Top Gun MIG-MAG 250I-SWF User manual

THANKS FOR PURCHASING OUR PRODUCT
MIG-MAG 250I-SWF
Inverter MIG/MAG/MMA Semi-auto ARC Welding Machine
(with preset voltage,wire speed)
Operation Manual
(Read the manual carefully before installation ,operation and maintenance)
（BE SUITABLE FOR 1~220V/230V/240V）

SAFETY PRECAUTIONS
Follow these precautions carefully. Improper use of any welder can result in injury
or death.
1. ONLY CONNECT WELDER TO A POWER SOURCE FOR WHICH IT WAS
DESIGEND. The specification plate on the welder lists this information. When welding outdoors
only use an extension cord intended for such use.
2. ONLY OPERATE WELDER IN DRY LOCATIONS and on cement or masonry floor.
Keep area clean and uncluttered.
3. KEEP ALL COMBUSTIBLES AWAY FROM WORK SITE.
4. DO NOT WEAR CLOTHING THAT HAS BEEN CONTAMINATED with grease or oil.
5. KEEP CABLES DRY AND FREE FROM OIL AND GREASE and never coil around
shoulders.
6. SECURE WORK WITH CLAMPS or other means; don't overreach when working.
7. NEVER STRIKE AN ARC ON A COMPRESSED GAS CYLINDER
8. DON'T ALLOW THE INSULATED PORTION OF THE ELECTRODE HOLDER TO
TOUCH THE WELDING GROUND WHILE CURRENT IS FLOWING.
9. SHUT OFF POWER AND UNPLUG MACHINE WHEN REPAIRING OR ADJUSTING.
Inspect before every use. Only use identical replacement parl.
10. FOLLOW ALL MANUFACTURER'S RULES on operating switches and making
adjustments.
11. ALWAYS WEAR PROTECTIVE CLOTHING when welding . This includes: long
sleeved shirt(leather sleeves), protective apron without pockets, long protective pants and boots.
When handing hot materials, wear asbestos gloves.
12. ALWAYS WEAR A WELDER'S HELMET WITH PROTECTIVE EYE PIECE when
welding. Arcs may cause blindness. Wear a protective cap underneath the helmet.
13. WHEN WELDING OVERHEAD, BEWARE OF HOT METAL DROPPINGS. Always
protect the head, hand, feet and body.
14. KEEP A FIRE EXTINGUISHER CLOSE BY AT ALL TIMES.
15. DO NOT EXCEED THE DUTY CYCLE OF THE MACHINE. The rated cycle of a
welding machine is the percentage of a ten minute period that the machine can operate safely at
a given output setting.
16. KEEP ALL CHILDREN AWAY FROM WORK AREA. When storing equipment, make
sure it is out of reach of children.
17. GUARD AGAINST ELECTRIC SHOCK. DO not work when tired. Do not let body
come In'contact with grounded surfaces.

Prolegomenon
We do very appreciated for your selecting our products.
This kind of welding power Model MIG-MAG250I-SWF is taken foreign advanced
technology to develop and manufacture the new generation inverter integrated controlling
Semi-auto MIG/MAG ARC Welding machine.
It can be composed the MIG-MAG250I-SWF DC MMA/DC&sopt CO2/MIG/MAG ARC
Welding system equipped with wire feeder and welding gun .It has many characteristic such
as easy Arc starting .good Arc shininess .adjustable arc thrusting ,low splash,good welding
form ,easy welding operation,wide range and electricity save.
The MIG/MAG semi-auto Arc welding machine model MIG-MAG250I-SWF is advanced
welding machine and it cam be compared with foreign products.
This operation manual can help you for the machine installation, operation and maintenance
correctly and safely.Pay attention to the points as following.
．Installation of the power cord. Be grounded correctly.
. Don't put sundries under the welder.Otherwise it will affect the heat released.
. Installation for the positive and negative cable of the power output.
. Welding voltage selection (the potentiometer on the wire feeder )
. Welding current selection (speed of wire feeder)
. Selection of Arc thrusting(potentiometer on the front panel)
The amendment right and the explanation right of the manual belonging to my company.We
have no special notice if the manual is amended.

