Klutch MIG250S User manual

MIG250S
OWNER’S MANUAL
WARNING:
Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other
basic safety precautions may result in serious personal injury.
Item# 44452

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Thank you very much for choosing a KLUTCH product! For future reference, please complete
the owner’s record below:
Model: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire manual
to become familiar with this product before you begin using it.
This machine is designed for certain applications only. The distributor cannot be responsible for
issues arising from modification. We strongly recommend this machine not be modified and/or
used for any application other than that for which it was designed. If you have any questions
relative to a particular application, DO NOT use the machine until you have first contacted the
distributor to determine if it can or should be performed on the product.
For technical questions please call the Northern Tool Welder Help Line at 1-877-304-0294.
INTENDED USE
The MIG 250S is a 230V wire feed welder for Flux Core and MIG Welding. It comes complete
with a regulator and gas hose for easy connection for MIG and has its own built in running gear
and cylinder rack. It is designed to weld materials as thin as 24 gauge all the way up to 3/8" in a
single pass. Add the optional Quick Draw Spool Gun #44453, for welding aluminum with 4"
spools of aluminum wire.
Welding with flux core wire gives the operator the flexibility to use this wire feed welder for
mobile applications, including outdoor applications. Flux core wire does not require the use of a
separate shielding gas which can be blown away by the wind in outdoor applications. Since flux
core welding does not use shielding gas, the operator will not have to have shielding gas bottles,
or use the regulator and gas hose.
Welding with a MIG wire does require the use a bottle of shielding gas. See the Set-Up guide
inside the wire compartment door for recommendations on shielding gas based on the material
you are welding. MIG welding is limited to indoor applications, or applications where the
influence of wind can be controlled to prevent shielding gas from blowing away. MIG welding
allows you to weld thinner materials without burn through. It also creates a much cleaner weld
with less spatter and no slag. This results in little post-weld cleaning of the weld joint.
This unit is intended to be used on a 50 amp 230V AC circuit without the use of an extension
cord. If an extension cord is necessary for your application, please use the appropriate size and
length of extension cord that will handle 50 amps the entire length of the extension. We highly
recommend talking with a qualified electrician for cord size recommendations. This unit is
supplied with a NEMA Class 6-50P plug and will require a NEMA Class 6-50R receptacle. Do
not remove the power plug!

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GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed
below may result in serious injury.
CAUTION: Do not allow persons to operate or assemble this MIG/Stick 220Si until they
have read this manual and have developed a thorough understanding of how the MIG/Stick
220Si works.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors which cannot be built into
this product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY CONSIDERATIONS
1.1 Your Welding Environment
-Keep the environment you will be welding in free from flammable materials.
-Always keep a fire extinguisher accessible to your welding environment.
-Always have a qualified person install and operate this equipment.
-Make sure the area is clean, dry and ventilated. Do not operate the welder in humid, wet or poorly
ventilated areas.
-Always have your welder maintained by a qualified technician in accordance with local, state and
national codes.
-Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.
-Keep harmful arc rays shielded from the view of others.
-Mount the welder on a secure bench or cart that will keep the welder secure and prevent it from
tipping over or falling.
1.2 Your Welder’s Condition
-Check ground cable, power cord and welding cable to be sure the insulation is not damaged.
Always replace or repair damaged components before using the welder.
-Check all components to ensure they are clean and in good operating condition before use.
1.3 Use of Your Welder
Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do
not immerse them in water. These components and the welder must be completely dry before
attempting to use them.
-Follow the instructions in this manual.
-Keep welder in the off position when not in use.
-Connect ground lead as close to the area being welded as possible to ensure a good ground.

