctly connected after replacing the
PCBs, and then the machine can be run. Otherwise, there is a risk of damage to property.
Make sure there are no foreign bodies such as wire leads, screws, gaskets and metal bars
falling into the machine inside when replacing the components.
Carrying or moving the machine can be dangerous.
Cut the input power off via the switching box before moving the welding machine.
The handle can only be used for moving the welding machine by hand in short distance, and
it cannot be used for lifting. Otherwise, personal injury or property damage may be caused by
a drop.
Make sure that the flying rings are tightened, and that the machine enclosure and cover are
fixed when moving the welding machine with a crane,
Two lifting belts should be used when lifting the welding machine, and the angle formed by the

2
lifting belt and the vertical should be smaller than 15°.
Do not apply any stress on the operation panel and cover when moving the welding machine.
Otherwise, personal injury or property damage may be caused by a drop.
Do not install and run the welding machine when the machine is damaged or lacks any
components. Otherwise, fire hazard or personal injury may be caused.
Precautions for operation
Smoke-may be harmful to your health!
Keep your head away from the smoke to avoid inhalation of waste
gas in welding.
Keep the working environment well ventilated with exhaust or
ventilation equipment when welding.
Arc radiation-may hurt your eyes and burn your skin!
Use proper welding mask and wear protective clothing to protect
your eyes and body.
Use proper mask or curtain to protect onlooker from being injured.
Magnetic field can make cardiac pacemaker a bit wonky.
People with cardiac pacemaker should consult the doctor before
carrying out welding.
Stay away from the welding source to reduce the effect of magnetic
field.
Improper use and operation may result in a fire or an explosion.
Welding spark may result in a fire, so please make ensure there are
no inflammables near the welding position, and pay attention to fire
safety.
Ensure there is fire extinguisher nearby, and make sure someone
has been trained to operate the fire extinguisher.
Do not weld closed container.
Do not use this machine for pipe thawing.
Hot work piece can cause severe scald.
Do not touch hot work piece with bare hands.
Cool the welding torch for a while after continuously working.
Excessive noise does great harm to people’s hearing.
Wear ear covers or other hearing protectors when welding.
Give warning to onlooker that noise may be potentially hazardous to
hearing.

3
Moving parts may injure your body.
Please keep away from moving parts (like fan).
Each door, panel, cover, baffle plate, and protective device the like
should be closed and located correctly.
Seek professional support when trouble strikes.
When trouble strikes in installation and operation, please inspect
according to related contents in this manual.
If you still cannot understand fully, or you still cannot solve the
problem, please contact the service center to obtain professional
support.

4
TABLE OF CONTENTS
1. SAFETY....................................................................................................1-3
Technical parameters ..............................................................................5
2. INSTALLATION AND CONNECTION ..........................................................2
Installation requirements............................................................................
Electrical connection..................................................................................
3. OPERATION.............................................................................................7-9
Panel functions of MIG C250i ..................................................................
Operation of the panel functions................................................................
Input Power Supply ...................................................................................
Wire Feeding Mechanism..........................................................................
Work after welding.....................................................................................
4. MAINTENANCE .....................................................................................9-11
Daily maintenance.....................................................................................
Periodic check...........................................................................................
5. TROUBLESHOOTING..........................................................................12-13
6. WIRING DIAGRAM....................................................................................14
7. SPARES LISTAND EXPLODED DIAGRAM ........................................15-17

5
Technical Parameters of MIG C250i
Description
Specification
Model
MIG C250i
Input Voltage V
1Phase 220V
3Phase 415V
Frequency Hz
50/60
Rated input current A
45
14.8
Rated KVA
10.3
10.8
MMA welding current A
20A~200A
MIG welding current A
30A~250A
Welding current（10min）A
60%@250
Efficiency η
85%
Power factor Cosφ
0.9
Insulation class
F
Enclosure protection IP
21S
Cooling type
Fan cooled
Weight Kg
53
Dimension L×W×H mm
1000*490*730
The MIG C250i series is a DC inverter compact MIG welding machine with MMA
function. This unit uses 1~Phase 220V, 50/60Hz or 3~Phase 415V, 50/60Hz input AC
power.

6
INSTALLATION AND CONNECTION
Installation requirements
1) Environment requirements
a) Do not install the machine at places with excessive dusts and metal powders.
b) Do not install the machine at places with corrosive or explosive gas.
c) The temperature of the working environment should be between -10℃and 40℃.
d) Do not carry out welding with the welding machine placed on a platform with a pitch
greater than 15°.
e) The machine should be installed in a well-ventilated place with humidity of 90% or
less and without water condense.
f) Pay attention to the wind at the welding site, and use wind deflector if necessary.
Otherwise, the welding process will be affected.
2) Installation space requirements
The welding machine should be at least 20cm away from the walls, and there
should be at least 30cm between them when two machines are installed side by side.
Please refer to the table below to determine the installation position of the welding
machine. Table 2-1: Reserved space when installing the welding machine
Machine part
Front
Top
Left
Right
Rear
Reserved space
≥20cm
≥10cm
≥20cm
≥20cm
≥20cm
Electrical connection
•High voltage danger from power source! Consult a qualified electrician for proper
installation of receptacle. This welder must be grounded while in use to protect the
operator from electrical shock.
• Do not remove grounding connection or alter the plug in any way. Do not use any
adapters between the welder’s power cord and the power source receptacle. Make
sure the POWER switch is OFF when connecting your welder’s power cord to a
properly grounded input AC supply.

