LOTOS MIG250i User manual

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MMMIIIGGG WWWeeellldddeeerrr

INSTRUCTION MANUAL·M I G 250 1
CCC OOO NNN T T T EEE NNN TT T SSS
- Safety…………………………..………………..…………………………….…..……....……….. 2
-General Description……...……….......……...…………………….………...……….....………. 3
-M a i n Parameter…….……...…. .........…….....………………………………….…..……….….. 4
-Installation& Operation……………………………………………………………………………. 5
-Speed-r e a d Table…………….….……….......………...…..……….……………………....….… 8
-Caution..……..………..…... .........…. ..................……………………….………..………….… 10
-Maintenance....................…………………………………………...………………. .....…......... 10
-Daily Checking………….…………………………………………………….….……....….…….. 11
Hereby westate t h a t weprovide oneyear ofguarantee f o r t h i s welding equipment since
t h e dateofpurchase.
P l e a s e read a n d understand t h i s instruction manual carefully before t h e installation a n d
operation oft h i s equipment.
T h e contents oft h i s manual m a y berevised without prior notice.
Please visit us http://www.uwelding.com.au/ for more information.
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INSTRUCTION MANUAL·M I G 250 2
SSS AAA FF F EEE TT T YYY
Welding andcutting is dangerous t o t h e operator, people in o r near t h e working area, andt h e
surrounding, if t h e machine is notcorrectly operated. Therefore, t h e performance o f welding/cutting
m u s t onlybeunder t h e strict andcomprehensive observance ofa l l relevant safety regulations.
P l e a s e read a n d understand t h i s instruction manual carefully before t h e installation a n d operation.
·T h e switching offunction modes is possibly damaging t o t h e
machine, while t h e welding operation isperformed.
·Do disconnect t h e electrode-holder cable witht h e machine,
before t h e performance o f welding.
·Asafety switch is necessary t o prevent t h e machine f r o m
electric-leakage.
·Welding t o o l s should beofh i g h quality.
·Operators should bequalified.
EEE l l l eee ccc t t t r r r i i i ccc sss hhh ooo ccc kkk : : : III ttt ccc aaa nnn kkk iii lll lll ...
·Connect t h e earthcable according t o standard regulation.
·A v o i d a l l contact withlive electrical partsoft h e welding circuit,
electrodes andwireswithbare hands. I t is necessary f o r t h e
operator t o wear d r y welding gloves while heperforms t h e
welding task.
·T h e operator should keep t h e working p i e c e insulating f r o m
himself/herself.
SSS mmm ooo kkk eee aa a nnn ddd ggg aaa sss ggg eee nnn eee r r r aaa t t t eee ddd wwwhhhiiillleee www ee e l l l ddd i i i nnn ggg ooorrr ccc uuu t t t t t t i i i nnn ggg : : : hhh aa a r r r mmm f f f uuu l l l
tttoooppp eee ooo ppp l l l ee e ’ ’ ’ ss s hhh eee aa a l l l t t t hhh . . .
·A v o i d breathing t h e smoke andgasgenerated while welding o r
cutting.
·K e e p t h e working area ingood ventilation.
AAArrrcccr r r aaa yyy sss : : : hhh aa a r r r mmm f f f uuu l l l tttoooppp ee e ooo ppp l l l ee e ’ ’ ’ sss eee yyy eee sss aa a nnn ddd sss kkk i i i nnn . . .
·Wear welding helmet, anti-radiation glassa n d workclothes
while t h e welding operation isperformed.
·Measures a l s o should bet a k e n t o protect people ino r near t h e
working area.
.
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·T h e welding splash m a y cause f i r e , t h u s remove flammable
material away f r o m t h e working place.
·Have af i r e extinguisher nearby, andhaveatrained person
ready t o useit.
NNN ooo i i i sss eee : : : ppp ooo ss s ss s i i i bbb l l l yyy hhh aa a r r r mmm f f f uuu l l l tttoooppp ee e ooo ppp l l l ee e ss s ’ ’ ’ hhh eee aa a r r r i i i nnn ggg . . .
·Noise is generated while welding/cutting, wear approved ear
protection ifnoiselevel ishigh.
MMM aaa ccc hhh i i i nnn eee fff aaa uuu ll l ttt :::
·Consult t h i s instruction manual.
·Contact your local dealer o r supplier f o r further advice.
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INSTRUCTION MANUAL·MIG 250 3
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This welding machine is manufactured with advanced inverter technology. With high-power
component IGBT and PWM technology, the inverter convert the DC voltage, which is rectified from
input 50Hz/60Hz AC voltage, to high-frequency 20KHz AC voltage; as aconsequence, the voltage
is transformed and rectified. The features of this product are as follows:
-IGBT inverter technology, current control, high quality, stable performance;
-Closed feedback circuit, invariable voltage output, great ability of balance voltage up to ±15%;
-Electron reactor control, stable welding, little splash, deep melting, excellent welding seam
reshaping;
-Slow weld wire feeding for arc starting, be able to cut small ball after welding ，successful arc
starting;
-Suit for welding medium thin plate more than 0.8mm;
-Small-sized, light-weighed, easy to operate, economical, practical.
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ttthhheee t t t r r r aa a ddd i i i t t t i i i ooo nnn aa a l l l mmm aaa ccc hhh i i i nnn eee . . .
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INSTRUCTION MANUAL·4
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TTTYYY PPP EEE MMMIIIGGG222 555 000 iii
Input Voltage (VAC) 1phase 240V±15%
Input current (A) 14
Power capacitance (KVA)) 9.2
Output current range (A) 50-250
Output voltage (VDC) 15-29
Duty cycle 60%
Power factor 0.85
Efficiency 85%
Type of wire feeder Embedded
Post-flow time (s) 1
Diameter of the coil (mm) 270
Diameter of the wire (mm) 0.8/1.0
Size of the machine (mm) 500×270×440
Weight (Kg) 26
Thickness (mm) ≥0.8
Insulation class F
Protection class IP21

