Inverter DC GMAW

Welding Machine
MIG250C

Operating Manual
_________________________________________________________
AOTAI ELECTRIC CO., LTD
National Leading Manufacturer in Inverter Welding & Cutting Equipments
877 Shunya Ave, High-Tech Development Zone Shandong, 250101 P.R. China
Tel. 0086-531- 81921006 Fax. 0086-531-88876665
Email:[email protected] Web: www.aotaiwelding.com
 -

Index

1. Safety Precautions……….……….………………………………..( 1 )

2. Principle &Technical data…………………………………………( 6 )

3. Features & Applications…………………………………………...(10)

4. Installation Guide………………………………………………….(11)

5. Operating Instruction …………...………………………………...(15)

6. Repair & Maintenance…………………………………………….(17)

Appendix A: EMC Suggestion for installation and use of welder…….(21)

Appendix B: Feedback Form………………………………………….(23)

 MIG250C

Safety Precautions

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM

POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.BE
SURE THAT ONLY QUALIFIED INDIVIDUALS PERFORM ALL INSTALLATION,
OPERATION, MAINTENANCE AND REPAIR PROCEDURES

For Engine Powered equipments

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance
work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the
engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine until fumes have been eliminated.
1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep
hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to perform required
maintenance. Remove guards only when necessary and replace them when the
maintenance requiring their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler
by pushing on the throttle control rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding
generator during maintenance work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic
Fields(EMF). Welding current creates EMF fields around welding cables and welding
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 MIG250C
machines.
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should
consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not
known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF
fields from the welding circuit:
2.d.1. Route the electrode and work cables together-Secure them with tape when possible.
2.d.2. Never coil electrode lead around your body.
2.d.3. Do not place your body between your electrode and work cables. If the electrode
cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the work piece as close as possible to the area being
welded.
2.d.5. Do not work next to welding power source.

ELECTRIC SHOCK can kill

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is
large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under
electrically hazardous conditions (in damp locations or wearing wet clothing; on metal
structures such as floors, gratings or scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or accidental contact with the work
piece or ground) use the following equipment:
Semiautomatic DC Constant Voltage (Wire) Welder
DC Manual (Stick) Welder
AC Welder with Reduced voltage control
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being
welded. The connection should be as close as possible to the area being welded.

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 MIG250C
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good,
safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two
welders because voltage between the two can be the total of the open circuit voltage of
both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding. Head shield and filter lens
should conform to ANSI Z87.I standard.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and
that of your helpers from the arc rays.
4.c. protect other nearby personnel with suitable, non-flammable screening and/or warn them
not to watch the arc nor expose themselves to the arc rays or to hot spatter or material.

FUMES AND GASES can be dangerous

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes
and gases. When welding, keep your head out of the fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases away from the breathing zone. When welding
with electrodes which require special ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or cadmium and plated steel and other
materials or coatings which produce highly toxic fumes, keep exposure as low as possible
and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding on galvanized steel.
5.b. The operation of welding fume control equipment is affected by various factors including
proper use and positioning of the equipment, maintenance of the equipment and the
specific welding procedure and application involved. Worker exposure level should be
checked upon installation and periodically thereafter to be certain it is within applicable

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 MIG250C
OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors
to form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always
use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used, including the material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from your welding distributor pr
from the manufacturer.
5.f. Also see item 1.b.

WELDING AND CUTTING SPARKS can cause fire or explosion.

6.a. Remove fire hazardous from the welding area. If this is not possible, cover them to prevent
the welding sparks from starting a fire. Remember that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Avoid
welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used
to prevent hazardous situations. Refer to “Safety in Welding & Cutting” (ANSI Standard
Z59.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or
ground. Accidental contact can cause overheating and create a fire hazard.
6.d. 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. They can cause an explosion even though they have been “cleaned”. For
information, purchase “Recommended Safe Practices for the Preparations for Welding and
Cutting of Containers and Piping That Have Hazardous Substances”, AWS F4.1 from the
American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such
as leather gloves, heavy shirt, high shoes and a cap over your hair. Wear ear plugs when
welding out of position or in confined places. Always wear safety glasses with side shields
when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables
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 MIG250C
connected to the building framework or other locations away from the welding area
increase the possibility of the welding current passing through lifting chains, crane cables
or other alternate circuits. This can create fire hazards or overheat lifting chains or cable
until they fail.
6.h. Also see item 1.c.
6.i. Do not use a welding power source for pipe thawing.

