Klutch MP250Si LCD Owner's Manual
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Klutch MP250Si LCD Owner's Manual

Klutch MP250Si LCD Owner's Manual

Mig/stick/tig 250 amp, 230 volt multi-process welder
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MIG/Stick/TIG MP250Si LCD
250 Amp, 230 Volt Multi-Process Welder
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 #62480
READ & SAVE THESE INSTRUCTIONS

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  • Page 1 MIG/Stick/TIG MP250Si LCD 250 Amp, 230 Volt Multi-Process Welder 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.
  • Page 2 ® Thank you very much for choosing a Klutch product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it.

  • Page 3: Table Of Contents

    Packaging Contents ..........................4 Technical Specifications ........................5 Important Safety Information ....................... 5 Specific Operation Warnings ....................... 7 Main Parts of MP250Si LCD ....................... 12 Setting Up Equipment ......................... 12 Assembly Instructions ........................19 Before Each Use ..........................22 Operating Instructions ........................23 After Each Use .............................

  • Page 4: Intended Use

    Intended Use The Klutch MIG/Stick/TIG MP250Si LCD is an inverter-powered, wire feed welder for flux core and MIG welding plus a DC stick welder. It uses a state of the art LCD control screen for easy set-up. It comes complete with a regulator and gas hose for easy connection for MIG welding plus a weld cable and electrode holder for DC stick welding.

  • Page 5: Technical Specifications

    Technical Specifications Property Specification Power Supply 230V, 45A, 50/60 Hz, Single Phase No-Load Voltage 69V DC Output Range – MIG/FLUX Core 40 to 250A DC Output Range - STICK 20 to 200A DC Output Range - TIG 15 to 250A DC Duty Cycle - MIG 20% @ 250A Duty Cycle –...

  • Page 6: Personal Safety

     Do not use the product where there is a risk of causing a fire or an explosion; e.g., in the presence of flammable liquids, gases, or dust. The product can create sparks, which may ignite the flammable liquids, gases, or dust. ...

  • Page 7: Specific Operation Warnings

    another tool. Never use an accessory that has a lower operating speed or operating pressure than the tool itself.  Keep guards in place and in working order. Never operate the product without the guards in place. Specific Operation Warnings ⚠WARNING Your Welding Environment ...
  • Page 8  Do not weld if you are in an awkward position. Always have a secure stance while welding to prevent accidents. Wear a safety harness if working above ground.  Do not drape cables over or around your body.  Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety glasses while welding.
  • Page 9 environment where you will be working.  Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury, or barium). They will emit harmful fumes that are dangerous to breathe. If necessary use a ventilator, respirator with air supply, or remove the coating from the material in the weld area. ...
  • Page 10 unintended paths of electrical current from causing electrical shock and fire hazards.  To prevent any unintended arcs, cut the wire back to ¼" stick out after welding. ⚠CAUTION Hot Materials - Welded materials are hot and can cause severe burns if handled improperly. ...
  • Page 11  If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. ⚠WARNING Shielding Gas Cylinders Can Explode High pressure cylinders can explode if damaged; treat them carefully. ...

  • Page 12: Main Parts Of Mp250Si Lcd

    Main Parts of MP250Si LCD Figure 1 Reference Subassembly MP250SILCD Spool Gun Dual Bottle Cylinder Rack Electrode Holder & Cable MIG Torch MIG Accessory Kit Ground Cable & Clamp Regulator/Flow Gauge with Gas Hose (2) Storage Drawer Setting Up Equipment ⚠WARNING...
  • Page 13  High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle. This welder must be grounded while in use to protect the operator from electrical shock.  Do not remove the grounding prong or alter the plug in any way. Use only the supplied adapter between the welder's power cord and the power source receptacle.
  • Page 14 the wire into the hole on the outside edge of the wire spool and bend it over to hold the wire in place. Remove the spool of wire from the drive compartment of the welder. c. Remove the drive roller by turning the drive roll securement knob (4) counter- clockwise.
  • Page 15 Make sure the proper groove on the drive roller is in place for the wire installed. If not, change the drive roller as described in INSTALL THE WIRE ROLLER above. iii. Remove the packaging from the spool of wire and then identify the leading end of the wire secured on the edge of the spool.
  • Page 16 c. If TOO MUCH tension is applied to the wire spool, the wire will slip on the drive roller or will not be able to feed at all. If TOO LITTLE tension is applied, the spool of wire will want to unspool itself when the trigger is released.

