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Klutch MIG250S Owner's Manual

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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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  Summary of Contents for Klutch MIG250S

  • Page 1 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...
  • Page 2: Intended Use

    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.
  • Page 3: General Safety Rules

    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.
  • Page 4 -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.
  • Page 5 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;...
  • Page 6: Technical Specifications

    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.
  • Page 7: 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.
  • Page 8 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.
  • Page 9 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. Retaining Groove Retaining Bolt 1.3 Insert the back end of the MIG torch into the MIG socket on the front of your machine.
  • Page 10: Installation

    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.
  • Page 11 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.
  • Page 12 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...
  • Page 13 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 IT AT 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.
  • Page 14: Gas Installation

    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.
  • Page 15 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.
  • Page 16: Operation

    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.
  • Page 17: Welding Techniques

    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.
  • Page 18 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.
  • Page 19 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.
  • Page 20 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.
  • Page 21 8.5 Spot welding There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap. Each has advantages and disadvantages depending on the specific application as well as personal preference. 1. The BURN-THROUGH METHOD welds two overlapped pieces of metal together by burning through the top piece and into the bottom piece.
  • Page 22: Troubleshooting

    8.6 SPOT WELDING INSTRUCTIONS 1. Select the wire diameter and heat setting recommended above for the method of spot welding you intend to use. 2. Tune in the wire speed as if you were going to make a continuous weld. 3.
  • Page 23: Diagram & Parts List

    DIAGRAM & PARTS LIST Reference # Part# Description Qty. 1.1.02.01.7908 SPINDLE MOUNTING BRACKET 2.05.05.969 SPOOL HUB ASSEMBLY 2.05.05.158 SPOOL HOLDER NUT 2.01.29.006 CHAIN 0.8m 1.1.01.05.0116 CYLINDER SUPPORT Page of 26...
  • Page 24 1.1.02.02.0308 GAS CONNECTOR 1.1.01.05.2193 COPPER NUT 1.1.01.05.2194 GAS VALVE CONNECTOR 2.07.55.003 GAS VALVE 2.07.80.831 POWER SWITCH 2.04.30.103 POWER CORDER HOLDER 1.2.02.01.4326 BACK PANEL 2.05.07.103 REAR WHEEL 2.06.14.401 ACORN CONNECTOR NUT 2.08.07.803 DOOR LATCH 1.2.02.01.4328 DOOR 1.1.01.02.8550 SMALL SIDE PANEL 1.1.01.04.0415 BOTTOM 2.05.07.301 CASTER...
  • Page 25 1.2.02.01.3023 FAN PLATE 2.07.37.420 RECTIFIER ASSEMBLY 2.07.36.509 THERMO RELAY(ROHS) 2.07.41.050 AC CONTACTOR 1.1.01.02.8553 MIDDLE VERTICAL PANEL (2) 2.05.17.012 THE PLASTIC HINGE 2.0740.739 WIRE FEEDER ASSEMBLY 1.1.05.02.0145 MAIN PCB 2.07.25.825 CONTROL TRANSFORMER 2.07.13.051 CAPACITANCE 2.07.07.107 CEMENT RESISTANCE(ROHS) 2.20.08.874 MIG TORCH 2.20.03.692 .030 CONTACT TIP 2.20.03.691 .035 CONTACT TIP...
  • Page 26: Warranty

    WARRANTY EFFECTIVE JULY 1, 2014 LIMITED WARRANTY This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from the factory.