Hong Kong Easyweld EasyMig 250i User manual

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EasyMig EasyMig
MIG Welding System
Instruction Manual EasyMig 250i
EFFECTIVE October 2009
IMPORTANT
Safety and Operating
Instructions
For Your Safety...
PLEASE READ
AREFULLY!
Hong Kong EasyWeld Limited

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CONTENTS
- Instruction 3
- General Welding Safety Instruction 3
- Main Parameter 8
- Installation 8
- Operation 13
- Speed-Read Ta le 15
- Maintenance 17
- Daily Check 18
- Trou leshooting 20

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INTRODU TION
This User’s Guide provides specific information a out your EasyMig Welding System. This
guide provides pertinent information needed to safely and effectively use your Welding
System. The information in this manual applies to specific EasyMig Welding System
models. It gives instructions on set-up, installation and actual use of your EasyMig
Welding System.
SAFETY PROFILE
Tradesmen respect the tools and equipment with which they work. They are also aware
that tools and equipment are dangerous if used improperly or a used.
Read this guide prior to using your welding system. It ena les you to do a etter and
safer jo . You will also learn the machine’s application, limitations and the specific
potential hazards related to welding.
SAFETY INFORMATION
The following safety information is provided to you as a guideline. Use it to operate your
new Easyweld Welding System under the safest possi le conditions. Any equipment that
uses electrical power is potentially dangerous to use when the safety or safe handling
instructions are not known and/or are not followed. This safety information gives you the
necessary information for safe use and operation.
Items in this manual that significantly affect safety are identified with the following
headings. Please read and understand this manual. Pay special attention to items
identified with these headings.
WARNING- Means there is a possi ility of injury or death to yourself or others if the
proper safety precautions are not followed
AUTION-Means there is the possi ility of damage to the Easyweld Welding System
or other property.
NOTI E- Indicates points of interest for more efficient and convenient installation or
operation. It may e used efore or after a procedure to highlight or etter explain the
step.
READ ALL SAFETY AND WARNING INSTRUCTIONS CAREFULLY efore attempting
to install, operate or service this welding unit. Your failure to comply with the
instructions could result in personal injury and/or property damage.
IMPORTANT RETAIN THESE INSTRU TIONS FOR YOUR FUTURE REFEREN E.
GENERAL WELDING SAFETY INSTRU TIONS
LO ATION
Welding processes of any kind can e dangerous not only to the operator ut to any
person situated near the equipment, if safety and operating rules are not strictly
o served.

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PERSONAL PROTE TION
1. WEAR closed, non-flamma le protective clothing, without pockets or turned up
trousers.
2. WEAR a non-flamma le welding helmet to shield the neck, face and sides of the head.
Keep the protective lens clean. Replace the protective lens if roken or cracked.
Position a transparent glass etween the lens and the welding area. Weld in a closed
area that does not open into other working areas.
3. NEVER look at the arc without proper protection to the eyes.
4. Thoroughly clean metal of rust or paint to avoid producing harmful flumes. Parts
degreased with a solvent must dry efore welding.
5. NEVER weld on metals or coated metals containing zinc, mercury, chromium,
graphite, lead, cadmium or eryllium unless the operator and the people standing in
the same area use an air-supplied respirator.
SAFETY INSTRU TIONS
For your safety, BEFORE connecting the power source to the line, follow these
instructions:
1. Insert an adequate two-pole switch, equipped with time-delay fuses, efore the main
outlet.
2. Make the single-phase connection with a two-pole plug compati le with the a ove
mentioned outlet.
3. The two wires of the two-pole input ca le are used for the connection with the
single-phase line. The yellow/green wire is for the compulsory connection to the
ground in the welding area.
4. When working in a confined space, keep the power source outside the welding area
and fix the ground ca le to the work piece. NEVER work in a damp or wet area.
5. DO NOT use damaged input or welding ca les.
6. NEVER operate the power source without its panels in place. This could cause serious
injury to the operator and could damage the equipment.
FIRE PREVENTION
Welding operations use fire or com ustion as a asic tool.
1. The work area MUST have a fireproof floor.
2. Work enches or ta les used during welding operations MUST have fireproof tops. DO
NOT weld on wooden work enches.
3. Use heat-resistant shields or other approved material to protect near y walls or
unprotected flooring from sparks and hot metal.
4. Keep an approved fire extinguisher of the proper size and type in the work area.
Inspect it regularly to ensure that it is in proper working order. Know how to use the
fire extinguisher.
5. Remove all com usti le materials from the work site. If you can not remove them,
protect them with fireproof covers.
WARNING NEVER perform welding operations on a container that has held toxic, com-
usti le or flamma le liquids or vapors. NEVER perform welding operations in an area
containing com usti le vapors, flamma le liquids or explosive dust.

