Toolex MIG-200 User manual

!
SAVE THIS MANUAL
Keep this manual for the safety
warnings and precautions, assembly,
operating, inspection, maintenance and
cleaning procedures. Write the product’s
serial number in the back of the manual
near the assembly diagram (or month and
year of purchase if product has no
number). Keep this manual and the receipt
in a safe and dry place for future
reference.
IMPROTANT SAFETY INFORMATION
In this manual, on the labeling, and all
other information provided with this
product:
This is the safety alert symbol. It is
used to alert you to potential personal
injury hazards. Obey all safety
messages that follow this symbol to
avoid possible injury or death.
DANGER indicates a hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING: WARNING indicates a
hazardous situation which, if not
avoided, could result in death or
serious injury.
CAUTION: CAUTION, used with
the safety alert symbol, indicates a
hazardous situation which, if not
avoided, could result in minor or
moderate injury.
NOTICE:NOTICE is used to
address practices not related to
personal injury.
SAFETY WARNINGS AND
PRECAUTIONS
WARNING: When using tool, basic safety
precautions should always be followed to
reduce the risk of personal injury and
damage to equipment.
Read all instructions before using this
tool!
Work Area Precautions
1. Keep your work area clean and well
lit. Cluttered benches and dark areas
invite accidents.
2. Do not operate power tools in
explosive atmospheres, such as in
the presence of flammable liquids,
gases, or dust. Power tools create
sparks which may ignite the dust or
fumes.
3. Keep bystanders, children, and
visitors away while operating a
power tool. Distractions can cause
you to lose control. Protect others in
the work area from debris such as
chips and sparks. Provide barriers or
shields as needed.
WARNING!(
(
READ(AND(UNDERSTAND(ALL(
INSTRUCTIONS(
Failure(to(follow(all(instructions(listed(below(
may(result(in(electric(shock,(fire,(and/or(
serious(injury.(
SAVE(THESE(INSTRUCTIONS(

Electrical Safety
1. Grounded tools must be plugged
into an outlet properly installed and
grounded in accordance with all
codes and ordinances. Never
remove the grounding prong or
modify the plug in any way. Do not
use any adapter plugs. Check with
a qualified electrician if you are in
doubt whether the outlet is properly
grounded. If the tool should
electrically malfunction or break down,
grounding provides a low resistance
path to carry electricity away from the
user.
2. Double insulated tools are
equipped with a polarized plug (one
blade is wider than the other). This
plug will fit in a polarized outlet
only one way. If the plug does not
fit fully in the outlet, reverse the
plug. If it still does not fit, contact a
qualified electrician to install a
polarized outlet. Do not change the
plug in any way. Double insulation
eliminates the need for the three wire
grounded power cord and grounded
power supply system.
3. Avoid body contact with grounded
surfaces such as pipes, radiators,
ranges, and refrigerators. There is
an increased risk of electric shock if
your body is grounded.
4. Do not expose power tools to rain
or wet conditions. Water entering a
power tool will increase the risk of
electric shock.
5. Do not abuse the Power Cord.
Never use the Power Cord to carry
the tool or pull the Plug from an
outlet. Keep the Power Cord away
from heat, oil, sharp edges, or
moving parts. Replace damaged
Power Cords immediately.
Damaged Power Cords increase the
risk of electric shock.
6. When operating a power tool
outside, sue an outdoor extension
cord marker “W-A” or “W”. These
extension cords are rated for outdoor
use, and reduce the risk of electric
shock.
Personal Safety
1. Stay alert. Watch what you are
doing, and use common sense
when operating a power tool. Do
not use a power tool while tired or
under the influence of drugs,
alcohol, or medication. A moment of
inattention while operating power tools
may result in serious personal injury.
2. Dress properly. Do not wear loose
clothing or jewelry. Contain long
hair. Keep your hair, clothing, and
gloves away from moving parts.
Loose clothes, jewelry, or long hair
can be caught in moving parts.
3. Avoid accidental staring. Be sure
the Power Switch is off before
plugging in. Carrying power tools
with your finger on the Power Switch,
or plugging in power tools with the
Power Switch on, invites accidents.
4. Remove adjusting keys or
wrenches before turning the power
tool on. A wrench or a key that is left
attached to a rotating part of the power
tool may result in personal injury.
5. Do not overreach. Keep proper
footing and balance at all times.
Proper footing and balance enables
better control of the power tool in
unexpected situations.
6. Use safety equipment. Always wear
eye protection. Dust mask, non-skid
safety shoes, hard hat, or hearing