MAIN SWITCH
PPPRRROOOEEECCCTTT
CCCIIIRRRCCCUUUIIITTT
PPPOOOWWWEEERRR
SSSUUUPPPPPPLLLYYY CONTROL
CCCIIIRRRCCCUUUIIITTT WWWIIIRRREEE
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TYPE
CIRCUIT DIAGRAM
MIG 250i
MMM AAA I I I NNN PPP AAA RRR AAA MMM EE E TT T EEE RRR
MIG 250 i

INSTRUCTION MANUAL·5
I I I NNN SSS TTT AAA LLL LLL TTT I I I OOO NNN &&& OOO PPP EEE RRR AAA T T T I I I OOO NNN
111...CCC ooo nnn nnn ee e cc c t t t i i i ooo nnn ooofff ttthhheeei i i nnn ppp uuu t t t ccc aaa bbb l l l eee
- A primary power supply cable is available f o r t h i s welding equipment. Connect t h e power supply
cable withrequired voltage. MIG250i isof1-phase 240VAC.
-Theprimary wireshould b e connected t o t h e corresponding socket t o avoid oxidization.
-Usemulti-meter t o see whether t h e voltage value varies int h e givenrange0.
222...CCC ooo nnn nnn ee e cc c t t t i i i ooo nnn ooofff ooo uuu t t t ppp uuu t t t ccc aaa bbb l l l eee (according t o t h e following drawing)
2a.P l u g t h e f a s t connector, t o t h e “
” ont h e panel board, andtighten itclockwise, while t h e
earthclamp a t t h e other endisconnected t o t h e workpiece.
For convenient welding operation, t h e cross section area o f welding cable should be35mm
2,
50mm
2
,70mm
2in case oft h e maximum applicable current 170A, 250A, 450A. T h e increase of
t h e cross section area o f welding cable is necessary according t o t h e current density. T h e
recommended ratioofamperage a n d cross section area ofleadis5A/m m 2 .
2b.Connect t h e f a s t connector oft h e t o r c h t o t h e “ ” o f ont h e panel board, andtighten it
clockwise.
333...III nnn sss ttt aaa lll lll aaa ttt iii ooo nnn ooofff w w w i i i r r r e e e f f f eee eee ddd eee r r r
P l e a s e refert o following drawing f o r t h e cables’ connection. Install t h e wirefeeder.
-Fixt h e wirereel t o t h e racka x i s ont h e wirefeeder; m a k e sure t h e holeoft h e wirereel matches
wellwitht h e boltont h e racka x i s .
-The wireshould beunpacked in clockwise direction, andcut offt h e curved part,whicha r e t i e d
around t h e f i x e d hole.
-Unite t h e screw o n t h e wire-pressing wheel, andm a k e t h e wireinto t h e gloveoft h e wirefeed
wheel, press t h e wiretightly, butnott o o tight, andt h e n thread t h e wireintot h e torch.
-Different wiret o different gloves according t o t h e i r diameter. Please refert o page 8Speed-read
table.
-Press the” wirefeeding” button t o feed t h e wireoutoft h e welding gun.
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
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 
MIG 250 i