7
OPERATION
Panel Functions of MIG C250i
Serial
No.
Part name
Function
1
Current meter display
To display the welding current value.
2
Voltage meter display
To display the welding voltage value.
3
Wire Inching switch
To feed wire without welding.
4
2 / 4 Stroke
2 or 4 stroke operation in MIG.
5
Welding Process Selection
MIG or MMA Selection.
6
Voltage Control
Voltage adjustment in MIG
7
Current Control
Wire Speed/ Current Control in MIG/ MMA.
8
Positive Output
Positive Output Terminal
9
Output Selection
MIG Polarity Change Cable
10
Negative Output
Negative Output Terminal
11
Torch Connector
Euro type MIG Torch Connection
12
LEDS
Power On / Over Heating
13
Inductance Control
Inductance Adjustment in MIG mode

8
Rear panel
Input Power Supply
This unit uses 1~Phase 220V, 50/60Hz or 3~Phase 415V, 50/60Hz input AC power.
3 Phase supply connection:
Connect 3 Phase 415V, 50Hz input power supply (R, Y, B and Ground) to the
corresponding R, Y, B and ground wires of the power source.
1 Phase Supply connection:
Connect 1 phase 220V, 50Hz input power supply to “RED” and “BLACK” wires and
ground wire of the power source.
Wire Feeding Mechanism
Wire Feeding mechanism is inbuilt inside
the machine. Wire Spool mounting and
feed roller assembly both are available
on the right side of the machine.
Work after welding
1) Cut off the power of the welding machine 3~5min after the welding work is finished,
so as to cool the internal of the machine.
2) Turn off the air switch on the welding machine first and then switch off the power
in the switching box when shutting off the power.

9
MAINTENANCE
Daily maintenance
WARNING
The power of the switching box and the welding machine should be shut down
before daily checking (except appearance checking without contacting the
conductive body) to avoid personal injury accidents such as electric shock and
burns.
Tips:
1) Daily checking is very important in keeping the high performance and safe
operation of this welding machine.
2) Do daily checking according to the table below, and clean or replace components
when necessary.
3) In order to ensure the high performance of the machine, please choose
components provided when replacing components.
Table: Daily checking of the welding machine
Items
Checking requirements
Remarks
Front
panel
Whether any of the components are
damaged or loosely connected;
Whether the cables at the bottom are
tightly connected;
Whether the abnormity indicator
illuminates after starting the machine.
If unqualified, check the
interior of the machine, and
tighten or replace the
components.
Rear panel
Whether the input power cable is in
good condition;
Whether the air intake is unobstructed.
Cover
Whether the bolts are loosely
connected.
If unqualified, tighten or
replace the components.
Chassis
Whether the rubber feet are damaged
or loosely connected.
Side plates
Whether the side plate is distorted,
damaged or loosely connected.
Fan
Whether the fan or fan guard is
distorted or damaged.
Whether the fan works or sounds
normal when the machine is running;
If abnormal, eliminate the
failures or replace the fan.

10
Table: Daily checking of accessories
Items
Checking requirements
Remarks
Earth
cable
Whether the grounding wires (including
work piece GND wire and welding
machine GND wire) break off.
If not proper, tighten or
replace the components.
Welding
cable
Whether the insulating layer of the
cable is worn, or the conductive part of
the cable is exposed;
Whether the cable is drawn by an
external force;
Whether the cable connected to the
work piece is well connected.
Use appropriate methods
according to the work site
situation to ensure safety
and normal welding.
Periodic check
WARNING
Periodic check should be carried out by qualified professionals to ensure safety.
The power of the switching box and the welding machine should be shut down
before periodic check to avoid personal injury accidents such as electric shock
and burns. Due to the discharge of capacitors, checking should be carried out 5
minutes after the machine is powered off.
Tips
Safety
All maintenance and checking should be carry out after the power
is completely cut off. Make sure the power plug of the machine is
pulled out before uncovering the welding machine.
When the machine is powered on, keep hands, hair and tools
away from the moving parts such as the fan to avoid personal
injury or machine damage.
Periodic check
Check periodically whether inner circuit connection is in good
condition (esp. plugs). Tighten the loose connection. If there is
oxidization, remove it with sandpaper and then reconnect.
Check periodically whether the insulating layer of all cables is in
good condition. If there is any dilapidation, rewrap it or replace it.