protection must be used for
appropriate conditions.
Tool Use and Care
1. Use clamps (not included) or other
practical ways to secure and
support the workpiece to a stable
platform. Holding the work piece by
hand to against your body is unstable
and may lead to loss of control.
2. Do not force the tool. Use the
correct tool for your application.
The correct tool will do the job better
and safer at the rate for which it is
designed.
3. Do not use the power tool if the
Power Switch does not turn it on or
off. Any tool that cannot be controlled
with the Power Switch is dangerous
and must be replaced.
4. Disconnect the Power Cord Plug
from the power source before
making any adjustments, changing
accessories, or storing the tool.
Such preventive safety measures
reduce the risk of starting the tool
accidentally.
5. Store idle tools out of reach of
children and other untrained
persons. Tools are dangerous in the
hands of untrained users.
6. Maintain tools with care. Keep
cutting tools maintained and clean.
Properly maintained tools are less
likely to bind and are easier to control.
Do not use a damaged tool. Tag
damaged tools “Do not use” until
repaired
7. Check for misalignment or binding
of moving parts, breakage of parts,
and any other condition that may
affect the tool’s operation. If
damaged, have the tool serviced
before using. Many accidents are
caused by poorly maintained tools.
8. Use only accessories that are
recommended by the manufacturer
for your model. Accessories that may
be suitable for one tool may become
hazardous when used on another tool.
Service
1. Tool service must be performed only
by qualified repair personnel. Service
or maintenance performed by
unqualified personnel could result in a
risk of injury.
2. When servicing a tool, use only
identical replacement parts. Use of
unauthorized parts or failure to follow
maintenance instructions may create a
risk of electric shock or injury.
SPECIFIC SAFETY RULES
1. Maintain labels and nameplates on
the tool. These carry important
information. If unreadable or missing,
contact TOOLEX INDUSTRIAL for a
replacement.
2. Always wear the approved safety
impact eye goggles and heavy work
gloves when suing the tool. Using
personal safety devices reduce the
risk for injury. Safety impact eye
goggles and heavy work gloves are
available from Harbor Freight Tools.
3. Maintain a safe working
environment. Keep the work area
well lit. Make sure there is adequate
surrounding workspace. Always keep
the work area free of obstructions,
grease, oil, trash, and other debris. Do
not use a power tool in areas near
flammable chemicals, dusts, and
vapors. Do not use this product in a
damp or wet location.

4. Avoid unintentional starting. Make
sure you are prepared to begin work
before turning on the tool.
5. Never leave the tool unattended
when it is plugged into an electrical
outlet. Turn off the tool, and unplug it
from its electrical outlet before leaving.
6. Always unplug the tool from its
electrical outlet before performing
and inspection, maintenance, or
cleaning procedures.
7. Prevent eye injury and burns.
Wearing and using the approved
personal safety clothing and safety
devices reduce the risk for injury.
a. Wear the approved safety impact
eye goggles with a welding helmet
featuring at least a number 10
shade lens rating.
b. Leather leggings, fire resistant
shoes or boots should be worn
when using this product. Do not
wear pants with cuffs, shirts with
open pockets, or any clothing that
can catch and hold molten metal
or sparks.
c. Keep clothing free of grease, oil,
solvents, or any flammable
substances. Wear dry, insulating
gloves and protective clothing.
d. Wear an approved head covering
to protect the head and neck. Use
aprons, cape, sleeves, shoulder
covers, and bibs designed and
approved for welding and cutting
procedures.
e. When welding/cutting overhead or
in confined spaces, wear flame
resistant ear plugs or ear muffs to
keep sparks out of ears.
8. Prevent accidental fires. Remove
any combustible material from the
work area.
a. When possible, move the work to
a location well away from
combustible; protect the
combustibles with a cover made of
fire resistant material.
b. Remove or make safe all
combustible materials for a radius
of 35 feet (10 meters) around the
work area. Use a fire resistant
material to cover or block all open
doorways, windows, cracks, and
other openings.
c. Enclose the work area with
portable fire resistant screens.
Protect combustible walls, ceilings,
floors, etc., from sparks and heat
with fire resistant covers.
d. If working on a metal wall, ceiling,
etc., prevent ignition of
combustibles on the other side by
mobbing the combustibles to a
safe location. If relocation of
combustibles is not possible,
designate someone to serve as a
fire watch, equipped with a fire
extinguisher, during the welding
process and for at least one half
hour after the welding is
completed.
e. Do not weld or cut on materials
having a combustible coating or
combustible internal structure, as
in walls or ceilings, without an
approved method for eliminating
the hazard.
f. Do not dispose of hot slag in
containers holding combustible
materials. Keep a fire extinguisher
nearby and know how to use it.
g. After welding or cutting, make a
thorough examination for evidence
of fire. Be aware that easily visible
smoke or flame may not be
present for some time after the fire
has started. Do not weld or cut in