1. Main characteristic and suitable range
This kind of welding power Model MIG-MAG250I-SWF is taken foreign advanced
technology to develop and manufacture the new generation inverter integrated controlling
Semi-auto Arc welding machine.It makes use of the import key parts such as Siemens IGBT
module of Germany,alloy magnetic core and the resume diode module of America. It has the
perfect performance of high quality ,good reliability, quick speed of welding current, steady
welding process,low splash and good welding form . Anyway,It becomes the welding very easy.
1.1 Structure of the MIG-MAG250I-SWF semi-auto Arc welding machine
a.The name of the model
MIG-MAG250I-SWF
Model improvement
Rated max welding current
Semi-auto MIG/MAG Arc welding machine
b. Composing of the product
This product is composed by three parts as following
★Power source(MIG-MAG250I-SWF)
★Wire feeder
★welding gun
1.2 Suitable range of the MIG-MAG250I-SWF
★Suitable material: low-carbon steel, stainless steel,Al and its alloy
★Thickness of the material:
low-carbon steel and stainless: more than 1.0mm
Al and its alloy: more than 1.0mm
★Suitable position:all positions
★Suitable wire :
φ0.9,1.2solid wire/flux cord wire ,φ0.9,1.2, AL wire.
★Suitable welding rod :φ1.0 ~ 5.0 for low-carbon steel, stainless steel.
1.3 Characteristic of MIG-MAG250I-SWF
★Wide output current 30-250A: 0.9 -----------30-180A
1.2------------80-250A
★Steady welding process,low splash,easy control,good welding form.
★High efficiency:
250A/26.5V the duty cycle is 60%
200A/24V the duty cycle is 100%
continuous wire feed,the max speed of wire feed is 15m/min
★Low starting of wire feed

★2/4steps changing
★Preset the diameter of the wire to get the excellent arc steady and good welding
form.
★Preset the welding voltage :Preset the welding current to read the welding criterion
easy.
★Adjusting the arc thrusting: Control the splash and steady arc.
★Strong resistance for the fluctuate of the electricity
★Enlarge the output cable to 50m/50mm2to guarantee the welding current not
less than 250A when using the 1.2 welding wire.
2.Main technical Data :
★Input Voltage 1~220V/230V/240V ; 50/60Hz
★Rated Input current 40A
★Rated Input power 9 KVA
★No-load Voltage 55~75V
★Voltage adjusting Range 14±3V~36±3V
★Current output Range 30~250A (MIG/MAG)
30~200A(MMA)
★Suitable wire 0.9/1.2
★Duty cycle(MIG/MAG)
250A/26.5V the duty cycle is 60%
200A/24V the duty cycle is 100%
★Duty cycle(MMA) 200A/28V the duty cycle is 60%
★Efficiency η≥0.85
★Power factor λ=0.8
★Insulation class F
★Protection class of shell fan cooling
★Overall measurement ( l*w*h) 670mm*310mm*565mm
★Weight 48KG
Note:(1) Adjust the no-load voltage according to the requirements. Normally it is 70V.
3.Function
3.1 Adjusting function for the welding voltage and welding current
3.1.1 MIG-MAG250I-SWF supply the adjusting range at MIG/MAG as following,
Welding voltage : 16V±3V~36V±3V use the voltage adjusting knob on the wire feeder

Welding current : 30A~250A use the current adjusting knob on the wire feeder
3.1.2 MIG-MAG250I-SWF supply the adjusting range at MMA as following,
Welding current : 30A~200A use the welding current knob on the panel.
3.2 Adjusting function of the Arc thrusting
It has the important function to select the proper Arc thrusting for improvement of the
welding line ,control the welding splash and the steady Arc. Normally,.
If the thrusting is low ,the arc is soft and splash .
If the trusting is high,the arc is strong and high splash.
Use the arc thrusting continuously by the control knob on the front panel of
MIG-MAG250I-SWF.
3.3 2/4 steps change
3.4 Spot welding
When open the 'spot time' knob ,you can select right time (Intermittent welding
regulator to minimum, turning it anticlockwise to the end) , then spot welding
3.5 Intermittent welding
Open the the 'spot time' knob and the 'Intermittent welding time 'knob at one time,you can
achieve Intermittent welding
3.6 Function for low Arc starting
We design the function for low arc starting in order to improve the efficiency of arc
starting.
3.7 AC 36V/3A power function
When you use the CO2MIG/MAG welding machine, you may generally equip with
gas heating source. So we design the power function to meet the heating for 36V-3A /120W
heater .The out connection is down of the front panel of MIG-MAG250I-SWF.
3.8 Recycle function
We design the function to settle two problems.
1) Control the diameter of the wire ball at the end of wire .