CYLINDER may explode if damaged.

7.a. 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 application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed
support.
7.c. Cylinders should be located:
Away from areas where they may be struck or subjected to physical damage, A safe
distance from arc welding or cutting operations and any other source of heat, sparks, or
flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a
cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder
valve.
7.f. Valve protection caps should be always be in place and hand tight expect when the cylinder
is in use or connected for use.

FOR ELECTRICALLY powered equipment

8.a. Turn off input power using the disconnect switch at the fuse box before working on the
equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local cedes and
the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the
manufacturer’s recommendations.

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 MIG250C

Principle & Technical data

MIG250C Block diagram of principle shown as Figure 1

Input (3~230V/50Hz)
Output

3 phase HF HF Rectifier &

Rectifier Inverter Transformer Filter

Control circuit

Figure1: Block diagram of principle

This series welding machines apply IGBT soft switch inverter technology. 3- phase input
volt 230V are rectified by rectifier, inverted into HF AC, reduced by HF transformer, rectified
and filtered by HF rectifier, then output DC power suitable for welding. After this process, the
welder’s dynamically responsive speed has been greatly increased, so the welder size and
weight are reduced noticeably. Power source enjoys good anti-fluctuating ability and
high-quality performance.

MIG250C Volt-Ampere Curve as shown in Figure2:

U(V
- )
80 U2=14+0.05I2
-
60
-
40
-
I(A)
20
–
0

Figure 2: MIG250C Volt-Ampere Curve

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 MIG250C

1. Main technical parameters

№ Item MIG 250C

01 Voltage/ frequency Three phase 230±10% 50Hz

02 Rated input power 8KVA

03 Rated input current 20A

04 Rated duty cycle 60%

05 Output current 42～250A

06 Output voltage 14～30V

07 Open circuit voltage 48V

08 efficiency ≧89%

09 Power factor ≧0.87

10 Wire diameter(mm) 0.8～1.0

11 Weight 30Kg

12 Dimensions (mm3) 527×272×491

13 CO2 gas flow rate 7～15L/min

14 Insulation class of main transformer H

15 Insulation class of output reactor B

Table 1: Parameter Specification

７
 Ne Q1 A5
C1 Q2 RB2
+
N3 R3 C6
N1
G1 G3
C8
C4 T1
QB1 TB1 E1 RD1
E3

RE1 C2 R1
C9

C5
R2
C7 RA2
N2 N4
G2 G4 BE1 -
RB1
2. Main circuit diagram

GQ1

E2 E4 red
C3
white

0.33UF RA1
BE2

FA1 T2 2XJ1 2XG1 2XG2 2XJ2 2XJ3 2XG3 2XG4 2XJ4

2X1:1
6

2X3:1
2X3:2
~22V
7 2X1:3 A2
~22V 驱动板 BB1
1 8 2X1:2
C10
3

2X2:4
2X2:3
2
~22V
前面板
4
1X10:1
1X10:3 Rv
~22V V1
1X10:2 1X7:3

1X9:1
1X9:2
1X5:1
1X5:2
SF1

5 1X7:4
4007
1X1:2 1X7:1
9 V+
V2 Ri
~10V 1X1:1 1X7:2
4007
1X3:6
1X1:3
1X3:8
R4
10 1X3:7 Ne
1X2:7,8 QN1

Figure 3: Main Circuit Diagram

X2 T3 7 1X3:1 送 PH1
~31V 主控板
1 2 1
8 1X2:1,2 丝
-

1X3:2,3
RD2
~31V A1 机
2 9 1X3:4,5 M1
1X2:5,6
3 5 1X2:3
构
5
~33V 1X8
~27V
+

4 6 1X2:4 6
1X4
后面板

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MIG250C
 MIG250C

3. Main components list

No. Item Specification Memo

1 Circuit Breaker DZ47-63D(40A/3P)

2 3-phase rectifier module MDS100A-1200V Small

3 Polypropylene capacitor MFD-A(20uF/1400VDC)

4 IGBT module SKM75GB12T4

5 Polypropylene capacitor MFD-DA01 4uF/500VAC

6 Main transformer NBC-250YⅡ(PH).4.1.0-①

7 Fast recovery diode module DKR200AB60

8 Transformer for ZKB/QDBⅠ NBC-500Ⅱ(PH).3.4-1-①

9 Transformer for ZKB/QDBⅡ NBC-500Ⅲ(PH).3.2-2-①

10 Fuse 2A (6×30)

11 Fan 145FZY6-S 230V/60HZ

12 Thermal Switch JUC-079F/70℃±5℃-1D-A

13 Varistor MYL1-320/5 (510V)

14 Drive board NBC-500Ⅱ.7.0

Using for
15 Main control board NBC-500Ⅱ5.0
MIG250C

Table 2: Main Components List

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 MIG250C

Features & Application

This inverter CO2/MAG welders are high-quality performers that can be used for all-purpose,
semi-automatic CO2 gas shield welding with solid wire(Ф0.8-Ф1.0mm)for welding mild steel
and low alloy steel work pieces. This series welder enjoys reasonable static characteristic and
sound dynamic characteristic.

Features and Benefits:

◆Easy arc starting with slowly wire feeding.
◆Stopping arc procedure has reducing melting ball feature.
◆Low spatter with the integration of Inverter, advanced wave form control technology.
◆Low welding distortion, pretty weld formation, high welding deposit rate.
◆Non-source power factor compensation technology, high PF (power factor).
◆HF inverter, small size, light weight, energy-saving, low expense.
◆Continuous adjustment of current and voltage in wider range.
◆Default current/voltage match, easy for operation.
◆Used for solid/flux-cored electrode wire.
◆It can weld continuously for long time with high duty cycle.
◆Digital display, fine current preset.

Applications:
◆Electric power, petrochemical Constructions.
◆Metal shop.
◆Equipment manufacture.
◆Boiler Pressure container manufacture.
◆Steel structure workshops.
◆Light and heavy industries.

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 MIG250C

Installation Guide

1．Pre-installation
1.1 Installation Environment
The MIG250C is designed for use in adverse environments. Examples of
environments with increased adverse conditions are
z In locations in which freedom of movement is restricted, so that the operator is
forced to perform the work in a cramped (kneeling, sitting or lying) position with
physical contact with conductive parts;
z In locations which are fully or partially limited by conductive elements, and in
which there is a high risk of unavoidable or accidental contact by the operator;
z In wet or damp hot locations where humidity or perspiration considerably reduces
the skin resistance of the human body and the insulation properties of accessories.
z Environments with adverse conditions do not include places where electrically
conductive parts, in the near vicinity of the operator, which can cause increased
hazard, have been insulated.
1.2. Installation Location
Be sure to locate the welder according to the following guidelines:
z In areas, free from moisture and dust.
z Ambient temperature between 0 degrees C to 40 degrees C.
z In areas, free from oil, steam and corrosive gases.
z In areas, not subjected to abnormal vibration or shock.
z In areas, not exposed to direct sunlight or rain.
z Place at a distance of 12" (304.79mm) or more from walls or similar boundaries
that could restrict natural airflow for cooling.
z Must keep more than 20cm distance from the wall. And keep 10cm distance from
each welder.
1.3 Power Source Connections
Warning _______
AOTAI ELECTRIC advises that this equipment be electrically connected by a
qualified electrician.
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after
removal of input power.
DO NOT TOUCH live electrical parts. _____________
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 MIG250C

z SHUT DOWN welding power source, disconnect input power employing

lockout/tagging procedures.
z Lockout/tagging procedures consist of padlocking line disconnect switch in open
position.
z Removing fuses from fuse box, or shutting off and red-tagging circuit breaker or
other disconnecting device.
1.4．Power Supplier Requirements
z Input volt must be standard sine wave, effective value 230V, frequency 50Hz.
z Unbalance degree of 3-phase volt must be no more than 5%.
z Power supply

Product type MIG 250C

Power supply 3-phase AC230V

Power network 12KVA

Min. canpacity
Generator 20KVA

Input volt Fuse 20A

protection Circuit breaker 20A
Input volt ≥2.5mm2
Cable size
Output volt 25mm2
(cross-section)
Earth lead ≥2.5mm2

Table 4: Power supply connection

Note: The size of fuse and breaker in the table are for reference only.

