Fytech FY-4250/2E User manual

Owner’s Manual
FY-4250/2E
The equipment is approved by a number of car manufacturers(China)

CONTENTS
1.Safety Precautions Symbols
2. Symbols And Descriptions
3.Accessories And Spare Parts
4.Installation
4-1. Specifications
4-2. Duty Cycle And Overheating
4-3. Machine Installation
4-4. Selecting A Location
4-5. Installing Gas Supply
4-6. Connecting Input Power
4-7. Threading Welding Wire
4-8. Changing Drive Roll
4-9. Typical MIG process Connection
4-10.Welding Gun
5.Operation
5-1.Controls
5-2.Holding And Positioning Welding Gun
5-3.Conditions That Affect Weld Bead Shape
5-4.Gun Movement During Welding
5-5.Poor Weld Bead Characteristics
5-6.Good Weld Bead Characteristics
6.Troubshooting
6-1.Excessive Spatter
6-2.Porosity
6-3.Excess Penetration
6-4.Lack Of Penetration
6-5.Incomplete Fusion
6-6.Burn-Through
6-7.Waviness Of Bead
6-8.Distortion
6-9.Troubleshooting Guide For Semiautomatic Welding Equipment
7.Exploded View
8.Electrical Diagram
9.Packing List
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

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Preface
Please read this instruction manual carefully before using and the equipment and refer to it as
needed to ensure the continued safe operation of the equipment.
This instruction manual should be read completely before attempting to use or service the equipment.
Failure to follow the instructions in this manual could result in property damage, severe personal injury, or
death.
The followingwarningsand importantnotices are used in the instructionmanual:
!WARNING
Improper use of this equipment can cause
personal injury or property property damage
操作错误时。有可能会造成人体死亡或重伤的危险
DANGER
Improper use of this equipment can cause serious or fatal injury
.
Magnetic fields can affect pacemakers. Pacemaker wearers keep away from the equipment.
Wearers should consult their doctor before going near equipment operations.
Do not touch any live electrical parts. Wear dry, hole-free insulating gloves and body
protection. The input power circuit and machine internal circuit are live with high voltage
when power is on. Touching live electrical parts can cause fatal shocks or severe burns. High
voltage exists in the power supply socket. Never touch the conductor terminals with bare
hand.
Input power installation must meet national standard. All electrical connections must be
made by a qualified electrician. Insulated gloves and shoes must be worn when connecting
input power or maintaining equipment.
Never disassemble, repair, alter or
rebuild the equipment without approval
from the manufacturer. There is a risk
for electrical shock and fire.
Electric shock can kill. Properly ground
this equipment according to its user
manual and national standard.
Make sure the supply cable is up to national standard or
local code.Use only the right gauge of electrical
wire/cable.There is a risk of fire or electrical shock if
overload building wiring-be sure power supply system is
properly sized,rated and protected to handle this unit.
Replace power cord/wire/cable immediately-bare wiring can kill.
Do not step on, twist or pull the power cord..
Frequently inspect input power cord and regularly clean the unit to
remove dust and dirt.Any worn or damaged power cord or internal
components in heavy dust may cause electrical shock, short
circuit or fire.
In the event of abnormal, operation must be immediately stopped. If smoke, smell or abnormal noise is produced by the
unit, disconnect the power cord immediately and contact your local dealer. Do not use it until the problem is fixed.
Do not operate or place the device near water or in wet locations. Risk for electrical shock or damage to the device.
Do not operate the equipment in potential hazardous areas : chemicals, oil, gas and mining, or the worksites
where power supply system is in poor condition.
Use only well-maintained device. Inspect and maintain the device for safety every 12 months, including
cleaning and removing dust. Repair or replace damaged parts/cables at once.
Follow the installation and operation instruction to ensure user safety and proper equipment
performance. It is the responsibility of the owner to ensure that the equipment has been installed and
operated as specified in the instructions provided. The manufacturer takes no responsibility for any loss
or damage suffered as a result of using the equipment incorrectly or improperly.
XImproper use of this equipment
can cause serious or fatal injury
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◆Hot parts can cause severe burns.Do not touch workpieces or metallic parts of torch with bare hands during or after
welding.Allow cooling period and use a proper tools or wear welding gloves to handle hot parts to prevent burns.