11
Beware of static
In order to protect the semiconductor components and PCBs from
the static damage, please wear antistatic device or touch the
metal part of the enclosure to remove static in advance before
contacting the conductors and PCBs of the machine internal
wiring.
Keep it dry
Avoid rain, water and vapor infiltrating the machine. If there is, dry
it and check the insulation of the welding machine (including that
between the connections and that between the connection and
the enclosure) with an ohmmeter. Only when there are no
abnormal phenomena anymore, can the machine be used.
Put the machine into the original packing in dry location if it is not
to be used for a long time.
Pay attention to maintenance
Periodic check should be carried out to ensure the long-term
normal use of the machine. Be careful when doing the periodic
check, including the inspection and cleaning of the machine
interior.
Generally, periodic check should be carried out every 6 months,
and it should be carried out every 3 months if the welding
environment is dusty or with heavy oily smoke.
Beware of corrosion
Please clean the plastic parts with neutral detergent.

12
Trouble Shooting
No
Fault
Cause
Solutions
1
Yellow LED
Indicator is on.
Voltage is too high
(≥15%)
Switch off the power source; Check the
main supply. Restart machine when input
power recovers to normal state.
Voltage is too low
(≤15%)
Poor power
ventilation lead to
over-heat protection
Improve the ventilation condition.
High Environment
temperature.
It will automatically recover when the
temperature is low.
Using over the rated
duty-cycle.
It will automatically recover when the
temperature is low.
2
Wire feeding
motor is not
working.
Potentiometer faulty.
Change potentiometer
Nozzle is blocked up
Change nozzle.
Feed roller is loose.
Adjust Feed Roller Pressure.
3
Cooling Fan is
not working or
rotating very
slowly.
Switch faulty.
Replace the switch.
Fan faulty.
Replace or repair the fan.
Wire broken or
falling off.
Check the connection.
4
Arc is not
stable and
spatter is
large.
Too large contact tip
makes the current
unsteady.
Change the proper contact tip or roller.
Wire feeding is not
proper.
Clean or replace the liner and the torch
cable had better in the line direction.
5
Arc is not
establishing.
Earth cable break.
Connect earth cable.
Work piece has
much greasy dirty or
rusty stain.
Clean greasy dirty or rusty stain

13
6
No shielded
gas.
Torch is not
connected properly.
Connect the torch again.
Gas pipe is pressed
or blocked up.
Check gas system.
Gas system rubber
pipe faulty.
Connect gas system and bind firmly.
7
Others
Please connect ESAB service.

Wiring Diagram.

15
MIG C250i SPARES LIST AND EXPLODED VIEW
Sl.
No.
Item Description
Part Number
1
Plastic hinge
020050170009
2
Permanent magnet motor
020070400340
3
Wire feeder insulation washer
020050050154
4
Gun switch harness
012070020035
5
Radiator left and right windshield
011020012847
6
IGBT amplifier board assembly
012010100042
7
Radiator support column 3
020050050725
8
Panel
011050070455
9
Front Panel
011010030491
10
Handle
020050080081
11
Tap the switch harness
020030304757
12
Self-locking/non-self-locking switch wire harness 2
020030300014
13
Self-locking/non-self-locking switch wire harness 1
020030300013
14
Potentiometer knob
020070110056
15
Insulation flange
020050050106
16
Polarity conversion cable
012070031160
17
Quick Connector
020070570185
18
Blind fastening
011020011127
19
Intermediate frequency transformer
020070250652
20
Medium frequency transformer fixed plate welding
011020010770

16
21
Reactor coil
011020015246
22
Transformer harness
012070024170
23
Radiator insulation washer
020040110104
24
Radiator support column
020050050796
25
Radiator up and down windshield
020040110079
26
Universal wheel
020050070033
27
Bottom assembly
011010040452
28
Radiator
020070430195
29
IGBT amplifier board assembly
012010100042
30
Radiator support column 1
020050050727
31
Bottom bearing assembly
011010040451
32
Rubber single wheel
020050070078
33
Main control board
011050020924
34
Control transformer
020070250718
35
Control board
011050020967
36
Silicon - coated power board
011050010027
37
Fan harness 2
011120360010
38
Fan bracket
011020010208
39
Beam
011020011107
40
sequential plate
011050110038
41
Fan harness 1
012070020095
42
Valve wiring harness
012070024440
43
External force cable fixed head
020040300008
44
Line pressing board
020070990393
45
Universal switch
020070800051
46
Back panel
011010030490
47
Load the small plate
011050110206

17
48
Set panel
011020011134
49
Head cover
011010011600
50
Spool mounting plate
011020012570
51
Spool
020050050516
52
Rotating panel
011020011135

18
ESAB INDIA LIMITED
Registered and Head Office:
13, Industrial Estate, III Main Road, Ambattur,
Chennai - 600058.
Telephone: + 91 44 42281100
Fax: + 91 44 4228 1107
Web: www.esabindia.com