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VENTILATION
WARNING Ventilate welding work areas adequately. Maintain sufficient air flow to
prevent accumulation of explosive or toxic concentrations of gases. Welding operations
using certain com inations of metals, coatings and gases generate toxic fumes. Use
respiratory protection equipment in these circumstances. BEFORE welding, read and
understand the Material Safety Data Sheet for the welding alloy.
ELE TROMAGNETI OMPATIBILITY
BEFORE installing a MIG power source, inspect the surrounding area checking the
following points:
1. Make sure there are no other power supply ca les, control lines, telephone ca les or
other devices close to the power source.
2. Make sure those telephones, televisions, computers or other control systems are not
in the working area.
3. People with pace-makers or hearing aides should keep far from the power source. In
particular cases, special protection measures may e required.
Reduce interference y following these suggestions:
1. If there is interference in the power source line, mount an E.M.T. filter etween the
power supply and the power source.
2. Shorten the output ca les of the power source, keep them together and connected to
ground.
3. Securely fasten the panels of the power source in place after performing maintenance.
SAFETY WARNINGS
Please familiarize yourself with the warning message listed on this manual. Please e
alert e alert to the possi ility of personal injury and carefully read the message that
follows.
●ELE TRI SHO K AN KILL! Reduce the risk of death or serious injury from shock.
Read, understand and follow the following safety instructions. Additionally, make certain
that anyone else who uses this welding equipment, or who is a ystander in the welding
area, understands and follows these safety instructions as well.
●FIRE OR EXPLSION AN XAUSE DEATH, INJURY AND PROPERTY DAMAGE!
Reduce the risk of death, injury or property damage from fire or explosion. Read,
understand and follow the following safety instructions. Additionally, make certain that
anyone else who uses this welding equipment, or who is ystander in the welding area,
understands and follows these safety instructions as well. Remem er, welding y nature
produces sparks, hot spatter, molten metal drops, hot slag and hot metal parts that can
start fires, urn skin and damage eyes.
●AR RAYS AN INJURE EYES AND BURN SKIN! Reduce the risk of injury from arc
rays Read, understand and follow the following safety instructions. Additionally, make
certain that anyone else who uses this welding equipment, or who is a ystander in the
welding area, understands and follows these safety instructions as well.