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 MIG250C

1.4. Machine Assembling Guide:

This series welder is small, light and portable. They will be more convenient if place
them on the trolleys. Ensure the location where to place the welder is even.

Figure 4: Connection Chart for MIG500A

Preparation prior to operation procedure:

(1) Connect the welder’s terminal plug(-) to the work piece by work lead
(2) Connection the welding torch
(3) Connect feeder’s gas hose to the regulator
(4) Connect the regulator’s heater cable to the welder’s “gas heater power “cable socket.
(on the rear panel)
(5) Connect the welder’s power cable to the disconnection switchboard, while grounds
the lead safely.
(6) Reset the circuit breaker on the welder’s rear panel.

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 MIG250C

5. Operating procedure:
Reset the circuit breaker on the switchboard, then the welder’s indicator lamp will turn
on, and the cooling fan will spin. Press on the “wire test” button on the feeder’s controller,
the feeder begin to feed wire. Preset the process parameters, tuning the knob, and flipping
the switch to proper location on the front panel of the welder. When the torch trigger is
pulled, the feeder start to feed wire, and CO2 will blow out of the nozzle, therefore it can
be used for welding. Operators can select parameters from table listed below. Be sure to
turn off the valve of gas bottle and unplug the power cord while stop welding.

Welding current（A） Welding voltage（V） Suitable wire（mm）

60~80 17~18 Ф0.8、Ф1.0

80~130 18~21 Ф0.8、Ф1.0

130~200 20~24 Ф0.8、Ф1.0

200~250 24~27 Ф1.0

Table 5: Suggest welding parameters for selected wire

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 MIG250C

Operating Instruction

1. Panel l illustration and parts number reference

Front panel is illustrated below; other models are little different from this.

Figure 5: Front panel

1.1 European connector
Connect to gas-cooled welding torch.
1.2 Terminal lug (-)
Wire work piece by work lead
1.3 “Protection” indicator lamp
Welding machine will automatically stop working when it is overheat, and the lamp will
be light on.
1.4 Mode selection switch
When the switch is on “Gas test”, the electromagnetic valve will be opened, you can
check if the airflow is normal. When on “Wire test”, you can check up the welding
machine’s state, it is the same function as to push the weld torch trigger. When on
“normal”, the welding machine is on normal working state.
1.5 “Inductance” regulation knob
Altering welding stability, penetration and spatter volume.
1.6 “Current” regulation knob
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 MIG250C
1.7 “Output Amp” meter
Display relative feeding speed while in open load, and display practical value of current
while in welding.
1.8 “Output volt” meter
Display preset value of volt while in open load, and display practical value while in
welding.
1.9 “Voltage” regulation knob
1.10 “default phase” indicator lamp
Welding machine will automatically stop working when power supply has default phase
problem, and the lamp will be light on.
2. The rear panel and parts number reference

Fig.6: Rear panel

2.1 Input power cable
The mixed-colored wire must be firmly grounded, the rest wires connect to 3-phase
power (230V/50Hz) respectively.
2.2 Circuit breaker
The function of circuit breaker is to protect welding machine by automatic trip to
turn-off power supply while in machine overload or failure. Normally, the switch
flipped to upward which means power-on. Use switch on the disconnected
switchboard or switchbox (customers prepare by them) to start or stop welding
machine, avoiding using the circuit breaker.

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 MIG250C
2.3 Gas Heater power cable socket (AC36V)
Connect to CO2 regulator’s heating coil
2.4 Cooling fan
2.5 Ground bolt
To ensure operators not to be harmed and welding machine to be working normally, make
sure the ground bolt grounded firmly by ground lead specified in the table 1, or ground
wire (mixed-colored) of the input power cord grounded firmly.