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-Do not allow any body part to come in contact with the welding wire if you are in contact with the
material being welded, ground or electrode from another welder.
-Do not weld if you are in an awkward position. Always have a secure stance while welding to
prevent accidents. Wear a safety harness if working above ground.
-Do not drape cables over or around your body.
-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety
glasses while welding.
-Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals,
UV and IR rays.
-Do not overuse or overheat your welder. Allow proper cooling time between duty cycles.
-Keep hands and fingers away from moving parts and stay away from the drive rolls.
-Do not point torch at any body part of yourself or anyone else.
-Always use this welder in the rated duty cycle to prevent excessive heat and failure.
1.4 Specific Areas of Danger, Caution or Warning
Electrical Shock
Electric arc welders can produce a shock that can cause injury or death. Touching
electrically live parts can cause fatal shocks and severe burns. While welding, all metal
components connected to the wire are electrically hot. Poor ground connections are a hazard, so
secure the ground lead before welding.
-Wear dry protective apparel: coat, shirt, gloves and insulated footwear.
-Insulate yourself from the work piece.Avoid contacting the work piece or ground.
- Do not attempt to repair or maintain the welder while the power is on.
-Inspect all cables and cords for any exposed wire and replace immediately if found.
-Use only recommended replacement cables and cords.
-Always attach ground clamp to the work piece or work table as close to the weld area as possible.
-Do not touch the welding wire and the ground or grounded work piece at the same time.
-Do not use a welder to thaw frozen pipes.
Fumes and Gases
-Fumes emitted from the welding process displace clean air and can result in injury or
death.
-Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and
safe.
-Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the
environment where you will be working.
-Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury or
barium). They will emit harmful fumes that are dangerous to breathe. If necessary use a ventilator,
respirator with air supply or remove the coating from the material in the weld area.
-The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety
data sheet for the manufacturer’s instructions.
-Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners, sprays
and degreasers can be highly toxic when heated.
UV and IR Arc Rays
The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to

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your eyes and skin. Do not look at the welding arc without proper eye protection.
-Always use a helmet that covers your full face from the neck to top of head and to the back of each
ear.
-Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps output,
use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for
more information.
-Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant
cloth or leather shirts, coats, pants or coveralls are available for protection.
-Use screens or other barriers to protect other people from the arc rays emitted from your welding.
-Warn people in your welding area when you are going to strike an arc so they can protect
themselves.
Fire Hazards
Do not weld on containers or pipes that contain or have had flammable, gaseous or liquid
combustibles in them. Welding creates sparks and heat that can ignite flammable and
explosive materials.
-Do not operate any electric arc welder in areas where flammable or explosive materials are
present.
-Remove all flammable materials within 35 feet of the welding arc. If removal is not possible, tightly
cover them with fireproof covers.
-Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas,
cracks or areas you cannot see.
-Keep a fire extinguisher close in the case of fire.
-Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
-Do not have on your person any items that are combustible, such as lighters or matches.
-Keep work lead connected as close to the weld area as possible to prevent any unknown,
unintended paths of electrical current from causing electrical shock and fire hazards.
-To prevent any unintended arcs, cut wire back to ¼" stick out after welding.
Hot Materials
Welded materials are hot and can cause severe burns if handled improperly.
-Do not touch welded materials with bare hands.
-Do not touch torch nozzle after welding until it has had time to cool down.
Sparks/Flying Debris
Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying
debris.
-Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear
plugs to keep sparks out of ears and hair.

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Electromagnetic Field
-Electromagnetic fields can interfere with various electrical and electronic devices such as
pacemakers.
-Consult your doctor before using any electric arc welder or cutting device
-Keep people with pacemakers away from your welding area when welding.
-Do not wrap cable around your body while welding.
-Wrap MIG gun and ground cable together whenever possible.
-Keep MIG gun and ground cables on the same side of your body.
Shielding Gas Cylinders Can Explode
High pressure cylinders can explode if damaged, so treat them carefully.
-Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
-Do not touch cylinder with MIG gun.
-Do not weld on the cylinder
-Always secure cylinder upright to a cart or stationary object.
-Keep cylinders away from welding or electrical circuits.
-Use the proper regulators, gas hose and fittings for the specific application.
-Do not look into the valve when opening it.
-Use protective cylinder cap whenever possible
1.5 Proper Care, Maintenance and Repair
-Always have power disconnected when working on internal components.
- Do not touch or handle PC board without being properly grounded with a wrist strap. Put PC board
in static proof bag to move or ship.
-Do not put hands or fingers near moving parts such as drive rolls of fan
MIG 250S USE AND CARE
Do not modify the MIG 250S in any way. Unauthorized modification may impair the function
and/or safety and could affect the life of the equipment. There are specific applications for which
the MIG 250S was designed.
Always check of damaged or worn out parts before using the MIG 250S. Broken parts will
affect the MIG 250S operation. Replace or repair damaged or worn parts immediately.
Store idle MIG 250S. When MIG 250S is not in use, store it in a secure place out of the reach
of children. Inspect it for good working condition prior to storage and before re-use.
TECHNICAL SPECIFICATIONS
Item
Description
Power Supply
230V, 50A, 60 HZ, Single Phase
No-Load Voltage
43 Volts DC
Output Range
30 - 250 Amp DC
Duty Cycle
60% @ 177A; 30% @ 250A
Suggested Wire
MIG: Steel, Stainless Steel,Aluminum
Flux Core: Steel
Wire Diameter
.030,.035,.040
Dimensions
37.4" x 17.7" x 28.3"
Weight
187 lbs.

