Operating Manual for
MIGWELD 250 MP Table of Contents Table of Content Pg. 1 Thank you From LONGEVITY Pg. 2 Warranty/Shipping Damage/Order Information Pg. 3 Safety Information Pg. 4-5 Specifications and Ratings Pg. 6 What’s Included? Pg. 7 Main Unit Knob/Button/Function Diagram Pg. 8 General View of Control Panel Pg. 9 Parameter and Settings Pg. 15 Welding Parameters Pg.17 STICK Process Pg. 18 MIG Torch Description Pg. 20 Changing Wire Spool Pg. 25 Changing Wire Feeders Pg.
MIGWELD 250 MP THANK YOU! We, at LONGEVITY, want to thank you for purchasing our product. You are almost ready to experience Longevity Welding first hand. Longevity definitely appreciates your business and understand that this equipment may be overwhelming to setup and operate so we have prepared a manual that will assist you in understand your new welder.
MIGWELD 250 MP Warranty LONGEVITY Plasma Cutters, Welders, and Multi-Purpose Welders are covered for specific Parts and Labor warranty at our facility. For detailed information regarding your specific LONGEVITY welder or cutter, please view our Terms and Policies page on our website at the following website link: http://www.longevity-inc.com/terms/ Shipping Damage Your machine is insured against damage during shipping. Keep all packing materials and containers in case machine must be returned.
MIGWELD 250 MP Warnings and Safety Welding and plasma cutting may be dangerous to the operator and to bystanders, if the equipment is not operated properly. Welding or cutting must be performed in accordance with all relevant safety regulations. Carefully read and understand this instruction manual before installing and operating this equipment. Changing function modes during welding may damage equipment. Before welding, disconnect the power cable from the equipment.
MIGWELD 250 MP Safety Tips Consider the following tips to ensure safe operation of your welding/cutting equipment: • • Ensure that this welding equipment is installed in an area free of corrosive chemical gases, flammable gases or materials, and explosive chemicals. The area should contain little dust, and have a humidity of no more than 80%. • Operate the welding equipment in an area sheltered from direct sunlight and precipitation.
MIGWELD 250 MP Techinical Specifications and Ratings Rated input Single-phase, 220/240V/50/60Hz Input Power Capacity 9KVA No-load Voltage 58V Rated Output MIG: 250A/26.5V Current/Voltage MMA: 200A/28V Rated Duty Cycle 60% Pulse Frequency 0.1-9.9Hz Pulse Width (Balance) 10-90% Arc Inductance Degree 1-10 Pre-Gas/Glow-Gas Time 0.1-3.0S Wire Spool Capacity 300mm (15kg) Wire Diameters 0.8-1.2mm Dimensions 31.5L x 13W 25.5H Weight 76.
MIGWELD 250 MP What’s Included? 1 6 FT Ground Clamp 1 5 FT Stinger 1 9 FT 24K MIG Torch 1 24K MIG Nozzle~ 1 1-0.
MIGWELD 250 MP Main Unit Pictured: MIGWELD 250 MP 1 6 7 4 2 5 3 8 9 Main Unit Knob/Button/Function: 1. Control Panel 2. Welding Torch Connection 3. Positive Connector 4. Remote Control lead ~ Push Pull Torch Control Lead~ Spool Gun Control Lead 5. Negative Connector 6. Power Switch 7. Power Cable 8. Ground/Earth Connector 9.
MIGWELD 250 MP General View of Control Panel 1 2 3 4 5 6 7 9 8 10 11 9
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MIGWELD 250 MP Parameter and Settings Displays 1 2 3 11
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MIGWELD 250 MP Welding Process and Status Controls 6 3 7 1 2 4 5 8 9 13
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MIGWELD 250 MP Parameters & Settings 4 3 2 1 7 8 9 10 11 5 1 6 2 3 15
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MIGWELD 250 MP Welding Parameters 4 6 3 7 8 2 1 9 5 17
MIGWELD 250 MP 2T/4T/S4T Start: Amps & Volts For Pulse MIG: Only Valid for S4 mode Used for adjust of welding amps & volts in a cold aluminum plate situation. Welding Amps & Volts Adjust the main welding Amps & Volts on all the processes.
MIGWELD 250 MP STICK Process 1 Welding Process 3 2 Process Indication Encoder 1 Process Selection 19
MIGWELD 250 MP MIG Torch Description Welding torch and work-piece line connection Depending on the wire electrode diameter or type, either a spiral guide or plastic core with the correct inner diameter is inserted into the torch Recommendation: • Use a spiral guide to weld hard, unalloyed wire electrodes (steel). • Use a plastic core to weld or braze soft, high alloy wire electrodes or aluminum materials.