Repair & Maintenance

WARNING: Have a qualified electrician do the maintenance and trouble shooting work.
Turn the input power off, using the disconnect switch at the fuse box before working inside
the machine.
1. Cautions:
• Rivet equipment name tag on the specified area of the case, otherwise the inside parts
will possibly be damaged.
• Connect welding cable to terminals firmly, otherwise the terminals will be burn out
which will cause the instability of welding process.
• Avoid welding cable and control cable being broken, and prevent welding machine
from being short circuit.
• Never let welding machine be bumped into or stacked up by heavy objects.
• Ensure good ventilation
• Under high temperature, if work with large current for long period, welder may shut
down automatically due to thermal protection acts .At this point, let the machine runs
under open-load for a few minutes, and it will be automatically recover.
• Under high temperature, if work with large current for long period, welder may shut
down automatically due to air switcher trips. Cut off the power supply to the electricity
switchboard on frame, and wait for 5 minutes to turn on the air switcher on the power
source fist then connect the power supply to the electricity switchboard on frame. And
leave the machine runs under open-load condition for a while.
• After welding, cut off the gas supply and the power supply.
2. General maintenance
• Remove dust from power resource with pressure air by qualified individuals every 3-6
months. Check if the jointers are loose.
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 MIG250C
• Check regularly if cables are worn out, knobs are loose, and components of panel are
damaged.
• Check regularly if cables are tightly connected to cable connecting terminals in case of
terminals being burnt out.
• Clean and replace Contact Tip and Tungsten Electrode in time.

3. Procedure for regular checking prior to maintenance

• Check if all front panel switches are on the proper positions.
• Check if the input volt has the phase missing, and range are between 210~255V (Input
power 3 phase 230V/50HZ)
• Check if the input cable is connected correctly and firmly with the power source.
• Check if the ground lead is connected correctly and firmly.
• Check if the welding cables are connected correctly and firmly.
• Check if gas regulator is in good situation and gas flows out normally.
Warning: Don’t open up case uninstructed, the max volt inside machine is 500V.
Take safe precautions to prevent from being electric shock while in
maintenance.
Shut down power source before changing welding cable or torch.

4. Periodical check and maintenance

• Rivet equipment name tag on the specified area of the case, otherwise the inside parts
will possibly be damaged.
• Connect welding cable to terminals firmly, otherwise the terminals will be burn out
which will cause the instability of welding process.
• Avoid welding cable and control cable being broken, and prevent welding machine
from being short circuit.
• Never let welding machine be bumped into or stacked up by heavy objects.
• Ensure good ventilation
• Under high temperature, if work with large current for long period, welder may shut
down automatically due to thermal protection acts .At this point, let the machine runs
under open-load for a few minutes, and it will be automatically recover.
• Under high temperature, if work with large current for long period, welder may shut
down automatically due to air switcher trips. Cut off the power supply to the electricity
switchboard on frame, and wait for 5 minutes to turn on the air switcher on the power

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 MIG250C
source fist then connect the power supply to the electricity switchboard on frame. And
leave the machine runs under open-load condition for a while.
• After welding, cut off the gas supply and the power supply.

№ Trouble Causes What to do

(1)Check power
(1)Phase missing supply
Indicator lamp does not light on
01 (2)Circuit breaker is damaged (2)Change Air
when machine switches on.
(3)Fuse is broken switch
(3)Change fuse (2A)
(1)Circuit breaker is collapsed.
(1) Replace
(2)IGBT module is damaged
(2) Replace
Circuit breaker trips (3)3-phase rectifier bridge is
(3) Replace
02 immediately after the machine is damaged.
(4) Replace
switched on. (4)Varistor is damaged
(5) Replace Main
(5)Welder’s control board is
Control board
damaged
(1)Operating
(1)Welding machine operates in
Circuit breaker trips while in machine in rated
03 long term overload
welding duty cycle
(2)Circuit breaker is damaged
(2) Replace
(1) Replace control
(1)Wire feeder’s control cable is
cable or controller
broken or controller is damaged
Welding current can not be (2)Change control
04 (2)Control board is damaged
adjusted board
(3)Conductive wire connected
(3)Reconnect the
the rectifier is broken
broken wires
(1)Fine tune
(1)Incorrect welding parameters
Instable arc welding, more parameters
05 (2)Contact tip is worn out
spatter (2)Replace
severely