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KNOW YOUR WELDER
Description
The KLUTCH MIG 250S is a light industrial DC MIG and FLUX CORE welder capable of welding up
to 3/8" steel in a single pass. It requires 230 VAC (220-240), 60 Hz input power and a 50 Amp time
delayed fuse or circuit breaker. This unit has built-in wheels and casters along with a bottle rack for
easy maneuvering. The MIG 250S features 12 voltage settings, an infinite wire feed speed control,
adjustable spot weld timer, thermal overload protection and is spool gun ready. This unit is capable
of MIG welding steel and stainless steel with the correct shielding gas. Use the optional Quick Draw
Spool Gun #44453, for best results when MIG welding aluminum. The quick connect polarity
connections make switching from MIG (gas shielded) welding and Flux Core welding very easy.
The MIG 250S is an ideal machine for a wide variety of welding applications such as automotive
repair, construction, light fabrication and farm repair.
Indicator
Lights
Voltage
Setting
Wire Speed
Control
Ground Cable
And Clamp
Negative (-)
Output Connection
Gas Hose
Regulator/
Flowgauge
Spool Gun
Selector Switch
Spot Weld
Timer
MIG Torch
Positive (+)
Output Connection
MIG Socket
Weld Power Cable
5-Pin Trigger
Connection

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POWER INDICATOR LIGHT
In the “OFF” position no power is being supplied to the torch. In the “ON” position power is
supplied to the main transformer and control circuit.
PROTECTION INDICATOR LIGHT
If the duty cycle of the welder is exceeded, the internal temperature will exceed safe temperatures
and the machine will shut down. The Thermal overload light will come on indicating this. Leave the
unit on and allow 15 minutes for cool down before the light will go off and the temperature to fall into
an allowable operating range.
WELDING VOLTAGE
The voltage control is on the front panel of machine. Refer to the “set up” chart inside the wire feed
compartment for initial adjustment settings. You have 12 voltage options to help tune in the arc. DO
NOT SWITCH UNDER LOAD OR WHILE WELDING.
Negative (-) Output Connection
The ground clamp is connected to this quick connect when MIG welding. Connect the Weld Power
Cable to this connection when Flux Core Welding.
Positive (+) Output Connection
The Weld Power Cable is connected to this quick connect when MIG welding. Connect the Weld
ground clamp to this connection when Flux Core Welding.
GAS REGULATOR/FLOWGAUGE
Installs on the shielding gas cylinder for MIG welding with solid wires. The regulator controls the
compressed gas and allows you to adjust the flow rate of the gas.
GAS HOSE
The gas hose connects to the regulator/flowgauge and delivers the shielding gas from the shielding
gas bottle to the welder.
GROUND CABLE AND CLAMP
The ground cable and clamp are attached to the work piece to complete the circuit allowing the flow
of current needed to weld.
MIG TORCH
The welding wire is driven through the welding cable and torch to the work piece. It is attached to
the drive system. The trigger activates the drive motor.
SPOT WELD TIMER
The Spot Weld Timer allows you to set a time from 0.1 sec to 9.9 seconds for consistent spot welds.
SPOOL GUN SELECTOR SWITCH
When normal MIG welding, this switch should be up in MIG torch position. When using the spool
gun, the switch should be down in the spool gun position.
WIRE FEED SPEED
Adjustment of the wire feed speed in the MIG Torch or SPOOL GUN mode. Refer to the "set up"
chart inside the wire feed compartment for initial adjustment settings.
MIG SOCKET
The MIG socket accepts the MIG torch and transfers weld power, wire and shielding gas to the MIG
torch.
WELD POWER CABLE
Use the weld power cable to transfer weld power from the Output Connection to the Wire Drive
Assembly.
MIG Torch
Delivers wire, weld power and shielding gas to the arc.

