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.
® 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. This welder is designed for certain applications only.
Table of Contents Intended Use .......................................................................................................................................... 4 Packaging Contents .............................................................................................................................. 4 Technical Specifications ...................................................................................................................... 5 Important Safety Information .................
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. Directly connect this unit to a 230V NEMA 6-50R receptacle. It is designed to weld materials as thin as 24 gauge all the way up to 1/2" in a single pass.
Technical Specifications Property Power Supply No-Load Voltage Output Range – MIG/FLUX Core Output Range - STICK Output Range - TIG Duty Cycle - MIG Duty Cycle – Stick Duty Cycle – TIG Suggested Wire Suggested Wire Diameter Suggested Electrodes Electrode Diameter Dimensions Weight Specification 230V, 45A, 50/60 Hz, Single Phase 69V DC 40 to 250A DC 20 to 200A DC 15 to 250A DC 20% @ 250A 20% @ 200A 20% @ 250A Steel, Stainless Steel, Aluminum .023, .030; .035, .
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. Do not allow the product to come into contact with an electrical source. The tool is not insulated and contact will cause electrical shock. Keep children and bystanders away from the work area while operating the tool. Do not allow children to handle the product.
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 Keep the environment you will be welding in free from flammable materials. Always keep a fire extinguisher accessible to your welding environment. Always have a qualified person install and operate this equipment.
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. Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals, UV, and IR rays. Do not overuse or overheat your welder.
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. The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety data sheet for the manufacturer’s instructions.
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. Do not touch welded materials with bare hands. Do not touch the torch nozzle after welding until it has had time to cool down.
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. Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs. Do not touch the cylinder with the MIG gun. Do not weld on the cylinder.
Main Parts of MP250Si LCD Figure 1 Reference 1 2 3 4 5 6 7 8 9 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 ELECTRIC SHOCK CAN KILL! Page 12 of 48
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. Make sure the POWER switch is OFF when connecting your welder's power cord directly to a properly grounded 120V, 20 amp input power supply. 1.
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) counterclockwise. Carefully slide the drive roll assembly off of the drive shaft. This drive roll assembly consists of three pieces. The outer drive roll, inner drive roll, and a key. Be careful not to misplace the key. d.
ii. 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. DO NOT UNHOOK IT AT THIS TIME. iv. Place the spool on the spool hub so the wire will pull off the bottom of the spool.
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. Readjust the spool tension using the wing nut as necessary to correct for either problem. vii. With the welder disconnected from the power source, remove the leading end of the wire from the spool.
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. a. Press the trigger on the torch. b. Turn the drive tension adjustment knob (Figure 2) clockwise until the wire seems to feed smoothly without slipping. 6.
2 3 4 1 5 7 6 Reference 1 2 3 4 5 6 7 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. Use a wrench to snug up the connection. v. Before installing the regulator, it is good practice to make certain no debris is in the gas bottle connection.
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. (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.
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. 4.
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. 6. Connect the weld power connection to the bolt on the top of the MIG connector (2). 7.
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. Secure the ground clamp to the work piece. 3. Install the electrode cable quick connector to the positive (+) Weld Output Connector. 4. Make certain the SPOOL GUN option has been selected in the LCD control program.
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. Operating Instructions ⚠WARNING High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source.
Reference 1 2 3 4 5 6 7 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. 2. 3. 4. 5. 6. 7. 8. Press the START BUTTON. Turn the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to the SETTING selection. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. Language: a. The language function is not active on this unit. b.
3. 4. 5. 6. 7. 8. 9. 10. 11. 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. f. Flux Cored – Choose this option if you are welding a Shelf Shielded Flux Core Wire. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection. a. Follow the display set-up. b.
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. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection. iii. Choose the “X” to indicate “No” to using a spool gun. iv. Choose the “√” to indicate “Yes” to using a spool gun. v.
5. 6. 7. 8. 9. 10. 11. 12. 13. a. Connect the Electrode Holder to the Positive (+) Weld Output Connection. b. Connect the Ground Cable to the Negative (-) Weld Output Connection. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB. Use the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to select either 6000 series welding electrode or 7000 series welding electrode. Push in the MULTI-FUNCTION ADJUSTMENT/SELECTION KNOB to confirm your selection.