INSTRUCTION MANUAL·6
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1)
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Connect the CO2tube, which come from the wire-feeder
to the copper nozzle of gas bottle. The gas supply
system includes the gas bottle, the air regulator and the
gas hose, the heater cable which plug should be insert
into the socket of machine’s back, and use the hose
clamp to Tighten it to prevent leaking or air-in, so that
the welding point is protected.
Please note:
1) Leakage of shielding gas affects the performance
of arc welding.
2) Avoid the sun shining on the gas cylinder to
eliminate the possible explosion of gas cylinder
due to the increasing pressure of gas resulted by
heating of sun shining.
3) It is extremely forbid to knock at gas cylinder and
lay the cylinder horizontally.
4) Ensure no person is up against the regulator,
before the gas release or shut the gas output.
5) The gas output volume meter should be installed
vertically to ensure the precisely measuring.
6) Before the installation of gas regulator, release
and shut the gas for several time in order to
remove the possible dust on the sieve to avail the
gas output.
MIG 250 i

INSTRUCTION MANUAL·7
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- - - OOO ppp ee e r r r aaa t t t i i i ooo nnn sss t t t eee ppp sss
-Turn on the air switch of the welding machine, open the gas cylinder valve, and adjust the flow
meter to the desired position.
-Choose contact tip’s aperture of the welding gun according to the diameter of the welding wire.
-Adjust the voltage adjustment knob and current adjustment knob to the desired position according
to the thickness and craftwork of the work piece.
-Adjust the inductance adjustment knob to the desired position to get the right rigidity.
-Press the switch on the welding gun, then welding can be carried out.
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-The option of the welding current and welding voltage directly influences the welding stability,
welding quality and productivity. In order to obtain good weld, the welding current and welding
voltage should be set optimally. Generally, the setting of weld condition should be according to the
welding wire diameter, the melting form and the production requirement. Refer to the following
figure to set the welding current, while refer to the speed-read table on page 8to do the welding
operation according to different working condition.
Range of welding current and voltage in short circuit transition and granular transaction.
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The welding quality and productivity should be taken into consideration for the option of welding
speed. In case that the welding speed increases, it weakens the protection efficiency and quickens
the cooling. As aconsequence, it is not optimal for the seaming. In the event that the speed is too
slow, the work piece will be easily damaged, and the seaming is not ideal. In practical operation, the
welding speed should not exceed 30m/h.
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The length of wire stretching out the nozzle should be appropriate. The increase of the length of
wire stretching out of the nozzle can improve the productivity, but if it is too long, excessive spatter
presents in the welding process. Generally, the length of wire stretching out the nozzle should be 10
times as the welding wire diameter.
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The protection efficiency is the primary consideration. Besides, inner-angle welding has better
protection efficiency than external-angel welding. For the main parameter, refer to the following
figure.
Option of C02flow volume
Wireφ(mm) Short circuit transition Granular transition
Current（A）Voltage (V) Current（A）Voltage (V)
0.6 40~70 17~19 160~400 25~38
0.8 60~100 18~19 200~500 26~40
1.0 80~120 18~21 200~600 27~40
1.2 100~150 19~23 300~700 28~42
1.6 140~200 20~24 500~800 32~44
Welding mode Thin wire C02
welding
Thick wire C02
welding
Thick wire, big
current C02welding
C02（L/min）5～15 15～25 25～50
MIG 250 i