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ASSEMBLY
1. MIG TORCH ASSEMBLY
1.1 Locate the retaining bolt inside the front panel on the drive system. Loosen the retaining bolt.
1.2 Make note of the retaining groove on the back end of the MIG torch.
1.3 Insert the back end of the MIG torch into the MIG socket on the front of your machine. Make
certain to completely slide the torch all the way in. Slightly twist to assist with pushing the torch to
the back of the receptacle. The retaining bolt can then be tightened, making certain the bolt sets
down into the retaining groove on the back of the MIG torch.
1.4 Connect the 5-Pin trigger connection on the MIG torch to the 5-Pin trigger receptacle on the
front panel.
1.5 Connect the ground cable to the Negative (-) weld output connection for MIG welding. If
welding with self shielded flux core, connect the ground cable to the Positive (+) weld output
connection and move the Weld Power Cable to the Negative (-) weld output connection.
1.6 Make certain the SPOOL GUN SELECTOR SWITCH on the front panel is switched into the
MIG TORCH position.
2. SPOOL GUNASSEMBLY
2.1 This unit is set-up to accept the Quick Draw Spool gun only.
2.2 The Quick Draw Spool Gun has three connection points at the back of the spool gun. (1) The
gas connection is a slide on quick connector. (2) The weld power connection has a round ring
connection. (3) The trigger connection is the 5-Pin snap on connector.
Retaining
Bolt
Retaining
Groove

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2.3 We recommend removing the MIG torch when the Spool Gun is connected to avoid accidental
arcing. Loosen the retaining bolt and slide the MIG torch out of the front of the machine. Disconnect
the 5-Pin trigger connection on the front of the machine.
2.4 Carefully slide the gas connector and the weld power connection through the weld cable
access opening in the front of the machine.
2.5 Open the wire compartment door.
2.6 Connect the gas connection quick connector to the gas connector (1) on the back panel of the
wire compartment.
2.7 Connect the weld power connection to the bolt on the side of the MIG connector (2).
2.8 Connect the 5-Pin trigger connector to the 5-Pin receptacle on the front of the machine.
2.9 Make certain the SPOOL GUN SELECTOR SWITCH on the front panel is switched into the
SPOOL GUN position.
INSTALLATION
1. POWER REQUIREMENT - AC single phase 230V (200-240V) 60 HZ fused with a 50 amp time
delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if the ACTUAL power
source voltage is less than 215 volts AC or greater than 240 volts AC.
Electrical Shock
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 prong 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 230 VAC, 60 HZ, Single Phase, 50 Amp input power supply.
(1)
(2)

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2. EXTENSION CORD - We do not recommend an extension cord because of the voltage drop they
produce. This drop in voltage can affect the performance of the welder. If you need to use an
extension cord, it must be a size #12 or larger. Check with a qualified electrician and your local
electrical codes for your specific area. Do not use an extension cord over 25 ft. in length.
3. INSTALL THE WIRE ROLLER - The wire roller has been factory installed. However, check to
make certain the correct wire groove is in place to accommodate the size of wire you are using.
Open the wire feed compartment. Adjust the drive roller according to the following steps, see
following picture about the wire feeder structure:
3.1 Open the door to the welder drive compartment.
3.2 Remove the drive tension by loosening the Drive Tension Adjuster (1) and moving the Drive
Tension Adjustor away from the Drive Tension Arm (2). The Drive Tension Arm will spring away from
the Drive Roller (3).
3.3 If there is wire already installed in the welder, roll it back onto the wire spool by hand-turning the
spool clockwise. Be careful not to all the wire to come out of the rear end of the inlet guide tube
without holding onto it or the wire spool will unspool itself. Put the end of the wire into the hole on
the outside edge of the wire spool and bend it over to hold the wire in place. Remove the spool of
wire from the drive compartment of the welder.
3.4 Remove the drive roller by turning the drive roll knob (3) counter-clockwise. Carefully slide the
drive roll assembly off of the drive shaft. This drive roll assembly consist of three pieces. The thumb
screw, washer spacer and the drive roll. Take care to keep from misplacing any of these pieces.
(1)
(2)
(3)