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!WARNING
Improper use of this equipment can cause personal injury or property property damage
Follow the installation and operation instruction to ensure user safety and proper equipment
performance. It is the responsibility of the owner to ensure that the equipment has been installed and
operated as specified in the instructions provided. The manufacturer takes no responsibility for any
loss or damage suffered as a result of using the equipment incorrectly or improperly.
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NOTE
The equipment must be used by qualified personnel familiar with electronic equipment.
Do not place the equipment on unstable or uneven ground. The equipment might fall causing
injuries and damage to the equipment.
During operation process, the equipment should keep a distance about 10cm from the wall to keep air way clear.
Avoid using the equipment in the environments with high humidity (above 90% ), high temperature (above
40℃),low temperature(below5℃),high frequency source nearby, chemical and drug, water vapor for
condensation, dust or vibration.
Make sure the facility supply voltage and frequency are the same as shown on name plate. The supply
cable must be properly sized and rated.
The connection between the main power supply and the equipment should be as short as possible.
Use a dry cloth to clean the dirt on the equipment.
Do not forget to take back all repair tools/objects inside the equipment after repair/ maintenance, such as
screws, bolts or nuts. The left out metallic objects inside the equipment can cause damage to the
equipment.
Follow the instructions of this user manual to operate the equipment.
We have made installation and operation quick and easy. Please operate the buttons and switches gently with
your hands, only one button each time. The sensitive control circuit will be damaged if pressing the
buttons with a hard and sharp thing such as screw driver and, pen.
Turn off all equipment when not in use.
Follow the installation and operation instruction to ensure user safety and proper equipment
performance. It is the responsibility of the owner to ensure that the equipment has been installed and
operated as specified in the instructions provided. The manufacturer takes no responsibility for any
loss or damage suffered as a result of using the equipment incorrectly or improperly.
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The equipment is designed for welding of metals only. Do not use the
equipment for other purposes. This may cause fire or electrical shock
Never place any materials/objects on top of the equipment to avoid fire and
electrical shock.Do not locate equipment on,over,or near combustibles in worksite.
The flying sparks can cause fires and burns.Do not weld where flying sparks can
strike flammable material.
Read instruction manual before using
equipment. Use only the spare parts
supplied or approved by manufacturer.
Moving wire feed rollers and spools can
cause injury when changing welding wire.
Overuse can cause overheating.Avoid
overuse of the equipment which can cause
components to overheat and equipment to
shorter life.
Keep away from moving parts such as
fans. Moving fans cause injury when
changing welding wire.
Keep your hand away from the opening
of the welding torch when the torch
trigger is pressed. The wire coming out
from torch will cause injury of hands.
Make sure gas bottle and gas regulator are
in good conditions. It may cause
explosion if the gas bottle or regulator is
damaged.

Symbols And Descriptions
Symbols And Definitions
U1
U0
U2
I2
s1
HZ
A
V
Primary voltage
Hertz
IP
X
~
1
V
I
O
＋－
%
Adjust Air/Gas
Pressure
Description:
Our semi-automatic welder is an all-in-one MIG shielding gases welder (GMAW) with high
efficiency that is an ideal substitute for manual arc welding.
Most advanced circuit design and technology are adopted.Excellent performances,supreme reliability,
quality welding requirements can be satisfied.Spot weld,groove weld,and fillet weld are available.Most
commonly used shielding gases are applicable such as Co2,AR,CO2+AR,CO2+O,etc.
Suitable for welding of variou metallic materials such as mild steel,low carbon steel,low alloy steel,
stainless steel, steel,iron,copper, aluminum,nicket,etc.
Extensively used in the welding and field operation of oil pipeline,chemical,car fabrication,shipyard,
etc.
Gas Input
Gas Output Do Not switch
While welding
Amperes
Volts
Gas Metal Arc
Welding(GMAW)
Gun On Percent
Wire Feed Off Increase
Line Connection
Loose Shield Cup
Protective Earth
(Ground)
Degree Of
Protection
Rated Welding
Current
No--Do Not DO
This
Single Phase
Power Rating,Products
Of Voltage And Current
Duty cycle
Direct Current
Wire Feed
Spool Gun
Input
Constant Current
Voltage Input
Temperature
Rated No Load
Voltage(Average)
Conventional Load
Voltage
Page.2