atmospheres containing
h. Dangerously reactive or
flammable gases, vapors, liquids,
and dust.
i. Provide adequate ventilation in
work areas to prevent
accumulation of flammable gases,
vapors, and dust. Do not apply
heat to a container that has held
an unknown substance or a
combustible material whose
contents, when heated, can
produce flammable or explosive
vapors. Clean and purge
containers before applying heat.
Vent closed containers, including
castings, before preheating,
welding, or cutting.
9. Avoid overexposure to fumes and
gases. Always keep your head out of
the fumes. Do not breathe the fumes.
Use enough ventilation or exhaust, or
both, to keep fumes and gases from
your breathing zone and general area.
ℓWhere ventilation is questionable,
have a qualified technician take
an air sampling to determine the
need for corrective measures.
Use mechanical ventilation to
improve air quality. If engineering
controls are not feasible, use an
approved respirator.
ℓWork in a confined area only if it
is well ventilated, or while
wearing an air-supplied
respirator.
ℓFollow OSHA guidelines for
Permissible Exposure Limits
(PEL’s) for various fumes and
gases.
ℓFollow the American Conference
of Governmental Industrial
Hygienists recommendations for
Threshold Limit Values (TLV’s)
for fumes and gases.
ℓHave a recognized specialist in
Industrial Hygiene or
Environmental Services check
the operation and air quality and
make recommendations for the
specific welding or cutting
situation.
10. Always keep hoses away from
welding/cutting spot. Examine all
hoses and cables for cuts, burns, or
worn areas before each use. If any
damaged areas are found, replace the
hoses or cables immediately.
11. Read and understand all
instructions and safety precautions
as outlined in the manufacturer’s
WARNING(
INHALATION(HAZARD:(Welding(and(Plasma(
Cutting(Produce(
TOXIC(FUMES.(
Exposure!to!welding!or!cutting!exhaust!fumes!can!
increase! the! risk! of! developing! certain! cancers,!
such!as!cancer!of!the!larynx!and!lung!cancer.!Also,!
some!diseases!that!may!be!linked!to!exposure!to!
welding!or!plasma!cutting!exhaust!fumes!are:!
a. Early!onset!of!Parkinson’s!Disease!
b. Heart!disease!
c. Ulcers!
d. Damage!to!the!reproductive!organs! !
e. Inflammation! of! the! small! intestine! or!
stomach! !
f. Kidney!damage!
g. Respiratory! diseases! such! as! emphysema,!
bronchitis,!or!pneumonia!
Use! natural! or! forced! air! ventilation! and! wear! a!
respirator! approved! by! NIOSH! to! protect! against!
the! fumes! produced! to! reduce! the! risk! of!
developing!the!above!illnesses.!

Manual for the material you will
weld or cut.
12. Proper cylinder care. Secure
cylinders to a cart, wall, or post, to
prevent them from falling. All cylinders
should be used and stored in an
upright position. Never drop or strike a
cylinder. Do not use cylinders that
have been dented. Cylinder caps
should be used when moving or
storing cylinders. Empty cylinders
should be kept in specified areas and
clearly marked “empty.”
13. Never use oil or grease on any
inlet connector, outlet connector,
or cylinder valves.
14. Use only supplied Torch on this
Inverter Air Plasma Cutter. Using
components from other systems may
cause personal injury and damage
components within.
15. People with pacemakers should
consult their physician(s) before using
this product. Electromagnetic fields in
close proximity to a heart pacemaker
could cause interference to, or failure
of the pacemaker.
16. USE PROPER EXTENSION
CORD.
Make sure your extension cord is in
good condition. When using an
extension cord, be sure to sue one
heavy enough to carry the current your
product will draw. An undersized cord
will cause a drop in line voltage
resulting in loss of power and
overheating. A 50 foot extension cord
must be at least 12 gauges in diameter,
and a 100 foot extension cord must be
at least 10 gauges in diameter. If in
doubt, use the next heavier gauge.
The smaller the gauge number, the
heavier the cord.