  • Page 17: Gas Installation

    xxiii. Turn the welder ON. 5. SETTING THE DRIVE ROLL TENSION ⚠WARNING  Arc flash can injure eyes! To reduce the risk of arc flash, make certain that the wire coming out of the end of the torch does not come in contact with the work piece, ground clamp, or any grounded material during the drive tension setting process or arcing will occur.
  • Page 18 Reference Subassembly Gas Bottle Valve Gas Flow Gauge (Set at 20 CFH) Gas Pressure Gauge Regulator Gas Flow Adjuster Gas Hose Connection Gas Cylinder Figure 6 iv. Connect the other end of the gas hose to the gas hose connection on the supplied regulator/flow gauge.

  • Page 19: Assembly Instructions

    Mild Steel: Use 75% Argon and 25% CO2 for reduced spatter and reduced penetration for thinner materials. DO NOT USE Argon gas concentrations higher than 75% on steel. The result will be extremely poor penetration, porosity, and brittleness of weld. Mild Steel: Use CO2 for deeper penetration but increased spatter.
  • Page 20 Figure 8 3. Insert the back end of the MIG torch into the MIG socket on the front of your machine (Figure 8). Make certain to completely slide the torch all the way in. Slightly twist to assist with pushing the torch to the back of the receptacle. The retaining bolt can then be tightened, making certain the bolt sets down into the retaining groove on the back of the MIG torch.
  • Page 21 Figure 9 3. Carefully slide the gas connector and the weld power connection through the weld cable access opening in the front of the machine (Figure 10). Figure 10 4. Open the wire compartment door. 5. Connect the gas connection quick connector to the gas connector (1) on the back panel of the wire compartment.

  • Page 22: Before Each Use

    DC STICK WELDING ASSEMBLY ⚠CAUTION Be aware that the ELECTRODE HOLDER will be electrically HOT when the Input Power Switch on the welder is turned ON. 1. Install the ground cable quick connector to the negative (-) Weld Output Connector (Figure 3). 2.

  • Page 23: Operating Instructions

    3. Make certain your equipment is in good working order. 4. Make sure the area is clean, dry, and ventilated. Do not operate the welder in humid, wet, or poorly ventilated areas. 5. Always be aware of your work environment. Be sure to keep other people, especially children, away from you while welding.

  • Page 24: General System Setup

    Reference Description LCD Display Gas Purge Button Wire Jog Button Voltage Control Knob Multi-Function Adjustment/Selection Knob Previous Screen Button Start Button GENERAL SYSTEM SET-UP 1. Press the START BUTTON. 2. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to the SETTING selection. 3. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. 4.
  • Page 25 d. MIG AlMg with Pure Argon – Choose this option if you are welding an Aluminum Manganese Alloy Typically 3000, 5000, 6000 series alloy wire. e. MIG AlSi with Pure Argon – Choose this option if you are welding an Aluminum Silicon Alloy Typically 4000 series alloy wire.

  • Page 26: Stick Welding Set-Up

    an Icon. 12. Push In the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm selection. a. Spool Gun – This feature is only available in the MIG programs for MIG welding. b. Aluminum. i. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select the SPOOL GUN icon. ii.

  • Page 27: Control Knob

    a. Connect the Electrode Holder to the Positive (+) Weld Output Connection. b. Connect the Ground Cable to the Negative (-) Weld Output Connection. 5. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. 6. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select either 6000 series welding electrode or 7000 series welding electrode.

  • Page 28: Mig Operation

    MIG OPERATION 1. POWER SWITCH - The power switch supplies electrical current to the welder. Whenever the power switch is in the ON position, the welding circuit is activated. ALWAYS turn the power switch to the OFF position and unplug the welder before performing any maintenance. 2.

  • Page 29: Welding Techniques

    wire diameter, or a different roll of wire. 4. WELDING TECHNIQUES ⚠WARNING EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!  Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding until you are adequately protected.

  • Page 30: Welding Positions

    The WEAVE BEAD is used when you want to deposit metal over a wider space than would be possible with a stringer bead. It is made by weaving from side to side while moving with the torch. It is best to hesitate momentarily at each side before weaving back the other way.

  • Page 31: Multiple Pass Welding

    The OVERHEAD POSITION is the most difficult welding position. Angle A (see HOLDING THE TORCH) should be maintained at 60 degrees. Maintaining this angle will reduce the chances of molten metal falling into the nozzle. Angle B should be held at zero degrees so that the wire is aiming directly into the weld joint.

  • Page 32: Spot Welding

    NOTE: WHEN USING SELF-SHIELDING FLUX-CORE WIRE it is very important to thoroughly chip and brush the slag off each completed weld bead before making another pass or the next pass will be of poor quality. Fillet Weld Joints Most fillet weld joints, on metals of moderate to heavy thickness, will require multiple pass welds to produce strong joint.