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3.5 Based on the wire diameter select the correct groove. See the chart below for assistance.
When installing the drive roller, the number stamped on the drive roller for the wire size you are
using should be facing inward. Push the Drive Roller onto the Drive Roller Shaft.
Wire Diameter
Roller Groove
.023
0.6
.030
0.8
.035
0.9
.040
1.0
3.7 Reinstall the Drive Roller knob and tighten clockwise.
3.8 Close the door to the welder drive compartment.
4. INSTALL THE WIRE - We recommend the usage of .023, .030, and .035 MIG wire, or .030, .035
and .040 flux core wire, on this unit.
4.1 Select welding wire - Both 8" and 11" wire spools of .023, .030, .035 and .040 wire can be used
on this welder. You can also use 4" spools of wire when using the optional Quick Draw Spool Gun
#44453.
NOTE: - Burn through can occur if you attempt to weld mild or stainless steel thinner than 24 gauge.
- Remove all rusted wire from your wire spool. If the whole spool is rusty, discard it.
4.2 Installing the wire
Electrical Shock
Electric shock can kill! Always turn the POWER switch OFF and unplug the power cord
from the AC power source before installing wire.
NOTE:
- Before installing, make sure that you have removed any old wire from the torch assembly. This will
help to prevent the possibility of the wire jamming inside the gun liner.
- Be very careful when removing the welding nozzle. The contact tip on this welder is live whenever
the torch trigger is pulled. Make certain POWER is turned OFF.
4.2.1 Remove the nozzle and contact tip from the end of the torch assembly.
4.2.2 Make sure the proper groove on the drive roller is in place for the wire installed. If not,
change the drive roller as described in Section 3.

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4.2.3 Remove the packaging from the spool of wire and then identify the leading end of the wire
secured on the edge of the spool. DO NOT UNHOOK ITAT THIS TIME.
4.2.4 Place the spool on the spool hub so the wire will pull off the bottom of the spool. The
welding wire should always come off the bottom of the spool into the drive mechanism. See
following figure.
4.2.5 The welder can use either 8 inch or 11 inch spools. The wire spool retainer secures the
spool of wire onto the spool hub. The Wire Spool Tension Set Screw controls the tension on the
spool.
4.2.6 Setting the wire spool tension. a) Turn the spool of wire with one hand. b) Increase the
spool tension by tightening (turn clockwise) the Wire Spool Tension Set Screw while turning the
spool. Turn the spool while tightening the Wire Spool Tension Set Screw until the spool slows down
and you feel a slight drag. Stop tightening the Wire Spool Tension Set Screw, you may need to
repeat these steps until proper spool tension is achieved.
NOTE: If TOO MUCH tension is applied to the wire spool, the wire will slip on the drive roller or will
not be able to feed at all. If TOO LITTLE tension is applied, the spool of wire will want to unspool
itself when the trigger is released. Readjust the spool tension using the wing nut as necessary to
correct for either problem.
4.2.7 With the welder disconnected from the power source, remove the leading end of the wire
from the spool. Hold on to it securely, so as not to allow unspooling or tangling of the wire as it will
result in tangled wire and feeding problems.
4.2.8 Cut off any bent portion of the wire using a wire cutter.
4.2.9 Loosen the tension adjusting knob holding the drive tension arm in place and lift the
tension arm up off the drive roller.
4.2.10 Insert the wire into the inlet guide tube, feed it across the drive roller and into the torch
assembly about six inches.
-Make certain that the welding wire is actually going into the torch liner. If not, the wire will jam up in the
mechanism.
4.2.11 Line the wire up with the correct groove in the drive roller. Place the drive tension arm back
above the drive roller.
4.2.12 Place the drive tension adjustment arm back in place.
4.2.13 Tighten (turn clockwise) the drive tension adjusting knob until the tension roller is applying
enough force on the wire to prevent it from slipping in the drive rollers. DO NOT OVER TIGHTEN.
4.2.14 NOW YOU CAN LET GO OF THE WIRE.
Wire Spool
Retainer
Wire Spool
Tension Set Screw