SPECIFICATIONS
MIG- 200
MIG -250
MIG -250
MIG-315
Rated input voltage
1ph-220V/50/60HZ
1ph-220V/50/6
0HZ
3ph-380V/50/60H
Z
3ph-380V/50/60HZ
Rated input Current
cCcurrentower
ccininputcurrent（A）
30
40
13.4
16
Rated input power（KVA）
6.6
8.8
8.8
10.5
No load voltage（V）
62
62
62
62
Duty cycle
60%
60%
60%
60%
Welding current（A）
23-200
30-250
30-250
30-315
Welding voltage(V)
15-25
15-27
15-27
15-30
Finish arc current（A）
30-200
30-250
30-250
30-315
Finish arc voltage(V)
8-40
8-40
8-40
8-40
Wire diameter(mm)
Ф0.6-Ф1.0
Ф0.8-Ф1.2
Ф0.8-Ф1.2
Ф0.8-Ф1.2
Wire type
Solid/flux cord
Solid/flux cord
Solid/flux cord
Solid/flux cord
Welding type
Manual
setting/Synergic
Manual
setting/Synergi
c
Manual
setting/Synergic
Manual
setting/Synergic
Pre gas time(s)
0.1
0.1
0.1
0.1
Gas flow time(s)
0~5
0~5
0~5
0~5
Cover protection grade
IP21S
IP21S
IP21S
IP21S
Insulation
F
F
F
F
Dimension
（W×D×Hmm）
630×400×700
630×400×700
630×400×700
630×400×700
Weight（kg）
47
48
48
49
Duty Cycle
Duty Cycle is the equipment
specifications which defines the number of
minutes within a 10 minute period that a
piece of equipment can safely operate.
MAX (IGBT Module MIG machines with
60% duty cycle at maximum welding
output, which means that it continuously
operates for 6 minutes at maximum output
during a 10 minute period.
CAUTION: Failure to observe the duty
cycle limitations of this MIIG MACHINE
can easily damage this equipment, and
will void warranty.
Model!
Item!

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UNPACKING
When unpacking, checks to make sure the
following parts are included.
Inverter welding machine with
MIG torch with Power Cord
Ground cable with Clamp
If any parts are missing or broken, please
call EACO ELECTRIC at the number on
the cover of this manual.
Preparing Your Work Area
1. You must have a sturdy work table
that is open below the area you are
welding. Molten slag will be blown
through the work metal, and must be
able to fall away freely
2. Your work table must allow the work
metal to be firmly clamped to prevent it
accidentally falling or moving.
3. The floor and surrounding area of your
work site must not be flammable. A
clean cement floor is recommended.
The cutting process will eject molten
metal slag onto the floor, and it will
scatter for 8-10 feet or more in any
direction. Have an adequate fire
extinguisher available if needed.
ASSEMBLY
Grounding the tool:
Attach a ground wire to the screw on the
lower right of the back of the welder.
Connect the other end of the wire to an
appropriate ground, such as a steel
workbench, steel biding member or
grounding electrode.
Attach air supply:
Caution: Do not use an Argon/Mixed
pressure regulator/flow meter with CO2
Shielding gas. To use CO2 Shielding gas,
you must install a CO2 Shielding gas
pressure regulator/flow meter.
1. Make sure the Flow Adjust on the
Pressure Regulator/Flow Meter is
turned off. Then Pressure
Regulator/Flow Meter firmly onto the
cylinder valve.
2. Connect the gas air inlet (2) to your
supply CO2 Gas supply by one air
hose (not supplied). And remember to
fasten it with coupling.
Ground!
Screw!
Gas!inlet!(2)! !
Heat!power!(3)!

