Table of Contents
Related Manuals for Lincoln Electric Expressweld MasterMIG 250CT
Summary of Contents for Lincoln Electric Expressweld MasterMIG 250CT
- Page 1 USER MANUAL Welding Method and Specifications GMAW (MIG/MAG) Phase Eczacıbaşı - Lincoln Electric recommend to use “ASKAYNAK” gas metal arc welding wire for obtaining high performance from MasterMIG 250CT. askaynak www. .com.tr...
- Page 2 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...
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Page 3: Table Of Contents
Expressweld MasterMIG 250CT Table of Contents 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. - Page 4 Expressweld MasterMIG 250CT "Expressweld" is the registered trademark of Kaynak Tekniği Sanayi ve Ticaret A.Ş.
- Page 5 Expressweld MasterMIG 250CT "MasterMIG" is the registered trademark of Kaynak Tekniği Sanayi ve Ticaret A.Ş.
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Page 6: General Safety Rules
Expressweld MasterMIG 250CT 1 General Safety Rules THIS MACHINE HAS BEEN DESIGNED FOR GMAW (MIG/ MAG). SHALL NOT BE USED FOR ANY OTHER PURPOSE. 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. - Page 7 Expressweld MasterMIG 250CT 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.
- Page 8 Expressweld MasterMIG 250CT 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.
- Page 9 Expressweld MasterMIG 250CT 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.
- Page 10 Expressweld MasterMIG 250CT 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”...
- Page 11 Expressweld MasterMIG 250CT WELDING and CUTTING SPARKS can cause fire or explosion. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.
- Page 12 Expressweld MasterMIG 250CT If you are working above floor level or on stairway, make sure there is no flammable or explosive material below. Also please remember that slag and sparks may splash on people around. Special precautions should be used when welding in dusty environment. Dust particles ...
- Page 13 Expressweld MasterMIG 250CT CYLINDER may explode if damaged. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the welding application and maintained in good condition with a proper installation.
- Page 14 Expressweld MasterMIG 250CT For electrically powered equipment. Turn off input power using the disconnect switch at the fuse box before working on the equipment. Install equipment in accordance with local codes in force. GROUNDING: Power cables should be connected to a well grounded plug for your safety and proper operation of the equipment.
- Page 15 Expressweld MasterMIG 250CT EXTRA SAFETY MEASURES: In some situations applying safety measures may be difficult, but even so follow the mentioned rules. Keep your gloves dry, if getting wet is unavoidable then have an extra pair of gloves near you. Stand on a plywood, plastic mat or similar dry and insulating material.
- Page 16 INFORMATION ON RESIDUAL RISKS: Expressweld MasterMIG 250CT welder has been designed and manufactured in compliance with safety rules required by TS EN 60974-1 standard. To eliminate the safety risks all necessary precautions have been taken, precautions that need to be taken by operators and users and all rules to be followed have been stated in the user manual.
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Page 17: Electromagnetic Compatibility
Expressweld MasterMIG 250CT ELECTROMAGNETIC COMPATIBILITY ELECTROMAGNETIC fields may be hazardous. Designed according to TS EN 60974-1. EMU Class of machine according to TS EN 55011 is Group 2 Class A. For detailed information refer to TS EN 60974-10. While welding do not turn on/off the power switch. - Page 18 Expressweld MasterMIG 250CT Electromagnetic resistance of the equipments located and working in working area should be checked. User must be sure that other surrounding devices will operate in harmony with the machine. To achieve this extra protection measures may be necessary.
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Page 19: General Information, Warnings And Operation Conditions
Expressweld MasterMIG 250CT 2 General Information, Warnings and Operation Conditions Warning! Read entire section before installing and starting the machine. Do not install, operate or repair the welder without reading safety precautions included in user manual. Keep this user manual and place to an easy accessible place. - Page 20 Expressweld MasterMIG 250CT Heating tests have been performed in ambient temperature and operation cycle has been determined with simulation at 40°C. Operate the machine in a well ventilated environment and leave at least 50 cm free space around it. Do not operate in places higher than 100 m.