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4.2.15 Plug in the welder power cord and turn the welder ON. Set the Voltage switch to the
voltage setting recommended for the gauge metal that is to be welded. Refer to the set-up chart on
the back side of the drive compartment door.
-The welding wire is electrically hot when the power is on and the torch trigger is activated.
4.2.16 Set the WIRE SPEED control to the middle of the wire speed range.
4.2.17 Straighten the MIG torch cable and pull the trigger in the gun handle to feed the wire
through the torch assembly. When at least one inch of the wire sticks out past the end of the torch,
release the trigger.
4.2.18 Turn the Power Switch to the OFF position.
4.2.19 Select a contact tip stamped with the same diameter as the wire being used.
NOTE:
- Due to inherent variances in flux cored welding wire, it may be necessary to use a contact tip one
size larger than your flux core wire if wire jams occur.
4.2.20 Slide the contact tip over the wire (protruding from the end of the torch). Thread the contact
tip into the end of the torch and hand-tighten securely.
4.2.21 Install the nozzle on the torch assembly.
4.2.22 Cut off excess wire that extends past the end of the nozzle more than 1/4 inch.
4.2.23 Turn the welder ON.
5. SETTING THE DRIVE ROLL TENSION
Arc flash can injure eyes! To reduce the risk of arc flash, make certain that the wire
coming out of the end of the torch does not come in contact with the work piece, ground
clamp, or any grounded material during the drive tension setting process or arcing will
occur.
5.1 Press the trigger on the torch.
5.2 Turn the drive tension adjustment knob clockwise until the wire seems to feed smoothly without
slipping.
6. GAS INSTALLATION
Shielding gas cylinders and high pressure cylinders can explode if damaged, so treat them
carefully.
Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs.
Do not weld on the cylinder.
Always secure cylinder upright to a cart or stationary object.
Keep cylinders away from welding or electrical circuits.
Use the proper regulators, gas hose and fittings for the specific application.

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6.1 Polarity Changing - When MIG wire is used, shielding gas is required and the polarity on this
unit needs to be electrode positive.
6.1.1 Electrode Positive for MIG Welding - The Weld Power Cable should be connected to the
positive (+) weld output connection on the front of the machine. The ground cable would then be
connected to the negative (-) weld output connection. Refer to the polarity setting label inside the
wire compartment.
6.1.2 Electrode Negative for Flux Core Welding - The Weld Power Cable should be connected to
the negative (-) weld output connection on the front of the machine. The ground cable would then be
connected to the positive (+) weld output connection. Refer to the polarity setting label inside the
wire compartment.
6.2 Connect one end of the gas hose to the gas hose connection on the back of the welder. Use a
wrench to snug up the connection.
6.3 Connect the other end of the gas hose to the gas hose connection on the supplied
regulator/flowgauge. Use a wrench to snug up the connection.
6.4 Before installing the regulator, it is good practice to make certain no debris is in the gas bottle
connection. Rotate the bottle so the gas connection is not pointing toward you or any other person.
Turn the valve on the gas bottle clockwise and quickly close. This quick thrust of gas will clear any
debris in the connection. Connect the regulator to the gas bottle connection. Use a wrench to snug
up the connection.
(1) Gas Bottle Valve
(2) Gas Flow Gauge (Set at 20 CFM)
(3) Gas Pressure Gauge
(4) Regulator
(5) Gas Flow Adjuster
(6) Gas Hose
(7) Gas Cylinder
6.5 Open the Gas Bottle Valve on the cylinder of gas.
6.6 Turn the Gas Flow Adjuster on the regulator so that the gas flow rate is set at approximately 20
CFM. Make certain you are reading the correct scale on the gauge.
NOTE: Slowly open the cylinder valve by turning it counterclockwise until the cylinder pressure
gauge registers on the first gauge of the regulator. Turn the adjustment knob clockwise (right) slowly
to increase gas flow to 20 cfm. To reduce the gas flow turn the adjustment counterclockwise (left).
The gas valve is located on the back panel of the welder and activated by the trigger. Gas flow
should be heard when the trigger is activated. No gas flow will result in a harsh arc with excessive
spatter, a smooth weld bead will be difficult to obtain. Avoid unnecessary gas loss by closing the
tank valve when finished welding.
6.7. Gas selection
Different materials require different shielding gas when MIG welding, refer to the set up chart inside
the wire feed compartment.
Mild steel: Use 75% Argon and 25% CO2 for reduced spatter and reduced penetration for thinner
materials. Do NOT USE Argon gas concentrations higher than 75% on steel. The result will be
extremely poor penetration, porosity, and brittleness of weld.
7
3
2
1