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●FUMES, GASSES AND VAPORS AN AUSE DIS OMFORT, ILLNESS AND DEATH!
Reduce the risk of discomfort, illness or death Read, understand and follow the following
safety instructions. Additionally, make certain that anyone else who uses this welding
equipment, or who is a ystander in the welding area, understands and follows these
safety instructions as well.
●IMPROPER HANDLING AND MAINTENAN E OF OMPRESSED GAS YLINDERS
AND REGULATORS AN RESULT IN SERIOUS INJURY OR DEATH! Reduce the risk
of injury or death from compressed gasses and equipment hazards. Read, understand
and follow the following safety instructions. Additionally, make certain that anyone else
who uses this welding equipment, or who is a ystander in the welding area,
understands and follows these safety instructions as well.
PROTE TIVE WELDING GASSES
1. These welders use only inert or non-flamma le gases for welding arc protection. It is
important to choose the appropriate gas for the type of welding eing performed.
2. DO NOT use gas from unidentified cylinders.
3. DO NOT connect the cylinder directly to the welder. Use a pressure regulator.
4. Make sure the pressure regulator and the gauges function properly.
5. DO NOT lu ricate the regulator with oil or grease.
6. Each regulator is designed for use with a specific gas. Make sure the regulator is
designed for the protective gas eing used.
7. DO NOT use damaged cylinders.
8. Make sure that the cylinder is safely secured tightly to the welder with the chain
provided.
9. DO NOT carry the cylinder y holding it y the valve.
10. NEVER expose cylinders to excessive heat, sparks, slag or flame.
11. Make sure that the gas hose is ALWAYS in good condition.
12. Keep the gas hose away from the working area.
HEALTH HAZARDS
The welding process can e hazardous to your health. Therefore, follow these
precautions:
1. ALWAYS wear protective clothing without pockets and cuffs. Wear a helmet, gloves
and shoes with an insulating sole.
2. ALWAYS use a welding mask or helmet with the properly tinted protective glass in the
shade adequate to the welding operation eing performed and to the current intensity.
3. Make certain that ystanders in the welding area are also following these precautions.
4. ALWAYS keep the welding mask glass clean. Replace it if it is cracked or chipped.
5. NEVER weld in a damp area or come in contact with a moist or wet surface when
welding.
6. If the welding area lacks proper ventilation, use flume extractors.
7. Be sure the welding pieces are free of solvents or alogenous grease which develops
toxic gases when exposed to heat.
ELE TRI SHO K
WARNING ELE TRI SHO K AN KILL! Reduce the risk of death or serious injury
from shock. Read, understand and follow ALL safety instructions. Be sure that
everyone who uses this welding equipment or who is a ystander in the welding area
understands and follows ALL safety instructions as well.
WARNING ELE TRI SHO K AN BE FATAL. A person qualified in First Aid

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techniques should ALWAYS e present in the working area. If a person is
unconscious and electric shock is suspected, DO NOT touches the person if he or she
is in contact with ca les or electric wires. Disconnect power from the machine, and
then use First Aid. Use dry wood or other insulating materials to move ca les, if
necessary, away from the person.
1. Never touch or come in physical contact with any part of the input current circuit and
welding current circuit.
2. Frequently, check that the input ca le and plug are in good condition.
3. Make sure that the welder is disconnected from the mains BEFORE attempting any
repairs, opening the side panels of the machine or repairing the input ca le.
4. Fit the main line, BEFORE the distri ution outlet, with a three-pole switch with
adequate delayed fuses (check the welder data plate for fuse values).
5. DO NOT weld with ca les, torch or ground clamp in poor shape.
6. DO NOT coil the torch or the ground ca les around your ody.
7. DO NOT point the welding torch at yourself or at ystanders.
8. Should you feel the slightest electrical shock, STOP welding IMMEDIATELY. DO NOT
use the welder until the fault is found and resolved.
WELDER OPERATING HARA TERISTI S
The duty rating defines how long the user can weld and how long the welder must rest
and cool down. Duty Cycle ratings are expressed as a percentage of a ten-minute period.
It represents the maximum welding time allowed at the specified amperage setting. The
remaining alance of a ten-minute period is required for cooling off the unit.
All EasyMig Welding Systems are rated at the required input amperage for proper
operation. Please refer to the data plate located on the front of the unit for the specific
rating that applies to your unit.
INTERNAL THERMAL OVERLOAD PROTE TION
CAUTION DO NOT constantly exceed the duty cycle or damage could result to your
welder. If you do exceed the duty cycle of your welder, the internal thermal overload
protection shuts off all welder functions. If this happens, DO NOT SHUT OFF THE
WELDER. Leave the welder turned on and the fan running. After the welder is
properly cooled, the thermal protector automatically resets and your welder will
function properly.
If you find that your welder does not weld for a 1-5 minute time period without stopping,
reduce the wire speed slightly. Welding with the wire speed set too high not only causes
poor visi le welds ut also increases amperage thaw and shortens the duty cycle.