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. HOLDING THE TORCH - The best way to hold the welding torch is the way it feels most comfortable to you.
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. Wear flame-proof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding helmet.
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. See the following illustration: c. Welding Positions The FLAT POSITION is the easiest of the welding positions and is most commonly used.
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. 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. d.
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. The following illustration will show the sequence of laying multiple pass beads into a T fillet joint and a lap fillet joint. e.
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. Do not use 0.
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.
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. ELECTRODE The welding electrode is a rod coated with a layer of flux. When welding, electrical current flows between the electrode (rod) and the grounded metal work piece.
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. Once the arc is started, the angle of the electrode in relation to the work piece should be between 10 and 30 degrees.
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. It is made by weaving from side to side while moving with the electrode.
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. f. Finish the bead As the coating on the outside of the electrode burns off, it forms an envelope of protective gases around the weld.
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. 1. Remove the ground cable and the electrode holder from the weld output connections. Install the ground cable to the Positive (+) weld output connection. 2. Secure the ground clamp to the work piece.
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. Turn OFF the power switch when not using the equipment. 2. Turn OFF any shielding gases you may have used during the operation of this equipment. 3. Inspect all cords and power cables. Replace any cords or power cables that are damaged or cracked. 4.
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. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection.
Failure Wire Feeds Inconsistently. Cannot Create an Arc. Welding Arc is Unstable, Creating Excessive Spatter. Possible Cause Corrective Action Wire drive motor Is damaged. Replace wire drive motor. Feed roller is not correctly installed. See installation section to correctly 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 contact tip. Increase the contact tip one size.
Parts Diagram Power Source Parts List Power Source Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part Number 105200327 105200328 105200052 105200292 105200293 105200294 105200295 105200296 105200297 105200298 105200299 105200300 105200136 105200060 105200148 105200301 Part Description TORCH SELECTION SWITCH MALE GAS QUICK CONNECT FEMALE GAS QUICK CONNECT CONTROL PCB MAIN PCB MAIN PCB SUPPORT BRACKET REACTOR HANDLE PLASTIC FRONT BEZEL LCD CONTROL PCB LCD SUPPORT PANEL POTENTIOMETER KNOB QUICK CONNNECTO
Reference 17 18 19 20 21 ** ** 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 ** ** 37 ** ** ** ** Part Number 105200302 105200277 105200303 105200055 105200329 105200162 105200163 105200284 105200304 125300090 105200120 105200080 105200114 105200305 105200306 105200307 105200308 105200309 105200310 105200311 105200312 125300089 125400006 105200041 105200296 125200071 105200081 105200082 105200087 Part Description BOTTOM 5-PIN TRIGGER RECEPTACLE MIDDLE SUPPORT PANEL MIG BLOCK WIRE FEED DRIVE ASSEMBLY DRIVE
Parts Diagram Cart Parts List Cart Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 Part Number 105200330 105200331 105200332 105100052 105200333 105200334 105200335 105200336 105200337 105200338 105200339 105200340 105200341 Part Description CONNECTING BAR CART ENCLOSURE CART BACK PANEL DRAWER SLIDING RAIL CART BACK WHEEL CYLINDER RACK CART DRAWER CART BOTTOM ACCESSORIES BIN FRONT WHEEL MOUNTING BAR CASTER WHEEL CART FRONT BEZEL DRAWER SUPPORT BAR Page 45 of 48 Quantity 2 1 1 2 2 1 1 1 1 1 1 1 1
Reference 1 2 3 4 ** ** ** ** ** ** ** ** 5 6 Part Number 105200062 105200043 105200088 105200089 105200092 105200093 105200094 105200095 105200096 105200097 105200098 105200099 105200090 105200091 Part Description NOZZLE CONTACT TIP SPOOL GUN COPPER CONNECTOR DRIVE ROLL DRIVE ROLL PRESSURE ARM INLET GUIDE IDLE ROLL LINER BARREL L SHAPED HEX WRENCH SPOOL SECUREMENT SCREW GAS CONNECTOR 5 PIN PLUG Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ** Item not shown.
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. The foregoing warranty is valid only if the installation and use of the product is strictly in accordance with product instructions.
Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.