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MIGWELD 250 MP Spiral Diagram 23
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MIGWELD 250 MP Changing Wire Spool Removing the Wire Spool 1. Unlock the right-hand cover on the machine. 2. Open the cover, and then remove upwards. Inserting the Wire Spool 1. Loosen knurled nut from spool holder. 2. Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore. 3. Fasten wire spool using knurled nut.
MIGWELD 250 MP Changing Wire Feeders 1. Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller. 2. Screw the drive rollers in place with knurled screws.
MIGWELD 250 MP • Extend and lay out the torch hose package • Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards) • Unwind welding wire carefully from the wire spool and insert through the wire connector over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.
MIGWELD 250 MP Spool Brake Setting • Tighten the Allen screw (8mm) in the clockwise direction to increase the braking effect.
MIGWELD 250 MP MIG/MAG/CO2 1. Push the button to choose the process. 2. Push the <2T/4T> button to choose hold type of 2T or 4T. 3. Push the button to select the welding process; check the panel, the available setting will be lighted on by pushing the Left or Right selection button. 4. Use & to adjust the welding parameters. 5. Push button to check the gas before start welding.
MIGWELD 250 MP MIG/MAG/CO2 & : 0-3.0S : 1-10 : (1) Welding Current, 0-250A (2) Welding Voltage, 0-26.5V (1) End Arc Current, 10-250A (2) End Arc Voltage, 14-26 5V Time 0.01-0.
MIGWELD 250 MP Pulse MIG 1. Push the button to choose the process. 2. Push the <2T/4T> button to choose hold type of 2T or 4T. 3. Push the button to choose the welding wire size. 4. Push the button to choose the welding material. 3. Push the button to select the welding process, check the panel, the available setting will be lighted on by pushing the Left or Right selection button. 4.
MIGWELD 250 MP Pulse MIG & : 0-3.0S : 1-10 : (1) Welding Current, 0-250A (2) Welding Voltage, 0-26.5V (1) End Arc Current, 10-250A (2) End Arc Voltage, 14-26 5V Time 0.01-0.
MIGWELD 250 MP Double Pulse MIG 1. Push the button to choose the process. 2. Push the <2T/4T> button to choose hold type of 2T or 4T. 3. Push the button to choose the welding wire size. 4. Push the button to choose the welding material. 3. Push the button to select the welding process, check the panel, the available setting will be lighted on by pushing the Left or Right selection button. 4.
MIGWELD 250 MP Double Pulse MIG & : 0-3.0S : 1-10 : (1) Welding Current, 0-250A (2) Welding Voltage, 0-26.5V (1) End Arc Current, 10-250A (2) End Arc Voltage, 14-26 5V Time 0.01-0.
MIGWELD 250 MP Store Memory • In the buttons you can: 1. Set the welding parameters and store it into memory. The memory capacity right now is valid to store 10 sets. 2. Select the memory channel for direct welding jobs. 3. Also, you can select a memory channel and open the parameter to make for fast adjusting from the memory parameters. • Also, you can clear all the memories and restore to the factory settings. 1.
MIGWELD 250 MP 3 2 1 Process Selection Welding Process 5 3 4 Encoder 2 DISP 2 DISP 3 7 36
MIGWELD 250 MP MIG Welding Tips and Tricks • MIG Welding Tips 1. Direct your wire at the leading edge of your weld pool for the most control of your weld bead. 2. For the most bead control when doing more difficult welds such as; Vertical, horizontal, and overhead welds, use the smallest wire diameter possible, and keep your weld pool small. 3 Your contact tube, gun liner, and drive rolls should coincide with your wire. 4. Keep your gun liner, drive rolls, and gun nozzles clean.
MIGWELD 250 MP • Welding Wire Thin Metal= Thin Diameter. Thick Metal= Larger wire, with a larger machine. Use the wire that matches your metal. Don’t use aluminum with stainless, or vice versa RECOMMENDED WIRE SIZES Material Thickness MIG Solid Wire .024” .030” .035” Gasless Flux-Core Wire .045” .030” .035” .045” 24 Gauge (.025) 22 Gauge (.031) 20 Gauge (.037) 18 Gauge (.050) 16 Gauge (.063) 14 Gauge (.078) 1/8” (.125) 3/16” (.188) 1/4” (.25) 5/16” (.313) 3/8” (.375) 1/2” (.
