Lincoln Electric Expressweld MasterMIG 250CT User manual

Eczacıbaşı - Lincoln Electric recommend to use “ASKAYNAK” gas metal arc
welding wire for obtaining high performance from MasterMIG 250CT.
www.askaynak.com.tr
Expressweld Model : MasterMIG 250CT
Gas Metal Arc Welding Machine
USER MANUAL
GMAW (MIG/MAG)
Welding Method and Specifications
CO
235%
Phase

AT - UYGUNLUK BEYANI
EU - DECLARATION of CONFORMITY
EU - KONFORMITÄTSERKLÄRUNG
Déclaration de Conformité de l'EU
KAYNAK TEKNİĞİ SANAYİ ve TİCARET A.Ş.
Şirket / Firm / Firma / Société
aşağıda modeli belirtilen kaynak makinesinin
declares that the welding machine
erklärt, daß die Bauart der Maschine
déclare que le poste de soudage
® ®
EXPRESSWELD MasterMIG 250CT
aşağıda belirtilen yönergelere uygun olduğunu
conforms to the following directives
den folgenden Bestimmungen entspricht
est conformé aux directives suivantes
2004/108/EC, 2006/95/EC
ve yine aşağıda belirtilen normlara uygun olarak tasarlandığını beyan eder.
and has been designed in compliance with the following standards
und in Überienstimmung mit den nachstehenden normen hergestellt wurde
et qu'il a été conçu en conformité avec les normes
TS EN 60974-1:2007, TS EN 60974-10:2009
Pazarlama ve Lojistik Müdürü / Marketing and Logistics Manager / Directeur de Marché et Logistiques
Sertaç ÖZEN
22.03.2010Tarih / Date / Datum / Date :
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41480 Çayırova, Kocaeli - TURKEY

1. General Safety Rules
Electromagnetic Compatibility
2. General Information, Warnings and Operation Conditions
3. Specifications
4. Technical Data
5. Front Panel Controls
6. Back Panel Controls
7. Controls in Wire Feeder System
8. Connection Diagram
9. Installation and Operation of Machine
9.1. Mains Supply
9.2. Shielding Gas Connection
9.3. Welding Torch Connection
9.4. Connecting Shielding Gas Cylinder to Welding Machine
9.5. Installing Welding Wire
10. Functions of Wire Feeder System
11. GMAW (MIG/MAG) Method
12. Environment Conditions
13. Efficient Use of Machine In Terms of Energy Consumption
14. Storage and Transportation
15. Unpacking
16. Expirty of Machine's Physical Life
17. Maintenance and Repair
18. Troubleshooting Guide
19. Failures in Welding Seams
20. Spare Part List
21. Electrical Circuit Diagram
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Table of Contents
December 2014
Kaynak Tekniği Sanayi ve Ticaret A.Ş.
TOSB Otomotiv Yan Sanayi İhtisas Organize Sanayi Bölgesi
2. Cadde, No: 5, Şekerpınar 41480 Çayırova, KOCAELİ
Phone: [phone] Fax: [phone]
www.askaynak.com.tr
MANUFACTURER
Manufactured in People's Republic of China by KAYNAK
TEKNİĞİ SANAYİ ve TİCARET A.Ş.
Physical life determined by Ministry of Industry and Trade is 10 years.
(This is the period for providing spare parts required for the machine to operate.)
Expressweld MasterMIG 250CT
21. Warning and Specifications of Welding Machine 40

"Expressweld"
is the registered trademark of Kaynak Tekniği
Sanayi ve Ticaret A.Ş.
Expressweld MasterMIG 250CT

"MasterMIG"
is the registered trademark of Kaynak Tekniği
Sanayi ve Ticaret A.Ş.
Expressweld MasterMIG 250CT

