Hot Max 250WFG Manual de usuario
WARNING: Do not assemble, install, or operate this equipment without reading ALL of this manual
and the safety precautions and warnings illustrated in this manual.
KDAR Company Tel: (314) 692-8555
1 Mulch Lane Fax: (314) 692-8578
St. Louis, MO 63044 Web Site: www.hotmaxtorches.com
Operator’s Manual
Model 250WFG
MIG/TIG/ARC Welder
MIG/TIG/ARC
Welder
SAFETY PRECAUTIONS AND WARNINGS
PLEASE READ BEFORE USING EQUIPMENT
WARNING Keep children away from this equipment
Protect yourself and others from possible injury
Pacemaker wearers should consult with their doctor before operating
Read and follow all instructions in this manual before operating
All installation, operation, and maintenance procedures are to be
performed only by qualified individuals
ELECTRIC SHOCK CAN KILL.
The input circuits are live and hot when the power is on
Do not touch live electrical parts
Wear dry, hole free insulated work gloves and body protection when operating
Do not touch torch components if in contact with the work piece or ground
Always turn off power before cleaning, checking, or changing parts
Properly ground this piece of equipment per state and federal requirements
Inspect and replace any worn or damaged torch cables or leads
Keep all panels and covers securely in place
Keep away from the torch tip and weld arc when trigger is pressed
Ground the metal or work piece to the ground cable (Earth Clamp)
Never dip the tip into water to cool or attempt to use welder in or under water
This DC equipment holds a lot of power in the off position, before touching, make sure voltage is
near zero on input capacitors before touching any parts.
ARC RAYS CAN BURN SKIN AND EYES
Arc rays when welding produce intense ultraviolet and infrared rays that can burn skin and eyes
Wear face protection, either helmet or shield, when operating. ANSI Z49.1 approved shade #9
recommended for all cutting currents less than 300 amperes. The lens should conform to ANSI
Z87.1 standards for testing.
Wear approved safety glasses with side shields under the face protection
Warn others not to stare at the arc as it can cause damage to the eyes. Provide barriers to protect
other workers in the area from the arc while operating
Wear flame resistant gloves, clothing, and shoes when operating
FUMES AND GASES CAN BE HAZARDOUS
Arc welding produces fumes and gases and breathing these gases is hazardous to your health
Keep your head out of the fumes and do not breath the fumes while welding
Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied
respirator. Fumes from welding deplete the oxygen supply and can be harmful. Always be sure
there is ample breathing air
Read the MSDS sheets and the instructions from manufacturers for metals to be welded, coatings,
and cleaners
Do not use the welder near hydrocarbon vapors coming from degreasing, cleaning, or spraying
operations. The heat and rays can react with solvent vapors to create the gas phosgene, a very toxic
gas and other irritating gases
Do not weld coated metals, such as galvanized, lead, or cadmium plated steel. Before welding, all
plating must be removed. The area must be well ventilated or an air supplied hood must be used.
The coatings and chemicals when burned cause highly irritating and toxic fumes.
Do not weld containers with toxic, flammable, or reactive elements stored in them. They must be
emptied and properly prepared before welding.
KDAR Company 1
WELDING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION
Remove all flammable materials from the welding area
Always have a charged fire extinguisher available in the welding area
When not welding make sure the welding tip is not grounded, this causes a heat build up and
possible fire
Avoid welding near hydraulic lines, fuel lines, electrical cords, air hoses, or welding guns and
cables
Sparks and hot metal fly out from the work area when welding, wear approved safety glasses with
side shields under approved helmets, wear proper body and hand protection, and wear flame
resistant ear plugs to keep sparks from entering the ears
CYLINDERS CAN EXPLODE IF DAMAGED
Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder ex-
ploding. Gas cylinders are a major part of metalworking and must be treated with care.
Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs
Always keep cylinders in an upright position securely fastened to a fixed support
Valve protection caps should always be in place and hand tight except when the cylinder is in use
Keep all cylinders away from any welding or electrical circuits
Never allow the arc from a welder to contact a cylinder
Never cut any type of pressurized cylinder, an explosion could result
Always turn your face away from the valve when opening the cylinder
Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA pub-
lication P-1 listed in the Safety Standards before using
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS
Electric current used in arc welding can create Electro-Magnetic Fields (EMF)
Magnetic fields can affect pacemakers and wearers should avoid proximity to EMF. Wearers need
to contact their doctors before operating this type of equipment
Exposure to EMF during operation of this equipment may have other health effects which are not
yet known
Route the work and torch cables together and not around your body
Do not place your body between the torch cable and the ground cable. They both need to be on the
same side of your body when operating
Do not work next to the welding machine
ELECTRICALLY POWERED EQUIPMENT
Disconnect power source or turn off circuit breaker at the power panel before working on any
equipment
Only install equipment using the US National Electrical Code, all local codes, and the manufactur-
er’s recommendations
KDAR Company 2
HOT PARTS CAN CAUSE SERIOUS BURNS
Do not touch hot parts without wearing protection.
Allow the torch to cool sufficiently before working with parts that could potentially be hot.
NOISE CAN DAMAGE HEARING
Prolonged noise exposure from welding equipment can cause damage if levels of noise exceed the
OSHA standards
Wear approved hearing protectors
Warn other workers nearby of the high noise level and hazard
CALIFORNIA PROPOSITION 65 WARNINGS
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause
birth defects, and in some cases, cancer. (California Health and Safety Code Section 25249.5 et seq.)