(1)CO2 regulator is damaged (1)Replace

06 CO2 gas regulator can’t heat (2)Heater cable is broken or (2) Repair heat cable
shorten (3)Replace Thermal

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 MIG250C
(3)Thermal-sensitive resistor in sensitive resistor
power source is damaged
Push welding torch trigger, wire (1)Control board is damaged
(1)Replace
07 feeding is normal but airflow is (2)Electromagnet valve is
(2)Replace
blocked damaged
(1)Replace welding
(1)Torch trigger is damaged
Push welding torch trigger, wire torch
(2)Feeder’s control cable is
08 feeder do not work and there is (2)Repair control
broken
no open load volt display cable
(3)Control board is damaged
(3)Replace

Table 8: Trouble Shooting Table

WARNING: Have a qualified electrician do the maintenance and trouble shooting work.
Turn the input power off, using the disconnect switch at the fuse box before working inside
the machine. Don’t open up case uninstructed, the max volt inside machine is 600V, Never
discharge high voltage to welder case with welding torch! Shut down power source before
changing or repairing welding cable or torch

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 MIG250C

Appendix A

1. General
The user is responsible for installing and using the arc welding equipment according to the
manufacturer’s instructions. If electromagnetic disturbances are detected, then it shall be the
responsibility of the user of the arc welding equipment to resolve the situation with the
technical assistance of the manufacturer. In some cases this remedial action may be as
simple as earthling the welding circuit, see note. In other cases it could involve constructing
an electromagnetic screen enclosing the welding power source and the word complete with
associated input filters. In all cases electromagnetic disturbances shall be reduced to the
point, where they are no longer troublesome.
NOTE: The welding circuit may not be earthed for safety reasons. Changing the earthling
arrangements should only be authorized by a person who is competent to assess
whether the changes will increase the risk of injury.
2. Assessment of area
Before installing arc welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into account:
1) Other supply cables, control cables, signaling and telephone cables, above, below and
adjacent to the arc welding equipment;
2) Radio and television transmitters and receivers;
3) Computer and other control equipment;
4) Safety critical equipment, for example guarding of industrial equipment;
5) The health of the people around, for example the use of pacemakers and hearing aids;
6) Equipment used for calibration or measurement;
7) The immunity of other equipment in the environment is compatible. The user shall ensure
that other equipment being used in the environment is compatible. This may require
additional protection measures;
8) The time of day that welding or other activities are to be carried out.
3. Methods of reducing emissions
1) Public supply system
Arc welding equipment should be connected to the public supply system according to the
manufacturer’s recommendations. If interference occurs, it may be necessary to take
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 MIG250C
additional precautions such as filtering of the public supply system. Consideration should
be given to shielding the supply cable of permanently installed arc welding equipment, in
metallic conduit or equivalent. Shielding should be electrically continuous its length. The
shielding should be connected to the welding power source so that good electrical contact
is maintained between the conduit and the welding power source enclosure.
2) Maintenance of the arc welding equipment
The arc welding equipment should be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and covers should be
closed and properly fastened when the arc welding equipment is in operation. The arc
welding equipment should not be modified in any way, except for those changes and
adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc
striking and stabilizing devices should be adjusted and maintained according to the
manufacturer’s recommendations.
3) Welding cables
The welding cables should be kept as short as possible and should be positioned close
together, running at or close to the floor level.
4) Equipotent bonding
Bonding of all metallic components in the welding installation and adjacent to it should be
considered. However, metallic components bonded to the word piece will increase the risk
that the operator could receive an electric shock by touching these metallic components
and the electrode at the same time. The operator should be insulated from all such bonded
metallic components.
5) Earthling of the work piece
Where the work piece is nor bonded to earth for electrical safety, nor connected to earth
because of its size and position, for example ships hull or building steelwork, a connection
bonding the work piece to earth may reduce emissions in some, but not all instances. Care
should be taken to prevent the earthling of the work piece increasing the risk of injury to
users, or damage to other electrical equipment. Where necessary, the connection of the
work piece to earth should be made by a direct connection to the work piece, but in some
countries where direct connection is not permitted, the bonding should be achieved by
suitable capacitance, selected according to national regulations.
6) Screening and shielding
Selective screening and shielding of other cables and equipment in the surrounding area
may alleviate problems of interference. Screening of the entire welding installation may
be considered for special applications.
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 MIG250C

Appendix B

Feedback Form
Name of Company

Address

Contact person Title

Telephone No Fax No.

Email Address

Company’s filed of business

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