2) Prevent the wire into the pool after the Arc stopped.
3.9 Over current function of the wire feed motor
In order to protect the motor, the wire feed motor may stop rolling automatically if
the current reaches 10A .When it is lower than 10A ,the motor begins rolling automatically.
3.10 Quick wire feed function
The spot wire feed speed can be adjusted by the welding current knob on the wire
feed panel, so that it is convenient for the customers to get the quick wire feed speed.
3.11 Arc defeated protection function
If the Arc starting defeated, the system stops the wire feed and turn off the power
automatically(only 4 steps useful).Turn on the welding gun again if continuous welding.
4. Indicating and warning on the MIG-MAG250I-SWF control
panel
4.1 Indicating and adjusting
1. FRONT PANEL 2. BACK PANEL
1.indication of welding current 2.indication of welding voltage 3. Welding current regulator(for MMA)
4. Spot welding regulator 5.warning indicating light 6. over heat indicating light 7. indicating light of power
8.arc force 9.MMA/MIG SWITCH 10. Intermittent welding regulator 11.crater switch(2T/4T)
12gas outlet 13. power switch14. output"+" 15 feeder control 16.output"-" 17. 36Vacpower plug
18. nameplate 19.power supply 20.safety earthing column 21. fuse 22.fan
23.burnback time regulator 24.gas inlet
4.1.1 Voltage indicating
The voltage meter on the front panel can indicate the actual welding voltage or preset
voltage.The indicating number has the precision of 0.1V .The meter indicates the preset during

no welding.
4.1.2 Current indicating
The current indicating meter on the front panel indicates the actual welding current during
the welding.The adjusting range is 30A to 250A.
The current indicating meter indicates the Preset the speed of the wire during no welding.
The adjusting range is 2~-100.
4.1.3 Welding current regulator (for MMA)
Regulating the knob, It can be selected between 40A to max Amp..
4.1.4 Spot welding regulator
Regulating the knob, It can be selected between 0.2 to 1.5s.
4.1.5 Warning
If the circuit is over current ,the light is ON.The control circuit stop the power
automatically.
4.1.6 excess temper(over heat)
In the condition of more than 40℃temperature,large current is used continuously
(I2>200A),efficiency radiator temperature id more than 80±5℃,overheat circuit begins
working.The indicating light is on ,the power stop the welding automatically.The fan running
continuously.If the temperature is lower,the indicating is off,the power can work and weld can be
continued automatically ,Remind:Don't turn off the machine while te indicating overheat light is
ON. 4.1.7 Power indicating
Turn power on, it will illuminate indicating.
4.1.8 arc force regulator
Regulating suitable arc force, splash can be reduced .
4.1.9 MMA/MIG SWITCH
Select the mode of output
4.1.10 Intermittent welding
4.1.11 2/4 steps switch

MIG/MAG Trigger Sequences
For the machine , MIG/MAG welding can be done in either the 2-step or 4-step mode
which is selected with the Trigger Mode Push Button.
4.1.12 gas outlet
4.1.13 power switch
Input line switch turns input power ON or OFF, as indicated by the on or off status of the
front panel digital display (See Item 1&2).
4.1.14 output"+"
For quick disconnect system using Twist-Mate cable plugs
In MIG/MAG welding, connected with wire feeder.
In MMA welding, connected with cable and electrode holder or clamp according to the
kind of welding rod.
4.1.15 feeder control
In mig/mag welding, you must connect wire feeder with the feeder control
4.1.16 output"-"
This quick connect Twist-Mate receptacle provides electrical connection to the electrode
holder and cable for Stick welding and connection for the mig/mag clamp when mig/mag welding.
4.1.17 36 Vacpower plug
connection for heated flow meter.
4.1.18 nameplate
The data plate stamped on the metal structure complies with the EN 60974-1,
EN50199(EN60974-10) international standards and contains the following information:
* (a) Manufacturer's name and address
* (b) Trademark
* (c) Model
* (No) Serial number
* ( ) The welding power source comprises a frequency converter
followed by an transformer and rectifier that transforms input voltage into direct current.
* (EN 60974-1/EN 50199) Standards applied.
* ( ) Direct current.
* (x) Utilisation factor expressed as a percentage of useful work over a cycle of 10 minutes