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MAIN PARAMETER
Model EasyMig 250i
Input Voltage(V) 220 Single
Phase
Frequency(Hz) 50/60Hz
Rated Input Capacity(KVA) 8.3
Rated Input Current(A) 37.7
Output Current Range(A) 50~250
Output Voltage Range(V) 16.5~26.5
Outlet Voltage for
Regulator(V) 220
Adjusta le Steps 7/10
Wire Diameter(mm) 0.6~1.0
Duty Cycle(%) 60
Efficiency(%) 85
Power Factor 0.93
Insulation Class F
Wire Feeder Type Compact
Wire Feeding Speed(m/min) 2~15
Diameter of Spool(mm) 270
Dimension(mm) 490 x 265 x 420
Weight(Kg) 25
ASSEMBLING THE WELDER
The following steps descri e the assem ly, installation, maintenance and operations of your
new welder.
1. Unpack the welder.
2. Install handle.
CAUTION Avoid contacts with wires or parts. DO NOT work with the side panels partially
opened or removed completely from the power source.
3. Place the power source in a well ventilated area. DO NOT o struct the air intake and output
vents. A reduced air flow can cause a reduced duty cycle and damage internal components.
4. Insure at least 6 feet of open space on each side of the welder.

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Two Gear
Drive Wire
Feed Unit
Cover
Wire Feed
Motor
Torch Socket
Handle
Wire Spool
Holder
Torch Connection
Welding Current
Knob
Ground Cable
Power Switch
Digital
Ampere
Metre
Gas Hose Inlet
220 Voltage
Outlet
Overheat Lamp
Power Cable
Inlet
Power Lamp
Wire Inching
Button
Welding
Inductance
Knob
Digital
Voltage
Metre
Handle
Welding
Voltage
Knob

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POWER SOUR E ONNE TION
Power Requirements
This welder is designed to operate on a properly grounded 220 volt, 50/60 HZ,
single-phase alternating current (AC) power source fused with a 50 amp time-delayed
fuse or circuit reaker. (Please consult local codes for proper plug and receptacle
applications.) A qualified electrician should verify the A TUAL VOLTAGE at the
receptacle into which the welder will e plugged and confirm that the receptacle is
properly grounded. The use of the proper circuit size can eliminate the nuisance of circuit
reaker tripping when welding.
Connection to Power Source
WARNING High voltage danger from power source! Consult a qualified electrician for
proper installation of receptacle at the power source.
This welder must e grounded while in use to protect the operators from electrical shock.
If you are not sure if your outlet is properly grounded, have it checked y a qualified
electrician. DO NOT cut off the grounding prong or alters the plug in any way. DO NOT
use any adapters etween the welder’s power cord and the power source receptacle.
CAUTION Make sure the POWER switch is OFF. Connect the welder’s power cord to a
properly grounded 220 VAC, 50/60 Hz, single-phase, 50 amp power source. DO NOT
operate this welder if the source voltage is less than 200 Volts AC or greater than 240
Volts AC. Contact a qualified electrician if this pro lem exists. Improper performance
and/or damage to the welder will result if operated on inadequate or excessive power.
INSTALLATION OF THE WELDING WIRE
Install the wire into the feeding system y following the instructions elow and referring
to following steps.
WARNING Remove the contact tip and gun nozzle from the MIG gun efore starting this
procedure.
1. Loosen the nut of the spool holder ( rake drum). Remove the spring and the external
ring.
2. Remove the plastic wrapper from the spool. Place the spool on the spool holder. Mount
the external ring, the spring and the plastic spool holder nut. These parts form the
raking system for the wire spool. Tighten nut to appropriate tightness. Excessive
pressure strains the wire feeding motor. Too little pressure does not immediately stop
the wire spool welding is stopped.
3. Loosen and lower the tension adjustment. Release the upper roll of the feeder. Extract
any remaining wire from the torch line.
4. Release the end of the wire from the spool. When it is disconnected grasp it with pliers
so that it cannot exit from the spool. If necessary, straighten it efore inserting it in
the wire input guide. Insert the wire on the lower roll and in the torch liner.
WARNING Keep the torch straight. When feeding a new wire through the liner, make
sure the wire is cut cleanly (no urrs or angles) and that at least 2” from the end is
straight (no curves). Failure to follow these instructions could cause damage to the
liner.
5. Lower the upper roll and lift the tension adjustment kno . Tighten slightly. If tightened
too much, the wire gets locked and could cause motor damage. If not tightened
enough, the rolls will not feed the wire.
NOTICE When changing the wire diameter eing used, or replacing the wire feed roll,
e sure that the correct groove for the wire diameter selected is inside, closest to the