!10!/!26!
!
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!10!
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3. Adjust the flow rate of the gas by
turning the Flow Adjust. The typical
flow rate is 10-30 CFH (cubic feet per
Hour). Make sure to check the Welding Wire manufacturer’s recommended flow
rate.
4. Plug the cord plug of CO2 Gas regulator into the heat power (3).
Distributing power and cables
Model
MIG 200
MIG 250
MIG 250
MIG 315
Power
1 phrase
AC(220V)
50HZ/60HZ
1 phrase
AC(220V)
50HZ/60HZ
3 phrase
AC(380V)
50HZ/60HZ
3 phrase
AC(380V)
50HZ/60HZ
Capacity
Suitable
power
6．6KVA
8．8KVA
8.8KVA
10.5KVA
Dynamot
or
≥7KVA
≥9KVA
≥9KVA
≥11KVA
Input
protection
Fuse
32A
60A
32A
32A
Breaker
32A
60A
32A
32A
Cables
Input
cables
≥2.5mm2
≥4mm2
≥4mm2
≥4mm2
Output
cables
≥25mm2
≥35mm2
≥35mm2
≥35mm2
Grounding
cables
≥4mm2
≥6mm2
≥6mm2
≥6mm2
Installation and connection
Grounding
1/ AC240V
Gas tube
Gas bottle
Welding
torch
Work piece
Welding cable
（-）
Input
cable
电源 过热
工作
检丝 非自锁
自锁
检气
收弧电压
min max
收弧电流
min max
焊接电压
min max
焊接电流
min max
电弧力
min max
EA SY M IG /M AG SER IES W ELD ER
V
A
Welding power
Heater cable
Gas regulator

!11!/!26!
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!11!
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Front Panel and Instruction
1. Power indicator light: This light will
illuminate when the machine is power
on
2. Thermal Overload Indicator Lamp.
This light will come on, Machine
auto-self protection when it is
over-heated or MIG torch is damaged.
3. Amperage Display:Shows actual
welding current, which will vary during
operation.
4. Voltage Display: Shows actual
welding voltage, which will vary during
operation.
5. Crater Voltage: The finishing voltage
can be adjusted by turning this knob.
6. Crater Current: The finishing
Amperage can be adjusted by turning
this knob.
7. Spatter Control: The spatter can be
adjusted by turning this knob.
8. MMA welding Current: The MMA
welding Amperage under MMA
welding pattern can be adjusted by
turning this knob.
9. MIG welding Voltage:The MIG
welding Voltage under MIG welding
pattern can be adjusted by turning this
knob.
10. MIG welding Current: The MIG
welding Amperage under MIG welding
pattern can be adjusted by turning this
knob.
11. “4T/2T” selection button：Selecting
“4T/2T” procedure functions, MIG
welding divides into “2T” action
（non-self lock）and “4T” action（self
lock）， “2T” means to start welding
when press the torch switch and stop
welding when the torch switch is
released. “4T” action style means output ARC
striking current when press torch
2!
1!
3!
4!
12
2!
11!
10!
9!
8!
7!
6!
5!
14
2!
13
2!

!12!/!26!
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!12!
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switch for the first time, current up to
standard welding current while
releasing the torch switch. Press the
torch switch again after welding is
finished, and then welding current
begin down to end-ARC current and
retain it. The welding machine stops
outputting current after releasing torch
switch for the second time. This is
suitable for long time welding.
12. MIG/ARC: This is to select MIG or
MMA welding; Turn up is MIG welding,
turn down is MMA welding.
13. Crater on/off: This is to select crater
function or not.
14. Gas Checking: This is to select Gas
checking beforehand or not.
15. MIG Torch connector:when
you chose MIG welding mode , please
plug the welding plug with cable to the
MIG control socket and plug the
ground cable to socket
16. “-“Ground cable connector: Plug
the ground cable to this connector and
clamp the other end to the work piece.
17. “+” MMA cable connector: when you
chose ARC welding mode(, please
plug the MMA welding plug with cable
to the MIG control socket and plug the
ground cable to socket
Assembly the wire feeder
Note: When installing wire of a different size or composition, maybe you will also need to
change wire settings, and, possibly, install a gas cylinder.
1. Important: Securely hold onto the end of the Welding Wire and keep tension on it
during the following steps. If this is not done the welding wire will spring back and
creating a tangled “bird’s nest” and resulting in wasted wire.
2. Hold the Welding Wire securely while you cut enough Wire off the end of the Spool to
remove all bent and crimped Wire. Make sure the cut end has no burrs or sharp edges
(cut again, if needed).
3. Loosen and lower the Tension Adjusting Knob (1a) on the Wire Feed Assembly. Then,
Tension Adjusting
Knob (1a)!
Wire Feed
Leader (3a)!
Swing
Arm (2a)!
Manual wire feeder
(4a)!
Wire feed
rolls (5a)!

