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KeyGree MIG-2500 Manual

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MIG-2500
2021

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Summary of Contents for KeyGree MIG-2500

  • Page 1 MIG-2500 2021...
  • Page 2 The KEYGREE MIG-2500 WELDER is designed for use by the serious hobbyist or the busy professional with the versatility to MIG, Stick or Lift TIG weld all from a single compact, space-saving and lightweight unit combined with self-sensing, dual-voltage capability for go anywhere convenience.

  • Page 3: Specifications

    The rated Duty cycle refers to the amount of welding that can be done within an amount of time. The KEYGREE MIG-2500 has a duty cycle of 60% at 200 Amps for 220 Volts. It is easiest to look at your welding time in blocks of 10 Minutes and the Duty Cycle being a percentage of that 10 Minutes.

  • Page 4: Read Instructions

    DANGER 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.
  • Page 5 HOT METAL AND TOOLS WILL BURN!! Electric welding heats metal and tools to temperatures that will cause severe burns! Use protective, heat resistant gloves and clothing when using KEYGREE or any other welding equipment. Never touch welded work surface, torch tip or nozzle until they have completely cooled.

  • Page 6: Control And Display Panel

    Welder. CONNECTING THE WELDER TO A POWER SOURCE The KEYGREE MIG2500 Welder requires a dedicated AC single phase 120V/230V,50/60HZ grounded outlet protected by a (50Amp @ 120V/ 50 Amp @ 230V) circuit breaker. CONTROL AND DISPLAY PANEL...
  • Page 7 Set the MATERIAL button on front panel to CO2 100% Fe or Ar 75% CO2 25% Ss(Ar 80% CO2 20% also works on this program). Set the WIRE button on front panel to .023'', .030'' or .035'' refer to the wire used in machine. Make sure the V type roller used and steel liner of torch used for Stainless Steel welding.
  • Page 8 E - Manual MIG Welding(Free Setting on Voltage and Wire feed Speed(Welding Amp will automatically fitting with Wire Feed Speed) Note: Gasless Flux Mig is only available for .035'' Wire Diameter, can weld with no Gas. M M I G - M a n u a l s e t t i n g V o l t a g e / W i r e F e e d S p e e d o n C a r b o n S t e e l / S t a i n l e s s Steel(.023/.030/.035'')(Recommend .030/.035'') And Aluminum Steel(.035/.045'') (Available for Professional Welder Only) Set the MODE button on front panel to M MIG(...
  • Page 9 MIG WELDING SET-UP AND OPERATION SET UP FOR MIG WELDING Installing the MIG Welding Gun Open the side door of the Welder and loosen the Torch Tensioner Wing Screw located on the side of the brass, hex shaped member of the Drive Motor Assembly (FIG 2). Plug the Brass Body End of the Welding Gun line into the designated socket (FIG 3).
  • Page 10 pull the steel liner (FIG.5-6) out of the torch, keep it in safe place, need install it back when we weld with ss or carbon steel. Install the teflon liner (FIG.5-7) into torch(make sure the liner into torch with correct direction, keep the steel part toward the torch head), insert the teflon liner to the torch socket on front panel (FIG.5-8), come cross liner hole of torch till to the edge of roller (FIG.5- 9).(aluminum material wire is soft, so we need keep using teflon liner used in weld and change U type roller for aluminum welding)
  • Page 11 Use proper equipment, procedures and have adequate help when moving or lifting cylinders. A Shielding Gas Bottle is NOT EQUIPPED with your KEYGREE MIG-2500 but is neces-sary to weld using Solid Wire. It can be bought at most local Welding Supply Stores.
  • Page 12 The KEYGREE MIG-2500 Wire Drive Roller has twin grooves to accommodate both 0.030''/0.035'' [0.8mm/0.9mm] wire. The MIG-2500 Drive Roller is factory set and up ready to use 0.030''/0.035'' [0.8mm/0.9mm] wire. IMPORTANT NOTE: In this position, the wider, 0.030''/0.035'' [0.8mm/0.9mm] grove is inboard, under the wire while the 0.8/0.9 marking is visible on the...

  • Page 13: Installing The Wire Spool

    INSTALLING THE WIRE SPOOL The KEYGREE MIG-250 PRO can be used with either a 4'' or an 8'' wire spool. SETTING THE WIRE PRESSURE ADJUSTER To set the tension on the wire, incrementally tighten the Spool Retaining Wingnut until there is a slight resistance to spinning the wire spool on the spindle.
  • Page 14 Turn the power switch on the Upper rear Panel to the “OFF” position and unplug the Welder from the power supply. Set the Process Selector Switch on the Front Panel to ‘MIG’. Remove the contact tip and nozzle from the end of the torch.