  • Page 33: Spot Welding Instructions

    i. The BURN-THROUGH METHOD welds two overlapped pieces of metal together by burning through the top piece and into the bottom piece. With the burn-through method, larger wire diameters tend to work better than smaller diameters. Wire diameters that tend to work best, with the burn-through method are 0.035 inch self-shielding flux-core wire.

  • Page 34: Setting Up The Work Piece

    DC STICK OPERATION ⚠WARNING High voltage danger from power source!  Consult a qualified electrician for proper installation of receptacle at the power source. This welder must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician.

  • Page 35: Ground Clamp Connection

    2. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil, or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 3.
  • Page 36 practice welds are of good appearance and free of slag or gas inclusions. a. Holding the electrode The best way to grip the electrode holder is the way that feels most comfortable to you. Position the electrode to the work piece when striking the initial arc. It may be necessary to hold the electrode perpendicular to the work piece.
  • Page 37 c. Types of weld bead The following paragraphs discuss the most commonly used arc welding beads. The stringer bead is formed by traveling with the electrode in a straight line while keeping the electrode centered over the weld joint. Stringer Bead Weave Bead The weave bead is used when you want to deposit metal over a wider space than would be possible with a stringer bead.
  • Page 38 A solid weld bead requires that the electrode be moved slowly and steadily along the weld seam. Moving the electrode rapidly or erratically will prevent proper fusion or create a lumpy, uneven bead. ⚠WARNING ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded workpiece.
  • Page 39 begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet. ⚠CAUTION Be aware that the TIG torch will be electrically HOT when the Input Power Switch on the welder is turned on.

  • Page 40: After Each Use

    After Each Use ⚠CAUTION Hot Materials - Welded materials are hot and can cause severe burns if handled improperly.  Do not touch welded materials with bare hands.  Do not touch the torch nozzle after welding until it has had time to cool down. 1.

  • Page 41: Troubleshooting

    Inspect all warning and caution labels affixed to this unit. If they are worn, torn or otherwise unreadable, replace the warning labels. Every 3 Months Inspect, clean, and tighten all weld power connections. Troubleshooting ⚠WARNING ELECTRIC SHOCK CAN KILL!  Touching live electrical parts can cause fatal shocks or severe burns.
  • Page 42 Failure Possible Cause Corrective Action Wire drive motor Is damaged. Replace wire drive motor. See installation section to correctly Feed roller is not correctly installed. install the drive roller. Torch liner is plugged. Clear or replace torch liner. Wire diameter may vary on spool of wire causing the wire to catch in the Increase the contact tip one size.

  • Page 43: Parts Diagram Power Source

    Parts Diagram Power Source Parts List Power Source Reference Part Number Part Description Quantity 105200327 TORCH SELECTION SWITCH 105200328 MALE GAS QUICK CONNECT 105200052 FEMALE GAS QUICK CONNECT 105200292 CONTROL PCB 105200293 MAIN PCB 105200294 MAIN PCB SUPPORT BRACKET 105200295 REACTOR 105200296 HANDLE...
  • Page 44 CYLINDER BRACKET 125300089 ENCLOSURE 125400006 WELDER HELP LABEL 105200041 MIG WARNING LABEL 105200296 HANDLE OWNER’S MANUAL MP250Si LCD 125200071 105200081 GAS HOSE TO REGULATOR 105200082 INERT GAS REGULATOR 105200087 ELECTRODE HOLDER WITH CABLE ** Item not shown. Page 44 of 48...

  • Page 45: Parts Diagram Cart

    Parts Diagram Cart Parts List Cart Reference Part Number Part Description Quantity 105200330 CONNECTING BAR 105200331 CART ENCLOSURE 105200332 CART BACK PANEL 105100052 DRAWER SLIDING RAIL 105200333 CART BACK WHEEL 105200334 CYLINDER RACK 105200335 CART DRAWER 105200336 CART BOTTOM 105200337 ACCESSORIES BIN 105200338 FRONT WHEEL MOUNTING BAR...

  • Page 46: Replacement Parts

    Reference Part Number Part Description Quantity 105200062 NOZZLE 105200043 CONTACT TIP 105200088 SPOOL GUN 105200089 COPPER CONNECTOR 105200092 DRIVE ROLL 105200093 DRIVE ROLL PRESSURE ARM 105200094 INLET GUIDE 105200095 IDLE ROLL 105200096 LINER 105200097 BARREL 105200098 L SHAPED HEX WRENCH 105200099 SPOOL SECUREMENT SCREW 105200090...

  • Page 47: Limited Warranty

    Northern Tool and Equipment Company, Inc. ("We'' or "Us'') warrants to the original purchaser only ("You'' or "Your") that the Klutch product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of three years from date of purchase.
  • Page 48 Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.com Made in China Page 48 of 48...

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