!
raise the Swing Arm (2a)
4. Keep tension on the Welding Wire, and guide at least 12 inches of Wire into the Wire
Feed Leader (3a).
5. Lower the Swing Arm (2a) on the Wire Feed Assembly. Lower and tighten the
Tension Adjusting Knob (1a). Once the Wire is held in place, you may release it.
6. Lay the Torch Cable out in a straight line so that the Welding Wire moves through it
easily.
Press the manual wire feeder knob (4a), the welding wire will keep running through the
torch. Then cut off any excess Welding Wire over 1/2 inches.
OPERATION
Note: Before beginning, please read and understand all the safety precautions
staring on page 1 and especially the section “Specific Safety Rules” starting on
page 3.
MIG Welding
1. Place the MIG welding unit no closer than six feet from the work piece to be welded
2. Connect the MIG torch control, cable plug as shown on page 10. Twist to lock in
place.
Plug in the Grounding Cable into the Ground Connector on the upper of the unit front.
Twist to lock.
3. Securely place the clamping end of the Grounding Cable Clamp to a part of the work
piece or metal table that is clean of paint, oil, or dirt. Clamp as close as possible to the
work piece without damaging the cable during welding.
4. Assembly wire feeder according page 11.and keep Welding Wire over 1/2 inches over
the torch. Then assembly the torch well.
5. Assemble the desired accessories and tips inside the tip of the MIG Torch handle.
Insert the Contact Tip (2b) onto the Welding Wire and screw it firmly into the Head
Tube (3b) of the Torch Handle. Replace the Nozzle (1b), and cut off any excess
Welding Wire over 1/2 inches.
6. Connect a hose and coupling from the gas regulator on a CO2gas tank (none
included) to the CO2Gas Inlet on the back of the unit. Follow the gas cylinder
manufacturer’s instructions for set-up and use.
7. Put the metal to be welded on the metal weeding-cutting table. Ensure the metals to
be welded are clean, so good welding efficiency can be promised.
8. Verify that the Power Switch is in the off position, and then connect the power cord
into an appropriate outlet and turn the welder ON. The Power Light” will

!
illuminate, but the Torch is not yet energized.
9. Point the torch away from all objects and press the trigger until the wire feeds out of
the gun two inches. If necessary, move the Torch Handle slightly in a circular motion to
help feed the Welding Wire properly out of the Head Tube
Caution: The Torch handle is now energized. Be careful not touch anything else with the
Torch except the work piece to be welded.
When everything is prepare well for welding. Preset parameter according the job needed. (Refer
to panel instruction on page 9). Hold the Trigger down and tilt the torch forward. Keep the
wire touch the work piece.
MIG Welding Tips
Welding current(A)
Welding voltage(V)
Dia. Of wire(mm)
60~80
17~18
0.8~1.0
80~130
18~21
1.0~1.2
130~200
20~24
1.0~1.2
200~250
24~27
1.0~1.2
Basic Welding Technique
1. Press (and hold) trigger and contact area to be welded with electrode wire to ignite arc
2. For a narrow weld, you can usually draw the Welding Wire in a steady straight line.
This is called a “stringer bead”.
For a wider weld, draw the Welding Wire back and forth across the joint in a curve.
This is called a “weave bead”.! !
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3. Hold Torch in one hand and the face shield in the other.
4. Direct the welding wire straight into the joint. This gives an angle of 90o(straight up
and down) for butt (end to end) welds, and an angle of 45ofor filter (T-shaped) welds.

!
5. The end of torch should be tilted so that wire is angled anywhere in between straight
on and 15o in the direction you are welding. The amount of tilt is called the drag
angle.
6. When the weld is complete, lift the Gun and welding wire clearly away from any
grounded object, and turn the powers switch off.
Arc (stick) Welding
1. Turn the Current Adjustment Knob to meet the needs of the job.
2. Move the Stick or TIG Switch to “TIG”
3. Connect the Electrode Clamp and Cable to the torch control connector (as 7 shown on
page 9 and twist to lock in place.
4. Plug the cable of the Grounding Clamp into the DC ground connector and secure the
clamp to a clean, exposed metal part of the work piece.
5. Place the metal portion of the welding rod inside the jaws of the Electrode Clamp.
Welding rod types vary for welding different metals.
Note: If too much current is drawn from the welder; the Thermal Overload protector will
activate, the Overload indicator will light, and the welder will turn off until it cools down. It
will automatically reset.
When finished welding
a) Release the Torch handle trigger and lift the Torch handle from the work
piece,
b) Press the Power Switch to the Off (O) position.
c) Set the Torch handle down on the metal workbench,
d) Turn the air supply off,
e) Unplug the line cord from the electrical outlet.