  • Page 15: Mig Welding Operation

    MIG WELDING OPERATION DANGER ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH! Improper use of an electric Welder can cause electric shock, injury and death! Read all precautions described in the Welder Manual to reduce the possibility of electric shock. Disconnect Welder from power supply before assembly, disassembly or maintenance of the torch, contact tip and when installing or removing nozzles.
  • Page 16 Verify that the facility power source has properly rated wiring to handle power requirements of this Welder. Your KEYGREE MIG-2500 can be used to form many different joints and welds all of which will require practice and testing before using on an actual project piece. This following welding process is just a baseline to get you started.
  • Page 17 Connect your ground clamp to the work pieces that are to be welded. Make sure the ground clamp contacts are placed on a clean piece of metal free of paint, grease, rust, oils, etc. It is recommended to place your ground clamp as close to the weld area as possible. Assess your weld area and make sure the welding area is also cleaned of any paint, grease, rust, oils, etc.
  • Page 18 HEAVY GAUGE METAL WELDING TECHNIQUES When welding heavy gauge metal, a continuous bead is formed using a ‘push’ method. This process is described below: Clean the metal to be welded of any paint, rust, oil, grease, dirt or any other contaminants that may be on the surface of the piece.
  • Page 19 HOT METAL AND TOOLS WILL BURN! Electric welding heats metal and tools to temperatures that will cause severe burns! Use protective, heat resistant gloves and clothing when using KEYGREE or any other welding equipment. Never touch welded work surface, torch tip or nozzle until they have completely cooled.
  • Page 20 STICK WELDING OPERATION Electrode Selection Before beginning welding with your KEYGREE MIG-2500, you will need to purchase electrodes as these are a consumable item in the ARC welding process. There are a variety of different types of rods available and should be selected depending on the project on hand. The chart below is an overview of some of the most popular electrodes.

  • Page 21: Polarity Selection

    POLARITY SELECTION The KEYGREE MIG-2500 can weld in both Direct Current Electrode Positive (DCEP) and Direct Current Electrode Negative (DCEN). The electrode, or rod, when welding in DCEP is positive and the grounded surface is negative. This polarity is used with electrodes that specify it and is usually the most commonly used polarity when ARC welding for general purpose use.
  • Page 22 DANGER ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH! Improper use of an electric Welder can cause electric shock, injury and death! Read all precautions described in the Welder Manual to reduce the possibility of electric shock. Disconnect Welder from power supply before assembly, disassembly or maintenance of the torch, contact tip and when installing or removing nozzles.
  • Page 23 CAUTION Electric welding heats metal and tools to temperatures that will cause severe burns! Use protective, heat resistant gloves and clothing when using KEYGREE or any other welding equipment. Never touch welded work surface, torch tip or nozzle until they have completely cooled.
  • Page 24 Insert the electrode into the electrode holder. Do not allow the electrode to contact the grounded area. To start welding, an arc must be struck. To do this, a motion similar to striking a match will have to be performed with the electrode. Slowly bring the electrode closer to the weld joint and then contact and drag the electrode across the piece to strike the arc.
  • Page 25 A Shielding Gas Bottle is NOT INCLUDED with your KEYGREE MIG-2500 Lift Lift TIG Torch Kit but is necessary for Lift TIG welding. A Shielding Gas Bottle can be bought at most local Welding Supply Stores. KEYGREE recommends the use of 100% Argon shielding gas when Lift TIG welding Steel and Stainless Steel.
  • Page 26 Tungsten grinding only. A fine grit standard 6'' synthetic stone grinding wheel on a bench top grinder is sufficient or our specifically designed KEYGREE Tungsten Grinders are available. Shut off the welder. Make sure the Tungsten and Torch are sufficiently...

  • Page 27: Lift Tig Welding

    Lift TIG WELDING DANGER ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH! Improper use of an electric Welder can cause electric shock, injury and death! Read all precautions described in the Welder Manual to reduce the possibility of electric shock. Disconnect Welder from power supply before assembly, disassembly or maintenance of the torch, contact tip and when installing or removing nozzles.
  • Page 28 WARNING ARC RAYS CAN BURN! Arc rays produce intense ultraviolet radiation which can burn exposed skin and cause eye damage. Use a shield with the proper filter (a minimum of #11) to protect your eyes from sparks and the rays of the arc when welding or when observing open arc welding (see ANSI Z49.1 and Z87.1 for safety standards).
  • Page 29 IMPORTANT NOTE: These instructions are intended only to provide the user with some familiarity of the KEYGREE MIG-2500. Lift TIG welding is a highly complex procedure with many variables. If you have no experience with Lift TIG welding; it is extremely important to seek the advice of someone...

  • Page 30: Overload Protection

    OVERLOAD PROTECTION Your KEYGREE MIG-2500 Welder is equipped with an overload breaker. This device will protect your Welder if the duty cycle is exceeded. If the output is exceeded, the internal breaker will trip and stop power supply to the drive motor although the fan will still run to cool the unit. If the breaker tripped resulting from an over-load, the Overload Indicator LED [J] will illuminate AMBER.
  • Page 31 Move the Contact Tip on the Welding Gun closer to the Excessive Wire Lack of work piece to shorten the length of exposed wire. Protruding Penetration The MIG-2500 is rated for a maximum thickness of 3/8'', Material Too Thick exceeding this will result in poor penetration. Page 30...

  • Page 32: Tig Welding Troubleshooting

    If welding heavy gauge metals, it is necessary to increase the welding gap between the two pieces and also bevel the Poor Material Prep edges on the weld side of the pieces. High Voltage Adjust voltage output to lower setting. Excessive Fast Wire Speed Adjust wire speed to slower setting.
  • Page 33 Adjust the flow rate of the shielding gas. Check for loose Poor Gas Flow fittings where gas could be leaking. Clean filler metal making sure to remove any oil, debris, or Contaminated moisture. Filler Metal Clean base metal making sure to remove any oil, debris, Contaminated Porosity in coatings, or moisture.
  • Page 34 Reduce heat and allow more time between passes. Too Much Heat in Material Base Metal is Weld Bead is Preheat base metal (consult welding codes for Absorbing Too Cracking requirements) Much Heat Use appropriate filler wire type and diameter for the joint Incorrect Filler Wire being welded.
  • Page 35 info@keygree.com...

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