at an ambient temperature of 40oC.
* (I2) Rated weld current.
* (U2) Conventional load voltage.
* (Uo) Rated no-load voltage.
* ( ) mig/mag welding.
* ( ) MMA welding.
* ( ) 1 input phases.
* (IP21S) Casing protection degree in compliance with the EN 60529 Standard:
IP2XX Casing protected against access to dangerous components with fingers and against
the introduction of foreign matters with diameter 12.5 mm.
IPX3X Casing protected against rain failing at 60Oon the vertical line.
IPXXC Casing protected against contact of a test gauge φ2.5 mm length 100 mm with live
dangerous parts,
* (U1) Rated power supply voltage.
* (50/60 Hz) Power supply rated frequency.
* (ll max) Maximum supply current.
(I1 eff ) Effective supply current.
* ( S ) Generator suitable for installation in places where major risks of electric shocks are
preset
* (CE) In compliance with the European regulations in force.
4.1.19power supply
connected main supply
4.1.20safety earthing column
The earthing must be made according to the national regulations. Make sure that the supply
mains and the earthing are sufficient and adequate
4.1.21 fuse
4.1.22 fan
4.1.23 burnback time regulator
4.1. 24.gas inlet

5.Safe and installation caution
Read the safe caution before installation and operation .It come down to the high voltage
electricity,electric Arc and high temperature splash.So keep the safe regulation ,operate the
machine properly,avoid the danger of electricity and high temperature arc.
★Check if any damage ot out looking ot the welder.
★Confirm the capacity:more than 60A.
★Power source is grounded,diagram 6
★Prohibit the combustible goods in the welding locale.
★There is fire proof measure in the welding locale with favorable ventilated condition.
★There is smoke discharge system if the welding is operated inside the house in
order to keep the safety of workers.
★The welding operator must be professional workers.
★The operator must be fitted with safe accessories .Such as safe
shoes,gloves,cover,welding make and welding dress etc.

6. Explanation of installation
★Check the products according to the packing list when open the package.
★Ground protection.Attached the diagram 6
The power source is 220v/230V/240Vac/(50~60)Hz with three phases and 3 lines.The
yellow/green double cable is grounding cable.Be sure to connect the yellow/green double cable
into the grounding connection in the welding locale .Another way is selecting the M8 bolt on the
back on the machine and connect the grounding as the diagram as following.
6.1 MIG/MAG welding
put the switch"9" into "MIG"
★confirm the positive and negative marks and install the cable
as diagram.
★Insert the connectors inside the positive "+" and negative "-"
position and roll it in 90. Do it oppositely when unloading the
connectors.Keep the surface clean

★Install the welding gun on the wire feeder and roll the welding gun in 90,then lock the
bolt. ★Connect the gas pipe with the gas bottle according to the locale conditions. Check the
air proof conditions to ensure the good airproof.
★Connect the control cable ot the wire feeder with the relative connection of the power
MIG-MAG250I-SWF.
6.2 MMA welding
put the switch"9" into "MMA（TIG）"
Selecting empiric formula: I=40*d ,d is dia. of the electrode.
Notice positive and negative connection during welding.
A negative connection B positive connection
7. Operatings
★"ON" and "OFF" indicating switch on the front panel.
★Preset the welding voltage ,welding current(voltage adjusting knob,current adjusting
knob on the wire feeder).Arc thrusting and selection switch of the wire diameter.Diagram 4
★Preset 2/4 steps switch (selection switch of second current)
★Confirm the specification of the wire feed hose
It affects the wire feed resistance and steady welding process.Specially theφ1.6 wire ,be