Page 1
1 General Safety Rules
Expressweld MasterMIG 250CT
THIS MACHINE HAS BEEN DESIGNED FOR GMAW (MIG/
MAG). SHALL NOT BE USED FOR ANY OTHER PURPOSE.
READ AND UNDERSTAND THE INSTRUCTIONS CAREFULLY:
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WARNING: This symbol indicates that the instructions within the user guide
must be followed to avoid potential serious personal injury, loss of life and
damages on machine. Protect yourself and other people.
Be sure that this machine should only operated by qualified personnel.
Be sure that all installation, operation, maintenance and repair
procedures are performed only by authorized personnel. Be sure to read
user guide carefully before operating the machine. Failure to follow the
instructions included in the user guide may cause serious injury, loss of
life and damage on machine. Please read the warnings next to the
symbols stated below. "Kaynak Tekniği Sanayi ve Ticaret A.Ş." is not
liable for any damages due to improper connection, storage conditions
and operation procedures.
Be sure to read and understand the user guide before
operating the machine. Failure to follow the instructions stated
in the user guide may cause serious injury, loss of life and
damage on equipment.
Do not weld while you are unattentive, unattentive, tired and sleepless.
Arc welding is a safe application when necessary measures are taken to protect the
welder against potential dangers. If these measures missed or disregarded, there
may be dangers such as electric shock, exposing to high levels of fume and gas, arc
radiation, fire and explode which may cause serious injury or even death.
Note: For detailed information on safety in welding, please read ANSI Z49.1 standard.
Protective Equipments:
Welding operators should wear protective clothing to protect themselves against
burning risk. Welding burns is a frequent risk which may be caused due to splash of
welding sparks on bare skin.
Clothing used while welding may vary based on used welding method but generally it
should provide easy movements and should cover welder's body to protect against
splashes, sparks and arc radiation.

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Expressweld MasterMIG 250CT
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Flame resistant clothing,
Gaiters,
Aprons,
Leather cuff gloves and capes,
Helmet used under the welding mask.
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Noise:
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Importance and Cleanliness of Working Environment:
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Wool y clothing should be preferred due to its resistance against flame. Synthetic clothing
should not be worn since they will melt when exposed to heat.
Protective clothing should be protected from grease and oil. This kind of materials may
flare and burn uncontrolledly in an environment with oxygen.
Shirtsleeves and trouser hems should not be folded. Since sparks and melted metals
may enter into these folds. Trousers should be kept outside the work shoes and should
not be inserted into it. Otherwise melted metals and sparks may enter into shoe.
Other protective clothing used in dangerous situations are stated below:
To protect hands against burns, cuts and scratches, gloves made from flame resistant
materials such as leather must be used. In addition, to provide some insulation against
electric shock, care should be taken that the gloves made from flame resistant material
are in good condition and dry.
To protect ears against sparks and melted metals and to prevent hearing impairment due
to noise of arc welder, ear protectors should be used. When the noise in working
environment is reached to a level that disturbing the ears and causing headache, auditory
problem may occur. In such a condition immediately use your ear protectors.
Hearing impairment may not be noticed until tested and then it may be too late for
treatment.
The tidiness and cleanliness of working environment is important as the maintenance of
welder. Even the level of potential damage rises up to number of people in the
environment. Although warnings related to machine are read and necessary measures
are taken, any of the personnel tripping over a cable may cause electric shock, contact to
hot metal or falling risk for himself, you and other people.