Accessories And Spare Parts
Accessories And Spare Parts List
Pressure Regulator NO.C001
Contact Tip NO.C004
Welding Gun NO.C007
Front Adaptor NO.C010
Trigger Potentiometer NO.C013
Capacitor NO.C016
Feeder Potentiometer NO.C019
Anti-Clogging Ointment NO.C022
Panel Socket NO.C025
Back Wheel NO.C028
Adjustment Switch NO.C002 European Connector NO.C003
Ouput Cable NO.C005
Collect Body NO.C008
Wire Guide NO.C011
Fuse Socket NO.C014
Electromagnetism NO.C017
15AK Gooseneck NO.C020
24AK Gooseneck NO.C018
Control Transformer NO.C023
Digital Display NO.C026
Hose NO.C029
Spool Spindle NO.C006
Fan NO.C009
Shield Cup NO.C012
Chain NO.C015
Feeder Motor NO.C021
NO.C024
Front Wheel NO.C027
Circuit Board NO.C030
Remarks:
1.Optional orders for above accessories and components are available.
2.Model and part number required when ordering parts from your local distributor.
European Connector
Shield
Page.3

Installation Instruction
Side panel
Gun holder
6" torx screw
6" nut
Wheel
Wheel axle
Rubber mat
Wheel washer
Wheel cap
6" torx screw
Side plate
Fender panel
Caster bracket
Caster
8" inner-
hexangular screw
Install the gun holer to the side panel; install the side plates to the fender panel; install the wheel
axle and wheels to the fender panel; install the fender panel to the back panel (using 6" torx screws
and nuts); install casters to the caster bracket (using 8" inner-hexagonal screws); put the rubber
mat on the fender panel.
Page.4

1.Specifications
INSTALLATION
Page.5
Model
Parameter
Voltage
(V)
Frequency
(Hz)
Rated Max
Input Current
(A)
Max Effective
Input Current
(A)
No-load Voltage
(V)
Welding Current
(A)
Output
Current/Voltage
Insulation Grade
Wire Diameter
Type
Dimensions
(mm)
Voltage
Adjustment
Weight
(kg)
Duty Cycle
35%
F
850×380×890
96
10.3
35A/17V-
250A/26.5V
13.6
20-32
35-250A
AC 380V/3ph
50 / 60
10 stages
One-piece
Mild Steel
Solid Wire
0.8/1.0mm
FY 4220 2E- /
98
12.5
35%
850×380×890
35A/17V-
250A/26.5V
F
16.8
20-37
35-250A
AC 380V/3ph
50 / 60
10/6 stages
One-piece
Mild Steel
Solid Wire
0.8/1.0mm
FY-4250/2E

2.Duty Cycle And Overheating
1.Overheat protection is installed on the aluminium board of main
transformer and rectifier.The unit products heat while welding.
2.If unit overheats ,output stops, and cooling fan runs.
3.Wait fifteen minutes for unit to cool.Reduce amperage or voltage,
or duty cycle before welding.
Overheating Stop working Wait 15 minutes
for unit to cool
Reduce amperage
or reduce duty
cycle
0
15
A
Weld again
Page.6

3.Machine Installation
1.Open the package and find out the Owner's Manual.
2.Check the details of accessories according to packing list
that attached to this manual.
3.Properly install this equipment as following diagram.Inspect the
unit for any damage. If so,contact your local distributor or service
agency.
4)The unit should not be located under sunshine.The worksite should
be in low humidity and without dust.
5)Operating Temperature range:-10℃-+40℃.
6)Storage Temperature range:-25℃-+56℃.
7)At least 20cm of space for airflow,30cm of space for two units
located side by side.
8)Use tent to protect the machine from stormy weather when operate
outdoor.
9)Welding produces fumes and gases,Breathing these fumes and gases
3
can be hazardous to your health.If inside,less than 300m,Venti-
late the area.
10)Properly ground this equipment.
11 ）The input power cord gradient should not more than 15°.
Page.7

4、Selecting a Location
1)Select a correct location to place the unit。
2)Determine input power cord length according to its actual operation
requirement.Input power cord must have a minimum inside diameter of
2
6mm。
3)Do not move or operate unit where it could tip。
4)Use cart or unit handle to move unit .Do not pull the cords to move
unit.
5)Moving gas cylinder and main unit to hight sparaely.Use lifting eye
to lift unit only ,not running gear,gas cylinders,or any other ac-
cessories.
6)Optional order for individual wire feeder is available.The wire fe-
eder and welding gun divide from the main unit.It is more convenient
to operate.
Page.8