sure to select the proper hose.
★Confirm the specification of nib base .It affects the extended length of the wire .
★Confirm the specification of nib. It affects the electric resistance.
★Confirm the wire slot of the roller is suitable for the diameter of the wire. Different
diameter of wire select different wire slot. Otherwise it affects the wire feed result.
★Confirm the pressure of the roller to avoid slipping.
If the pressure is not enough ,the wire feed is slow speed.
If the pressure is too much ,the wire will be anamotphic.
The wire feeder can not work properly.
★Confirm the flow of the gas and air proof.
We suggest the gas flow to be "L" more than 10D(D-diameter of wire ).If the selection is
not proper,it also affects the welding quality.When using the CO2gas,please confirm if the
heating power works properly or not .
★Straight the hose of welding gun as much as possible .The bending radius can not be less
than 200mm.Otherwise it affects the wire feeder.
7.1 2 steps/4 steps working process
4steps : Put the switch of the panel on the position "4 steps",press the switch of the
gun for the first time,the normal welding begins.Relax the switch for the first time,the welding
process keeps unchanged.Press the switch for the second time,the welding process keeps
unchanged.too.Relax the switch for the second time,the arc stops.
7.2Gas inspection
Press the switch of the gun before the wire roller is firmed,preset the gas flow through the
meter to check if it is gas proof.Otherwise ,it affects the welding result.
7.3Rip into the wire
Select the specification of the wire ,materials according to the craft requirements.Firm the
bolt and press the button on the front panel.The speed of ripping wire can be controlled by the
welding current knob.Unload the nib if necessary and load it again after the wire is out.

8.Suggested welding criterion
Select good quality welding wire to get the perfect welding result and smooth welding
process .Low quality wire can affect the welding quality by resistance welding process and
blocking etc.
8.1Selection switch for wire diameter
Please refer to rhe function on 1.3
8.2Selection for Arc thrusting
Please refer to the function on 2.2
8.3Selection for welding voltage and current Diagram 8
d(mm)
φ0.8
φ1.0
φ1.2
suitable
wel
ding
criterion
18~ 20V /80 ~
120A*
17 ~ 18V/50 ~
80A*
19 ~ 22V/100 ~
150A
17 ~ 18V/50 ~
80A*
17 ~ 19V/80 ~
100A*
18 ~ 19V/80 ~
100A*
19 ~ 22V/100 ~
150A*
19 ~ 22V/100 ~
160A*
22 ~ 24V/150 ~
200A*
22 ~ 24V/150 ~
200A*
24 ~ 27V/200 ~
250A*
24 ~ 30V/200 ~
300A
27 ~ 36V/250 ~
400A
9. working elements
Diagram for the MIG-MAG250I-SWF working elements.Digram9

Input AC 220V/230V/240V , rectifier and filter it into 310VDC.
Control the IGBT by PWM+FM,inverter the 310VDC to 20KHz AC.
High frequency transformer pass the power by insulation and voltage reducing with high
efficiency.
Output the second rectifier and the second filter.Output the required welding current and
voltage.
10.Maintenance
Check the safety measure be efficiency.
Get rid of the dust for the power source (FORexample,dry compressed air)
Before operating,,Check the "+""-"connectors of the power panel if they are relaxed
.Check the connection between the grounding cable and plug if they are relaxed,(If
relaxed,the serious heating will damaged the quick connectors)
.Check the fan if it works regularly.charge it if it is trouble.
Check the insulation and breakage of the input power cord
.Change it in time to ensure the safety.
check if there is any noisy for the wire feed motor.
Check the abrasion of the wire feed hose.Get rid of the dust inside of the hose.(!~2times
/40kg wire)
.Get rid of the splash inside the nib regularly to ensure the guaranteed result by the gas
blow.
Check the abrasion of the nib.Change it in time.(suggust 1~2pieces nibs/40kg wire).
11.Troubles and Remedy
Troubles and remedy and remedy are as the form 10 as following,,
Troubles
Cause
Remedy
1.Fan not works
properly
1.phase absent of the
power
2.the fan line lose
3.Fan breakage
1.Check the power
2.Connect the line
3.Change the fan
2.No indicating on
the front panel
1.phase absent of the
power
2.the fuse broken
3.Indicating light broken
1.Check the power
2.Change the fuse
10A/250V(back panel)
3.Change it(φ8)