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Excess or Burn-through
Weld droops on top
and underneath, or falls
through entirely,
making a hole
Proper
Weld is visible underneath and
bulges slightly on top.
Inadequat
e
Weld does not contact the
joint fully, just on the
surface.
Possible causes and Solutions
1. Excessive material at weld:
Reduce wire feed speed
2. Overheating:
Increase welding speed and
ensure that welding speed is kept
steady.
Welding not adhering properly
Gaps present between weld and previous
bead or between weld and work piece.
Possible causes and Solutions
1. Dirty work piece:
Make certain that work piece is clean
and free from oil, coatings, and other
residues.
2. Insufficient weld material:
Increase wire feed speed.
3. Incorrect welding technique:
Place stringer bead at correct place in
joint. Adjust work piece position or weld
angle to permit proper welding at
bottom of work- piece.
Pause briefly at sides when using a
weave bead. Keep arc on leading edge
of weld puddle. Hold gun at proper
angles and make tack welds to help
hold pieces.
Possible causes and Solutions
1. Work pieces too thick/close:
Joint design must allow weld to
reach bottom of groove and allow
proper welding procedures.
2. Incorrect welding technique:
Maintain
1
/ 2”or less stick out.Keep
arc on leading edge of weld puddle.
Hold gun at proper angles.
3. Insufficient weld material:
Increase wire feed speed.
4. Insufficient weld heat:
Reduce Welding Speed.
Bent at joint
Possible causes and Solutions
1. Improper clamping:
Make sure that pieces are clamped
securely in place.
2. Excessive heat:
Weld a small portion and allow
cooling before proceeding.
Reduce wire feed speed.

!
I n s pect io n , M a i ntenance , an d clean i n g
W arn i n
g!
Before performing any maintenance on the Welder, unplug the p ower
cord (54) from its electrical outlet and allow all components of the
Welder to completely cool.
.
1. Periodically open the Access Panel
from the machine and, using
compressed air, blow out all dust and
debris from the interior
2. Always store the welder in a clean,
dry, safe location out of reach of
children and other unauthorized
people.
3. For optimal weld quality, clean and
inspect the contact tip and nozzle
before each use, as follows:
4. inspect the Contact Tip (51b) and Nozzle (51a) before each use, as follows:
Nozzle Inspection, c leaning,
1. Turn the Nozzle (1b)
counterclockwise while
pulling to remove.
2. Scrub the interior of the Nozzle
clean with a wire brush.
3. Examine the end of the
nozzle(1a).The end should be flat
and even, If the end is uneven,
chipped, melted, cracked, or
otherwise damaged, the nozzle will
adversely effect the weld and
should be replaced.
4. Reinstall the Nozzle (1a)
after inspecting and cleaning
the Contact Tip.
Contact tip Inspection,
cleaning, and replacement
1. Make sure the entire Welding torch is
completely cool before proceeding.
2. Remove the nozzle as explained
above. Then remove the contact tip.
3. Scrub the exterior of the contact tip
clean with a wire brush. Check that
the contact tip is the proper type for
the wire size used.
4. Examine the hole at the end of the
contact tip for the following problems:
Shape: The hole should be an even
circle, and should not be oblong or
have any bulges in it.
Size: The Contact Tip will decrease
in efficiency as the center hole
enlarges. A Contact Tip that
measures 150% or more the original
size* should be replaced. (*.045” or
more for .030” t ips; .035” or more
for .023 t ips.)
5. If any problems are noted with a
Contact Tip (1b), it is recommended
to have it replaced.
6. When inspection and maintenance is
completed, reinstall the Contact Tip
(1b) and Nozzle (2b).