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Mild Steel: Use CO2 for deeper penetration but increased spatter. (A CO2 regulator adapter will be
needed)
Stainless steel: Use a mixed gas consisting of Helium, Argon and CO2.
Aluminum or bronze: Use 100% Argon.
OPERATION
High voltage danger from power source! Consult a qualified electrician for proper
installation of receptacle at the power source. This welder must be grounded while in use to
protect the operator from electrical shock. If you are not sure if your outlet is properly
grounded, have it checked by a qualified electrician. Do not cut off the grounding prong or
alter the plug in any way and do not use any adapter between the welder's power cord and
the power source receptacle. Make sure the POWER switch is OFF then connect your
welder's power cord to a properly grounded 230 VAC (220V - 240V), 60 HZ, single phase, 50
amp power source.
1. POWER SWITCH
The power switch supplies electrical current to the welder. Whenever the power switch is in the ON
position, the welding circuit is activated. ALWAYS turn the power switch to the OFF position and
unplug the welder before performing any maintenance.
2. VOLTAGE SELECTOR
The voltage selector controls the welding voltage/heat. This unit has a 12 position voltage control.
Refer to the label inside the welder side door for recommended voltage selector settings for your
welding job.
3. WIRE SPEED CONTROL
The wire speed control adjusts the speed at which the wire is fed out of the welding torch. The wire
speed needs to be closely matched (tuned-in) to the rate at which it is being melted off. Some things
that affect wire speed selection are the type and diameter of the wire being used, the heat setting
selected, and the welding position to be used. Refer to the label inside the welder side door for
recommended wire speed settings for your welding job.
NOTE: The wire will feed faster without an arc. When an arc is being drawn, the wire speed will
slow down.
4. HOLDING THE TORCH
The best way to hold the welding torch is the way it feels most comfortable to you. While practicing
to use your new welder, experiment holding the torch in different positions until you find the one that
seems to work best for you.
5. POSITION OF THE TORCH TO THE WORK PIECE
There are two angles of the torch nozzle in relation to the work piece that must be consider when
welding.
5.1. Angle a can be varied, but in most cases the optimum angle will be 60 degrees, the point at
which the torch angle is parallel to the work piece. If angle A is increased, penetration will increase.
If angleA is decreased, penetration will decrease also.

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5.2. Angle B can be varied for two reasons: to improve the availability to see the arc in relation to
the weld puddle and to direct the force of the arc.
6. DISTANCE FROM THE WORK PIECE - If the nozzle is held off the work piece, the distance
between the nozzle and the work piece should be kept constant and should not exceed 1/4 inch or
the arc may begin sputtering, signaling a loss in welding performance.
7. TUNING IN THE WIRE SPEED - This is one of the most important parts of wire welder operation
and must be done before starting each welding job or whenever the voltage setting or wire diameter
is changed.
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!
Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc
or begin welding until you are adequately protected. Wear flame-proof welding gloves, a
heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved
welding helmet.
7.1 Connect the Ground Clamp to a scrap piece of the same type of material which you will be
welding. It should be equal to or greater than the thickness of the actual work piece, and free of oil,
paint, rust, etc.
7.2 Select a heat setting.
7.3 Hold the torch in one hand. Hold the wire just off the work piece. (See HOLDING THE TORCH
section if you are uncertain of the angle at which you will be welding).
7.4 Set the wire feed speed based on the thickness of material and the set-up chart on the back
side of the wire feeder door.
7.5 Lower your welding helmet and pull the trigger on the torch and let the wire feed into the work
piece to start an arc, then begin to drag the torch toward you.
7.6 LISTEN! If the arc is sputtering, increase the wire speed slightly and try again. Continue
increasing the wire speed adjustment until you achieve a smooth buzzing sound. If the wire seems
to "pound" into the work piece, decrease wire speed slightly and try again. Use the wire speed
control to slightly increase or decrease the heat and penetration for a given voltage setting by
increasing or decreasing the wire speed slightly. Repeat this tune-in procedure if you select a new
voltage setting, a different wire diameter, or a different roll of wire.
8. WELDING TECHNIQUES
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!
Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc
or begin welding until you are adequately protected. Wear flame-proof welding gloves, a
heavy long sleeved shirt, trousers with out cuffs, high topped shoes, and an ANSI approved
welding helmet.