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Page 21: Specifications
Expressweld MasterMIG 250CT 3 Specifications MasterMIG 250CT is a compact type gas metal arc (MIG/MAG) welding machine with combined wire feeder unit and power unit. Especially suitable for spot welding and high quality welding of mild structural steels and stainless steels with medium thickness used in metal manufacturing industry. -
Page 22: Technical Data
Expressweld MasterMIG 250CT 4 Technical Data Welding Machine Model MasterMIG 250CT Nominal mains voltage 380 V ± 10, 50/60 % Hz, 3 Phase Maximum power consumption (% 35) 9.7 kVA Current taken from mains (% 35) 15.2 A (%100) 7.3 A 0.93... -
Page 23: Front Panel Controls
Expressweld MasterMIG 250CT 5 Front Panel Controls Power indicator thermal protection indicator handle on-off switch welding voltage Wire feed speed precise setting switch setting button welding voltage coarse setting switch torch connector (EURO socket) work cable connector rear wheel front wheel... -
Page 24: Back Panel Controls
Expressweld MasterMIG 250CT 6 Back Panel Controls Shielding gas cylinder fixing slot shielding gas hose connector Shielding gas (C02) heater fuse (8A) technical specifications for the metal plate shielding gas heater connector (24V) metal plate for specifications external power connector (3A) -
Page 25: Controls In Wire Feeder System
Expressweld MasterMIG 250CT 7 Controls in Wire Feeder System Cover providing easy access Wire feeder reel press to internal panel forced setting spindle Wire drive engine Wire inlet Wire outlet guide guide Welding wire reel connecting shaft and braking Welding torch... -
Page 26: Connection Diagram
Expressweld MasterMIG 250CT 8 Connection Diagram Page 21... -
Page 27: Installation And Operation Of Machine
Expressweld MasterMIG 250CT 9 Installation and Operation of Machine 9.1 Mains Supply Mains supply connection of the machine should be made as per rules and only by qualified personnel trained with necessary information. Welding machine has been designed for triphase mains supply, 380 V± 10, 50/60% and should be protected by 20A delay action fuse. -
Page 28: Connecting Shielding Gas Cylinder To Welding Machine
Expressweld MasterMIG 250CT 9.4 Connecting Shielding Gas Cylinder to Welding Machine To provide shielding gas to wire feeder system and welding torch, it is necessary to connect “Shielding Gas Hose” to “Shielding Gas Inlet Socket” located in the rear of welding machine. - Page 29 Expressweld MasterMIG 250CT Setting Braking Torque of Welding Wire Reel Connecting Shaft To prevent welding wire to discharge from the reel, fastener that holds the reel is equipped with a braking system. Braking setting is performed with a spring located in the fastener.
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Page 30: Functions Of Wire Feeder System
Expressweld MasterMIG 250CT 10 Functions of Wire Feeder System Wire drive system has the following functions: Wire Feeding Speed Setting: - It is possible to set the wire feeder speed between 1-20 m/min. 11 GMAW (MIG/MAG) Method Make sure that the welding machine is installed according to the explanations included on Page 22. -
Page 31: Environment Conditions
Expressweld MasterMIG 250CT 12 Environment Conditions Warning! Before starting the machine following procedures should be performed: Provide the necessary environment conditions for the welding machine. For example there shouldn't be any flammable gases and vapors, conducting dusts, burner/flammable fumes and other factors that may be hazardous for insulation and mechanical structure of the machine. -
Page 32: Efficient Use Of Machine In Terms Of Energy Consumption
Expressweld MasterMIG 250CT 13 Efficient Use of Machine In Terms of Energy Consumption Part Wire Guide Welding Welding Wire Flow Speed Thickness Diameter Current Voltage Inner Diameter (mm) (mm) (mm) (lt/min) 0.8 - 1.5 ø 0.8 ø 1.4 50 - 90 17 - 18 1.0 - 2.5... -
Page 33: Unpacking
15 Unpacking EXPRESSWELD MasterMIG 250CT Gas Metal Arc Welding Machine sold in its original cartoon box and on a pallet. Do not purchase the machines without packaging. To unpack the machine, cut the strap connected to the pallet and lift up the box. -
Page 34: Maintenance And Repair
Expressweld MasterMIG 250CT 17 Maintenance and Repair Warning! Proper usage and performing periodical maintenance fully will enable high performance and important for long economical life. Maintenance, repair and service works should only performed by the qualified personnel who had the required... - Page 35 Expressweld MasterMIG 250CT Make sure that the cooling fan is not damaged and turns normally. If the fan doesn't operate even after the overheating of the machine, check if the propeller of the fan is blocked. If the fan is damaged, contact with authorized service.