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Gas metal arc welding
Gas metal arc welding (GMAW),
sometimes referred to by its subtypes
metal inert gas (MIG) welding or metal
active gas (MAG) welding, is a
semi-automatic or automatic arc welding
process in which a continuous and
consumable wire electrode and a shielding
gas are fed through a welding gun. A
constant voltage, direct current power
source is most commonly used with
GMAW, but constant current systems, as
well as alternating current, can be used.
There are four primary methods of metal
transfer in GMAW, called globular,
short-circuiting, spray, and pulsed-spray,
each of which has distinct properties and
corresponding advantages and limitations.
Welding gun and wire feed unit
The typical GMAW welding gun has a
number of key parts—a control switch, a
contact tip, a power cable, a gas nozzle,
an electrode conduit and liner, and a gas
hose. The control switch, or trigger, when
pressed by the operator, initiates the wire
feed, electric power, and the shielding gas
flow, causing an electric arc to be struck.
The contact tip, normally made of copper
and sometimes chemically treated to
reduce spatter, is connected to the
welding power source through the power
cable and transmits the electrical energy
to the electrode while directing it to the
weld area. It must be firmly secured and
properly sized, since it must allow the
passage of the electrode while maintaining
an electrical contact. Before arriving at the
contact tip, the wire is protected and
guided by the electrode conduit and liner,
which help prevent buckling and maintain
an uninterrupted wire feed. The gas nozzle
is used to evenly direct the shielding gas
into the welding zone—if the flow is
inconsistent, it may not provide adequate
protection of the weld area. Larger nozzles
provide greater shielding gas flow, which
is useful for high current welding
operations, in which the size of the molten
weld pool is increased. The gas is
supplied to the nozzle through a gas hose,
which is connected to the tanks of
shielding gas. Sometimes, a water hose is
also built into the welding gun, cooling the
gun in high heat operations. The wire feed
unit supplies the electrode to the work,
driving it through the conduit and on to the
contact tip. Most models provide the wire
at a constant feed rate, but more
advanced machines can vary the feed rate
in response to the arc length and voltage.
Some wire feeders can reach feed rates
as high as 30.5 m/min (1200 in/min), but
feed rates for semiautomatic GMAW
typically range from 2 to 10 m/min
(75–400 in/min)

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Power supply
Most applications of gas metal arc welding
use a constant voltage power supply. As a
result, any change in arc length (which is
directly related to voltage) results in a
large change in heat input and current. A
shorter arc length will cause a much
greater heat input, which will make the
wire electrode melt more quickly and
thereby restore the original arc length.
This helps operators keep the arc length
consistent even when manually welding
with hand-held welding guns. To achieve a
similar effect, sometimes a constant
current power source is used in
combination with an arc voltage-controlled
wire feed unit. In this case, a change in arc
length makes the wire feed rate adjust in
order to maintain a relatively constant arc
length. In rare circumstances, a constant
current power source and a constant wire
feed rate unit might be coupled, especially
for the welding of metals with high thermal
conductivities, such as aluminum. This
grants the operator additional control over
the heat input into the weld, but requires
significant skill to perform successfully.
Alternating current is rarely used with
GMAW; instead, direct current is
employed and the electrode is generally
positively charged. Since the anode tends
to have a greater heat concentration, this
result in faster melting of the feed wire,
which increases weld penetration and
welding speed? The polarity can be
reversed only when special
emissive-coated electrode wires are used,
but since these are not popular, a
negatively charged electrode is rarely
employed
Technique
The basic technique for GMAW is quite
simple, since the electrode is fed
automatically through the torch. By
contrast, in gas tungsten arc welding, the
welder must handle a welding torch in one
hand and a separate filler wire in the other,
and in shielded metal arc welding, the
operator must frequently chip off slag and
change welding electrodes. GMAW
requires only that the operator guide the
welding gun with proper position and
orientation along the area being welded.
Keeping a consistent contact tip-to-work
distance (the stick out distance) is
important, because a long stick out
distance can cause the electrode to
overheat and will also waste shielding gas.
Stick out distance varies for different
GMAW weld processes and applications.
For short-circuit transfer, the sickout is
generally 1/4 inch to 1/2 inch, for spray
transfer the stick out is generally 1/2 inch.
The position of the end of the contact tip to
the gas nozzle are related to the stick out
distance and also varies with transfer type
and application. The orientation of the gun
is also important—it should be held so as
to bisect the angle between the work
pieces; that is, at 45 degrees for a fillet
weld and 90 degrees for welding a flat
surface. The travel angle, or lead angle, is
the angle of the torch with respect to the
direction of travel, and it should generally
remain approximately vertical. However,
the desirable angle changes somewhat
depending on the type of shielding gas
used—with pure inert gases; the bottom of
the torch is often slightly in front of the
upper section, while the opposite is true
when the welding atmosphere is carbon
dioxide.!

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ASSEMBLY DIAGRAM
The structure of ADVAN MIG 250(reference only):