MIGWELD 250 MP WELDING WIRES Shielding gas- C02 or 75%Argon/25% CO2 is recommended and will give you deeper penetration Solid Carbon-Steel ER70S-6 75%Argon/25% will give you less splatter and a nicer lookingbead Should be used indoors, where wind cannot harm your weld. Allows you to weld materials thinner than what you would weld with flux cored wires Great for auto body work .
MIGWELD 250 MP • Shielding Gas Co2 should be used with thick materials, but is too hot for thinner materials. Thin steel should be welded with 75% Argon/25% Co2. Aluminum should be welded with Argon.
MIGWELD 250 MP Push Perpendicular Drag 10º 10º Electrode back into bead Electrode ahead of bead Welding Direction (A) Push Technique (B) Gun Perpendicular (C) Drag- Pull Technique 41
MIGWELD 250 MP • Fillet Welds The leg of your weld should be equal to the thickness of the materials you welded. B A A • B Aluminum MIG Welding Tips • It is highly recommended to use a spool gun when welding with aluminum. However, if you don’t have access to one, you can try using an extremely short gun. • Keep your gun straight.
MIGWELD 250 MP • Fill the crater at the end of the weld to avoid a crack. One way to do this is to dwell in the weld pool for a second at the end of the weld. • Why Choose A Spool Gun? • Spool Guns are recommended to be used while welding aluminum. There are many benefits to using a spool gun on aluminum over your standard MIG torch, which include: • Using a spool gun prevents you from contaminating aluminum with a gun that had been used with previous metals, ensuring the highest quality weld.
MIGWELD 250 MP STICK Welding Tips and Tricks (Also known as MMA-Manual Metal Arc or Shielded Metal Arc Welding-SMAW) Connect the Stick torch to the - terminal and Torch Control receptacles. Connect the ground clamp to the + terminal and clamp the metal to be welded. Reverse the torch and ground connections for DCEP (Direct Current Electrode Positive). DC Stick - Select Stick, DC, desired amps using Base cur knob, Pulse Mode off. 1. Insert electrode into electrode holder.
MIGWELD 250 MP atmosphere or the weld will fail. 4. Use the Current control to change arc qualities. Adjust the amperage according to the recommendations of the electrode (welding rod) manufacturer for the type and size of the electrode used. Experimentation will be required to find the optimal setting desired. It is an excellent tool for out of position welding. 5. Electrode selection.
MIGWELD 250 MP Stick Electrode Chart Example: E 60 1 3 Strength 60--60,000 psi, 70--70,000 psi Weld Position 1--All positions: Flat, Vertical, Horizontal, & Overhead 2--Flat Position or Horizontal Fillets Only 3--Flat Position Only Weld Characteristics 0--Non-low hydrogen, DC Reverse polarity 1--Non-low hydrogen, AC or DC Reverse polarity 2--Non-low hydrogen, AC or DC Straight polarity 3--Non-low hydrogen, AC or DC Either polarity 4--Non-low hydrogen, iron powder coating, AC or DC Reverse polarity 5--Low-
MIGWELD 250 MP Proper weld identification: Overlap and undercutting are two main causes of weld failure. Proper washing of the weld bead into the sides or “toes” of the weld is important. Keep the welding electrode or the TIG tungsten and welding arc within the weld joint to prevent overlap. Pausing on the sides of the welds to wait for the sides to fill reduces the chance of undercutting, even if the current is a little too high.
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MIGWELD 250 MP Helpful Hints • Use a drag technique for most applications. • Take precautions with flying materials when chipping slag. • Keep electrodes clean and dry - follow manufacturer instructions. • Common steel electrodes (refer to chart above). • Penetration: DCEN- Less penetration; AC - Medium (can be more spatter also); DCEP Most penetration Catalog and Capabilities LONGEVITY has what you need for stick welding, from welders to welding supplies and protective clothing.
MIGWELD 250 MP Routine Maintenance The life of your machine and the quality of the work performed using your machine, will be enhanced by practicing periodic routine maintenance. • At regular intervals, clear dust that may accumulate in the machine using clean and dry compressed air. If the working condition has heavy smoke and pollution, the welding machine should be cleaned once a month. • Keep the machine exterior clean with a damp rag. • Do not walk on or store items on the cables or cords.
MIGWELD 250 MP LONGEVITY® Global, Inc. thanks you for your purchase and the opportunity to be able to serve you. If, after reviewing this manual, you have any problems in setting up or operating your machine, contact us at help@longevity-inc.com. LONGEVITY® Global, Inc. Toll-Free 1-877-LONG-INC / 1-877-566-4462 Website: www.longevity-inc.com Sales: sales@longevity-inc.com Customer Service: help@longevity-inc.com Dealers: dealers@longevity-inc.