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Page 36: Troubleshooting Guide
Expressweld MasterMIG 250CT 18 Troubleshooting Guide PROBLEM REASON SOLUTION Spiral is dirty. Clean the spiral. Channels of the drive reels are Check the channels of reels and not compatible with wire type or change with the reels suitable for diameter being used. Grooves the used wire. - Page 37 Expressweld MasterMIG 250CT PROBLEM REASON SOLUTION Contact nozzle and wire feed Check the contact nozzle and wire reels is not compatible with feed reels, change if necessary. the used wire. There is strain in any point of Check wire guides and spiral.
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Page 38: Failures In Welding Seams
Expressweld MasterMIG 250CT 19 Failures in Welding Seams Pore Creation Possible Reasons: 1.Insufficient gas shielding. 2.Used gas is dirty or gas flow speed is not suitable. 3.Surface of welding wire is dirty. 4.Work piece is dirty. 5.Voltage value is too high. - Page 39 Expressweld MasterMIG 250CT Solutions: 1. Clean scale and oxide residues from all surfaces in the welding seam area. 2. Increase wire feed speed and arc voltage. Decrease free wire length. 3. To control welding puddle more easily do not perform over oscillatory welding.
- Page 40 Expressweld MasterMIG 250CT Solutions: Increase the advancing speed. Adjust the torch angle. Increase the arc voltage. Splashing Possible Reasons: 1. Welding wire short circuits by contacting to work piece. 2. C02 is used as shielding gas. 3. Welding process is performed with global conduction by using argon gas. Solutions: Solutions: 1.
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Page 41: Spare Part List
Expressweld MasterMIG 250CT 20 Spare Parts List Power Unit and Wire Feeder System Page 36... - Page 42 Expressweld MasterMIG 250CT Part Name Part Code ERP Code AC contactor 8220741803 2.07.41.803 Control transformer 821104020140 1.1.04.02.0140 Wire drive PCB 821105020012 1.1.05.02.0012 Feedback and control PCB 821105020061 1.1.05.02.0061 Medium panel 821101030768 1.1.01.03.0768 8220789009 2.07.89.009 Plastic insulation pipe 8220506008 2.05.06.008 Plastic gasket 8220506022 2.05.06.022...
- Page 43 Expressweld MasterMIG 250CT Part Name Part Code ERP Code Grounding cable 821208020140 1.2.08.02.0140 Welding socket 8220757127 2.07.57.127 Wire speed setting potentiometer. 8220710043 2.07.10.043 MIG torch 8222008050 2.20.08.050 Potentiometer setting switch 8220711009 2.07.11.009 Coarse voltage setting switch (2 levels) 8220780578 2.07.80.578...
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Page 44: Electrical Circuit Diagram
Expressweld MasterMIG 250CT 21 Electrical Circuit Diagram Page 39... -
Page 45: Warning And Specifications Of Welding Machine
Expressweld MasterMIG 250CT 22 Warnings and Specifications of Welding Machine BEFORE STARTING and OPERATING THIS EQUIPMENT READ OPERATION INSTRUCTIONS. TO INSTALL THE MACHINE IN COMPLY WITH SPECIFICATIONS DETERMINED IN THE “ELECTROMAGNETIC COMPATIBILITY REGULATION” and FOR DETAILED INFORMATION ON USAGE LIMITS, ALWAYS REFER TO USER MANUAL. -
Page 46: Manufacturer
Manufacturer Kaynak Teknigi Sanayi ve Ticaret A.S. TOSB - Taysad Organize Sanayi Bolgesi, 2. Cadde, No: 5, Çayırova 41435 Kocaeli - TURKEY Phone: +(90.262) 679 78 00 Fax: +(90.262) 679 78 26 askaynak www. .com.tr Decembe 2011 - CanO...