Troubles
Cause
Remecly
3.The light for low
voltage on
1.the power voltage istoo
low (lower than 300-330v)
2.Input capacity not
enough
3.Control panel damaged
1.Check the power
2.Enlarge the
capacity(enlarge the thickness or
the cable)
3.Check the control panel
and change it
4.Over heating
light on
1.aeration is not good
2.The temperature is too
high 3.over-load use
4.Thermostat broken
5.Control plate broken
1.get rid of the bar 0.5m
around
2.Reduce the temperature
3.Reduce the use loading
4.Change the
thermostat(JUC-OF)
.Check and change the
control plate
5.Over-current
light ON
1.IGBT broken
2.output diode broken
3.Drive plate broken
4.Control plate broken
Contact the manufacturer
6.Wire feeder not
work
1.the fuse broken
2.the Cables are not
3.the wire blocked
4.the drive circuit broken
5.other reasons
1.Change the fuse
10A/250V(on back panel)
2.the Cables are not
connected properly
3.Check the gun
4.Change the control panel
5.Contact with the
namufacturer
7.Welding Voltage
and welding
current not adjustable
1.Potentiometer line fall
down
2.Potentiometer broken
3.fuse broken
4.the cables not
connectecl properly
5.The drive circuit broken
1.Connect the lines
2.Change it (5K)
3.Change the
fuse10A/250V(on back panel)
4.Check it
5.Change the control panel

12.Enlarge the length of the welding cable
The length of the welding cable includes the total length of the welding circuit including
the cables between the positive"+"of the power source.The cables longer,thesection area
thinner ,It caused large voltage reducing and large voltage loss,More over,it affect the quality of
the arc and the slag.So arrange the position of the welding machine properly to get the shortest
cable.
The cable between the welding power and wire feeder is the shorter,the better
Otherwise it affects thd maximum speed of wire feeder are the maximum welding current.
form 12 The relationship between cable length,section area and maximum output current
The maximum output is
36V
6V 30m
9.6V 60m
14V 100m
25mm2
250A/26.5-30V
200A/24-28V
160A/22-26V
on the condition of low speed (lower than 12m/min),we can enlarge the cable to 50m when
useφ0.9~1.2
★Straight the enlarged cable, otherwise it affects the arc stability.
13.Transportation,storage and environment conditions
★The package (Wooden cases or cartons)of the manufacturer is suitable for
air ,sea ,railway and highway (three class more) transportation..
★Pay attention to the indication on the package dure the transportation.
★the environment conditions
A Temperature range operating 0℃~ 40℃
transportation -25℃~+55℃
B The air humidity 40℃50%RH
20℃90%RH
C The dust ,acid and cause tic gas in the enviroment must be lower than the normal level
(The welding process produced not included)
D Rain proof when it is used outside.
14.Quality Guaranteed
If you have any problem of the quality ,please contact us in time .We generally have one
year quality guarantee on condition that you operate or transport the machine properly according
to the operation manual.

15.ACCESSORIES:SEE PACKING LIST,PLEASE
PACKING LIST
★★★★★★★★★★★★★★★★★★★★★★★★
No.
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Certificate of quality
Name of product: C02/MIG/MAG Semi-auto ARC Welding Machine
Type of product: MIG-MAG250I-SWF
Packing No:
Test results of this welder fulfils_____________
_________technical requirements and its release
from the works is granted.
Inspector_________ Date___________
MIG-MAG250I-SWF
Welding machine
1
wire feeder(FCS-203)
1
connector+cable+Ground pliers
1
connector+cable+holder
1
welding torch
1
gas pipe
1
flow meter
1
optional accessary
Spool welding torch(QLBT 5m)
1
optional accessory
feeder roller
2
Operation instructions
1
Certificate of quality
1