INSTRUCTION MANUAL·8
SSS PPP EEE EEE DDD - - - RRR EEE AAA DDD TTT AAA BBB LLL EEE
T h e option oft h e welding current andwelding voltage directly influences t h e welding stability,
welding quality andproductivity. I n order t o obtain t h e good weld,t h e welding current andwelding
voltage should b e set optimally. Generally, t h e setting ofweldcondition should b e according t o t h e
welding diameter andt h e melting f o r m aswellast h e production requirement.
T h e following parameter isavailable f o r reference.
PPP aaa r r r aaa mmm eee t t t eee r r r fffooorrrbbb uuu t t t t t t - - - www ee e l l l ddd i i i nnn ggg ( ( ( PPP l l l eee aaa sss eee rrr eee ff f eee rrr tttooottthhheeef f f ooo l l l l l l ooo www i i i nnn ggg fff ii i ggg uuu rrr eee .. . )))
PPP aaa r r r aaa mmm eee t t t eee r r r fffooorrrfff ll l aaa ttt fff iii lll lll eee ttt www eee l l l ddd i i i nnn ggg ( ( ( PPP l l l eee aaa sss eee rrr eee ff f eee rrr tttooottthhheeef f f ooo l l l l l l ooo www i i i nnn ggg fff ii i ggg uuu rrr eee .. . )))
P l a t e
thickness
t（m m ）
Gap
g(mm)
W i r e
φ(mm)
Welding
current
（A）
Welding
voltage
（V）
Welding
speed
（cm/min
）
Gas
volume
（L/min）
0.8 0 0.8~0.9 60~70 16~16.5 50~60 10
1.0 0 0.8~0.9 75~85 17~17.5 50~60 10~15
1.2 0 1.0 70~80 17~18 45~55 10
1.6 0 1.0 80~100 18~19 45~55 10~15
2.0 0~0.5 1.0 100~110 19~20 40~55 10~15
2.3 0.5~1.0 1.0 or 1.2 110~130 19~20 50~55 10~15
3.2 1.0~1.2 1.0 or 1.2 130~150 19~21 40~50 10~15
4.5 1.2~1.5 1.2 150~170 21~23 40~50 10~15
P l a t e
thickness
t（m m ）
C o r n size
I(mm)
W i r e
φ(mm)
Welding
current
（A）
Welding
voltage
（V）
Welding
speed
（cm/min
）
Gas
volume
（L/min）
1.0 2.5~3.0 0.8~0.9 70~80 17~18 50~60 10~15
1.2 2.5~3.0 1.0 70~100 18~19 50~60 10~15
1.6 2.5~3.0 1.0 ~ 1.2 90~120 18~20 50~60 10~15
2.0 3.0~3.5 1.0 ~ 1.2 100~130 19~20 50~60 10~20
2.3 2.5~3.0 1.0 ~ 1.2 120~140 19~21 50~60 10~20
3.2 3.0~4.0 1.0 ~ 1.2 130~170 19~21 45~55 10~20
4.5 4.0~4.5 1.2 190~230 22~24 45~55 10~20
MIG 250 i

INSTRUCTION MANUAL·9
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PPP aaa r r r aaa mmm eee t t t eee r r r fffooorrrLLL aa a ppp WWW ee e l l l ddd i i i nnn ggg ( ( ( PPP l l l eee aaa sss eee rrr eee fff eee rrr tttooottthhheeef f f ooo l l l l l l ooo www i i i nnn ggg fff iii ggg uuu rrr eee .. . )))
P l a t e
thickness
t（m m ）
C o r n size
I(mm)
W i r e
φ(mm)
Welding
current
（A）
Welding
voltage
（V）
Welding
speed
（cm/min
）
Gas
volume
（L/min）
1.2 2.5~3.0 1.0 70~100 18~19 50~60 10~15
1.6 2.5~3.0 1.0 ~ 1.2 90~120 18~20 50~60 10~15
2.0 3.0~3.5 1.0 ~ 1.2 100~130 19~20 50~60 10~20
2.3 3.0~3.5 1.0 ~ 1.2 120~140 19~21 50~60 10~20
3.2 3.0~4.0 1.0 ~ 1.2 130~170 22~22 45~55 10~20
4.5 4.0~4.5 1.2 200~250 23~26 45~55 10~20
P l a t e
thickness
t（m m ）
Welding
position
W i r e
φ(mm)
Welding
current
（A）
Welding
voltage
（V）
Welding
speed
（cm/min
）
Gas
volume
（L/min）
0.8 A 0.8~0.9 60~70 16~17 40~45 10~15
1.2 A 1.0 80~100 18~19 45~55 10~15
1.6 A 1.0 ~ 1.2 100~120 18~20 45~55 10~15
2.0
A or B 1.0 ~ 1.2 100~130 18~20 45~55 15~20
2.3 B 1.0 ~ 1.2 120~140 19~21 45~50 15~20
3.2 B1.0 ~ 1.2 130~160 19~22 45~50 15~20
4.5 B 1.2 150~200 21~24 40~45 15~20
MIG 250 i