1)、Cap
2)、Cylinder valve
(Remove cap,stand to side of valve,and open valve slightly.Gas flow
blows dust and dirt from vavle.Close vavle)
3)、Cylinder
4)、Regulator/Flowmeter
(Install so face is vertical)
5)、Flow Adjust
(Typical pressure is 0.05-0.15MPa)
6)、Hose
7)、Hose Connection
(Connect gas hose between regulator/flowmeter and the unit) )
8)、Regulator/Flowmeter heating socket
(For low temperature worksite,please plug the regulator/flowmeter
to the socket for heating.)
5、Installing Gas Supply
DO NOT use other gases regulator/flowmeter
with Co2 shielding gas.
Rear Panel
Page.9
7
8
ON
OFF
CO2
1
2
3
4
5
6

2
1. Input power cord (not less than 6mm copper cord).
2. Over-current protection.
3. Disconnect device line terminals.
4. Ground wire L1/L2 input conductors
Disconnect and lockout/tagount input power
before connecting input conductors from
unit.
Select type and size of over-current
protection.
Ground the earth cable.
Close and secure door on disconnect device .
Remove lockout/tagout device,and place
switch in the "on" position.
6、Connecting Input Power
Page.10
1
2
3
L1
L2
1
4
3
2
L3
L1
L2
Th e po we r su pp ly must have a ground connection.
Th e we ld er m us t also be connected to circuit brea ke r.
Th e p o wer su p ply mus t h ave a gro u nd conn e ctio n .
Th e w e lder m u st also b e c onnec t ed to cir c uit br e a ker.
ON
OFF
CO2
Power connection and installation must meet all
National and Local standards(Circuit breaker must
be installed).Only qualified persons are allowed to
make this installation.

7、Threading Welding Wire
1 、Wire spool spindle
2 、Welding Wire
3 、Pressure adjustment knob
1.Open wire spool spindle;install wire spool;release pressure adjustment knob;pull and hold wire.
Push wire thru guides into drive roll.Close wire spool spindle tightly to prevent slipping (Feed
wire to check wire spool installation).
2.Set a desired drive roll pressure, close and tighten pressure adjustment knob.
3.Press gun trigger and let go of wire.
4. Remove gun nozzle and contact tip.
5. Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle.
6. Feed wire to check drive roll pressure ,tighten knob enough to prevent slipping.
7. Cut off wire if welding wire extends too far beyond nozzle.
Page.11
1
2
3

8、Changing Drive Roll
1
2
3
4
1、Drive roll securing nut
2、Drive roll
3、Pressure adjustment knob
4、Press device
Changing Drive roll:
1、Release pressure adjustment knob .Press wire device springs open.
2、Loosen securing nut ,Remove drive roll.
3、The drive roll consists of two different sized grooves.Reinstall the desired wire sized groove
close to the motor shaft.
4、Tighten securing nut.
5、Replace press wire device,and set a desired pressure.
6、Make sure drive roll groove lines up with wire guide.
Page.12

9、Typical MIG Process Connection
Shielding gas
Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding
on a vehicle .Place work clamp as close to the weld as possible.
Regulator/Flowmeter
Wire feeder
Gun
Work clamp and
workpiece
Hose
Page.13
ON
OFF
CO2

10、
12
3
4
5
6
1、Shield cup C012
2、Contact tip C004
3、Front adaptor C010
4、Gooseneck(15/24AK) C020/018
5、Trigger
6、Spanner
Welding Gun
Page.14

1、Controls
Operation
Page.15
1. Display
2. Wire speed adjustment
3. Weld time extension
4. Weld current adjustment
5. Indicator light
5
4
2
3
1

0°-15°
0°-15°
45°
45°
90°
90°
2、Holding And Positioning Welding Gun
5
1
2
3
4
1、Hold Gun and Control Gun Trigger
2、Workpiece
3、Work Clamp
4、Electrode Extension (Stickout)
5、Cradle Gun and R est Hand on Workpiece
End View Of Work Angle Side View Of Gun Angle
GROOVE WELDS
End View Of Work Angle Side View Of Gun Angle
FILLET WELDS
Welding wire is energized when gun trigger is pressed.Before lowering helmet and pressing trigger,be
sure wire size is correct to past end of contact tip, and tip of wire is positioned correctly on seam.
Page.16

10°
10°
3、Conditions That Affect Weld Bead Shape
Push
Perpendicular Drag
GUN ANGLES AND WELD BEAD PROFILES
Short Normal Long
ELECTRODE EXTENSIONS(STICKOUT)
Short Normal Long
FILLET WELD ELECTRODE EXTENSIONS(STICKOUT)
Slow Normal Fast
GUN TRAVEL SPEED
Weld bead shape depends on gun angle ,direction of travel,electrode extension(stickout),travel speed,
thickness of base metal,wire feed speed(weld current),and voltage.
Page.17