Page 3
Expressweld MasterMIG 250CT
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Electric shock risk related to welding machine divides into two categories:
Primary voltage shock (e.g. 230-460 V)
Secondary voltage shock (e.g. 20-100 V)
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ELECTRIC SHOCK can kill.
All equipment, cables, hoses and gas cylinders should be kept away from busy places
such as doors, aisles and stairs. Care should be taken for the tidiness of the environment
and when welding is completed working environment should be cleaned. By this way,
both work safety and working efficiency will increase. Besides, other workers near the
welding area may step into weld pool by mistake, therefore safety guards should be
placed around the welding area during welding.
Electric shock danger is the most serious risk that operator may encounter frequently.
Contacting electrically hot parts may cause injuries, death or falling down due to electric
shock and sudden reflex. While machine is operating, do not touch to the electrode,
ground connection or live work piece connected to the machine. Insulate yourself against
electrode, grounding connection or work piece. Immediately after plugging out the power
cable, do not touch metal ends of power cable, there may be electric shock danger.
Primary electric shock is very dangerous since it is much higher than welding voltage.
When the power to the machine is open, you can encounter with primary electric
shock while your body is in contact with ground or touching a live point within the
machine. Please note that turning off the ON/OFF switch located on the machine do
not cut off the electric. To cut off the electric to the machine it is necessary to
disconnect the supply cable from connection point or to shut down the fuse of
incoming electric.
Never remove side covers of the machine and in case of failure have an authorized
technician to inspect and repair it.
Be sure to ground the machine and work piece.
While installing the machine and making ground connection, follow general electric
rules, all local laws and regulations and instructions of the manufacturer company.
Do not use uninsulated cables and pliers, replace with the new ones. Never dip the
electrode in water for cooling.

Page 4
Expressweld MasterMIG 250CT
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Welding Arc and Arc Rays can burn.
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Never simultaneously touch electrically "hot" parts of electrode holders connected to two
separate welders, because voltage between the two can be the total of the open circuit
voltage of both welders.
When working above floor level, use a safety belt to protect yourself from a fall should you
get a shock.
In semi-automatic or automatic welding, welding wire, electrode reel, welding head,
nozzle or torch are also electrically “hot”.
Always be sure the work cable makes a good electrical connection with the metal being
welded. The connection should be as close as possible to the area being welded.
While the welder is electrically hot, do not insert your hand or any other object inside it.
Use a shield with proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding. Skin should be protected by
clothing made from flame resistance material. Protect other nearby personnel with
suitable, non-flammable screening and/or warn them not to watch welding arc nor expose
themselves to the arc rays or to hot spatter or metal.
When eyes are exposed to UV rays even for a short time, also called as “Getting Welder's
Flash”, it may cause burns in your eyes. Getting Welder's Flash may not be noticed after
hours of exposing, but it is too irritating as well as may cause transient blindness. Normally
getting welder's flash is a temporary situation, but exposing eyes to UV rays for a long time
and frequently may cause permanent damage on eyes. As a protection measure besides
not to watch arc rays, also using welding goggles having proper filter is necessary.
As a rule, welding should start with a dark colored protective filter then should continue
with a lighter colored filter sufficient to see the area being welded providing that not to fall
under the minimum level. Welding masks protect head, face, ears and neck against
electric shock risk, heat, sparks and fire.

Page 5
Expressweld MasterMIG 250CT
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GASES and FUMES can be dangerous.
When welding with electrodes which require special ventilation such as stainless or hard
facing or on lead or cadmium plated steel and other metals or coatings which produce
highly toxic fumes, keep exposure as low as possible and keep the exposure level under
“Minimum Limit Values” using local exhaust or mechanical ventilation. In confined spaces
or in some circumstances, a respirator may be required even outdoors. Additional
precautions are also required when welding on galvanized steel.
Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent
vapors to form a highly toxic gas, and other irritating products.
Welding may cause fumes and gases that are injurious to health. Always enough
ventilation should be used or fumes and gases should be exhausted from breathing
place.
Generally in welding applications; temporary effects for short time can be seen such as
face and skin burning, dizziness, nausea and fever based on exposure period and
amount of fume. Long time fume exposure may cause iron loading and dysfunctions in
lungs. Bronchitis and pulmonary fibrosis are primary effects occurred.
Some electrodes may include alloys that entail special ventilation. Label of these
products that entails special ventilation should not be ignored and  gProduct Safety
Information Form h reports should be read carefully. When welding on this kind of
materials it may be necessary to use gas mask.
Keeping your head out of fume clouds is the easiest way for protection against toxic fumes
and gases.
Avoid breathing these fumes and gases, air circulation or mechanical ventilation
equipments should be used and if the ventilation is not enough gas mask should be used.