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ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding
while standing, kneeling, or lying directly on the grounded workpiece.
8.1 Moving the torch
Torch travel refers to the movement of the torch along the weld joint and is broken into two elements:
Direction and Speed. A solid weld bead requires that the welding torch be moved steadily and at the
right speed along the weld joint. Moving the torch too fast, too slow, or erratically will prevent proper
fusion or create a lumpy, uneven bead.
Travel direction is the direction the torch is moved along the weld joint in relation to the weld
puddle. The torch is either PUSHED into the weld puddle or PULLED away from the weld puddle.
For most welding jobs you will pull the torch along the weld joint to take advantage of the greater
weld puddle visibility.
Travel speed is the rate at which the torch is being pushed or pulled along the weld joint. For a
fixed heat setting, the faster the travel speed, the lower the penetration and the lower and narrower
the finished weld bead. Likewise, the slower the travel speed, the deeper the penetration and the
higher and wider the finished weld bead.
8.2 Types of welding beads
As you become more familiar with your new welder and better at laying some simple weld beads,
you can begin to try some different weld bead types.
The STRINGER BEAD is formed by traveling with the torch in a straight line while keeping the wire
and nozzle centered over the weld joint. See following figure.
The WEAVE BEAD Used when you want to deposit metal over a wider space than would be
possible with a stringer bead. It is made by weaving from side to side while moving with the torch. It
is best to hesitate momentarily at each side before weaving back the other way.

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8.3 Welding position
FLAT POSITION is easiest of the welding positions and is most commonly used. It is best if you can
weld in the flat position if at all possible as good results are easier to achieve.
HORIZONTAL POSITION Is performed very much the same as the flat weld except that angle B
(see HOLDING THE TORCH) is such that the wire, directed more toward the metal above the weld
joint is to help prevent the weld puddle from running downward while still allowing slow enough
travel speed. A good starting point for angle B is about 30 degrees DOWN from being
perpendicular to the work piece.
VERTICAL POSITION It is easier for many people to Pull the torch from top to bottom. It can be
difficult to prevent the puddle from running downward. Pushing the torch from bottom to top may
provide better puddle control and allow slower rates of travel speed to achieve deeper penetration.
When vertical welding, angle B (see HOLDING THE TORCH) is usually always kept at zero, but
angle A will generally range from 45 to 60 degrees to provide better puddle control.
OVERHEAD POSITION Is the most difficult welding position. Angle A(see HOLDING THE TORCH)
should be maintained at 60 degrees. Maintaining this angle will reduce the chances of molten metal

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falling into the nozzle. Angle B should be held at zero degrees so that the wire is aiming directly into
the weld joint. If you experience excessive dripping of the weld puddle, select a lower heat setting.
Also, the weave bead tends to work better than the stringer.
8.4 Multiple pass welding
Butt Weld Joints When butt welding thicker materials, you will need to prepare the edges of the
material to be joined by grinding a bevel on the edge of one or both pieces of the metal being joined.
When this is done, a “V” is created between the two pieces of metal, that will have to be welded
closed. In most cases more than one pass or bead will need to be laid into the joint to close the “V”.
Laying more than one bead into the same weld joint is known as a multiple-pass weld.
The illustrations in following figure show the sequence for laying multiple pass beads into a single
“V” butt joint.
NOTE:
WHEN USING SELF-SHIELDING FLUX-CORE WIRE it is very important to thoroughly chip and
brush the slag off each completed weld bead before making another pass or the next pass will be of
poor quality.
Fillet Weld Joints. Most fillet weld joints, on metals of moderate to heavy thickness, will require
multiple pass welds to produce strong joint. The following figure will show the sequence of laying
multiple pass beads into a T fillet joint and a lap fillet joint.