PRINCIPAL SAFETY STANDARDS
AMERICAN WELDING SOCIETY
AWS C5.2, Recommended Practices for Plasma Arc Cutting
AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting
OSHA STANDARDS
OSHA 29 CFR 1910, Safety and Health Standards
NATIONAL FIRE PROTECTION ASSOCIATION
NFPA Standard 70, National Electric Code
NFPA Standard 51B, Cutting and Welding Processes
AMERICAN NATIONAL STANDARDS INSTITUTE
ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection
ANSI Standard Z49.1, Safety in Welding and Cutting
KDAR Company 3
KDAR Company 4
Specifications
MIG Welding
Infinite output voltage controls which can be adjusted as you weld.
Infinite wire speed control.
Heavy duty, professional quality Trafimet 250 Amp MIG gun with 10’ hose.
Factory pre-wired and ready for optional spool gun.
Separate MIG shielding gas connection for Argon/CO2.
Heavy duty double drive motor easily handles 11 and 33 pound wire spools.
Comes with two sets of drive wheels to handle .030” (.8 mm), .040” (1.0 mm) and .045” (1.2 mm) MIG
wire.
Quick feed button allows for faster loading of MIG wire into the gun.
Comes with three .040” (1.0 mm) contact tips.
TIG Welding
250 Amp rated TIG Torch with 12’ hose.
Heavy duty metal foot petal with 15’ control wiring.
Separate TIG shielding gas connection for Argon.
Three TIG gas nozzles, one collet body, three collets, one short cap and one long cap.
Arc Welding
300 Amp electrode holder with 10’ cable assembly.
Common Features
300 Amp ground clamp with 10’ cable assembly
Tank tray that holds up to 9.5” diameter tacks weighing less than 330 pounds.
Heavy duty 10” solid rubber rear wheels and 3” castors in front for mobility.
Argon/CO2 regulator with 5’ hose included for MIG and TIG applications.
36V heated regulator output (optional heated regulator available)
Circuit breaker for overload protection.
6’ grounded power cord (plug not included).
Table 1
Rated Input 50 Amps @ 220 Volts, 60 Hz, Single Phase
Rated Output - Arc 30- 230 Amps, 21.2 to 29.2 Volts DC
Rated Output - MIG 50 - 250 Amps, 16.5 to 26.5 Volts DC
Rated Output - TIG 20 - 230 Amps, 10.8 to 19.2 Volts DC
Duty Cycle - Arc 60% at 230 Amps, 100% at 178 Amps
Duty Cycle - MIG 60% at 250 Amps, 100% at 194 Amps
Duty Cycle - TIG 60% at 230 Amps, 100% at 178 Amps
Welding Wire Spool Sizes 8" x 2" (200mm x 50mm)
12" x 4" (300mm x 100mm)
Weight 150 Pounds
Features & Benefits
KDAR Company 5
Installation/Setup
Package Contents
Safety Considerations
Warning
Improper Lifting Techniques Can Cause Injury
This unit requires two people when being lifted.
Always use proper lifting techniques.
Item Qty Item Qty Item Qty
6mm x 12mm Bolts 6Front Caster Wheels (attached) 2Tank Deck 1
6mm Lock Washers 6Gas Hose 5' 1TIG Collet Body 1
10" Solid Wheels 2Ground Clamp w/10" Cable 1TIG Collets 3
Axle 1Long Black Cap 1TIG Foot Peddle w/15' Lead 1
Caster Retention Nuts (attached) 8MIG Gun w/10' Hose 1TIG Gas Nozzle 3
Contact Tips 3Regulator 1TIG Gun w/12' Hose 1
Cotter Pins 2Shielding Gas Nozzle (attached) 1Universal Wrench 1
Drive Wheels 4Tank Chain 2Welder 1
Electrode Holder w/10' Cable 1Tank Cradle (attached) 2Wheel Washers 4
Pictures not to scale.
Installation/Setup
6KDAR Company
Selecting A Location
The 250WFG welder should be placed where clean cool air can easily flow through the vents in the front of
the unit. Dirt and dust can be drawn into the unit resulting in excessive operating temperatures and shutdowns,
therefore, dirt and dust around the unit should be kept to a minimum.
The 250WFG welder should be placed on a stable, level surface suitable to hold the unit’s weight.
Components and Controls
1. Output Voltage Adjust Knob (MIG)
2. Amps For MIG & Arc Welding
3. Wire Feed Speed for MIG Welding
4. Welding Method Indicator
5. MIG/Spool Gun Selector
6. Welding Method Selector
7. MIG Gun Port
8. MIG/TIG Trigger/Foot Pedal Lead Connector
9. TIG Foot Pedal Lead Connector
10. Electrode Holder Port
11. Ground Clamp Port
12. TIG Hose Port
13. Wire Spool Spindle/Shaft
14. Quick Feed Button
15. Wire Tension Lever
16. Drive Wheels/Wire feed gearbox
17. Wire Feed Port
18. 36V Heated Regulator Port
19. Power Switch
20. Power Cord
21. MIG Gas Port
22. TIG Gas Port
8
12
3
5
6
4
7
9
10
11
12
13
15
16
17
18
19
20
21
22
14
Figure 1
Figure 2
Figure 3 Figure 4
Installation/Setup
KDAR Company 7
Unit Assembly
1. With something to prevent scratching under the unit,
tip the welder forward onto its face.
2. Using the six 6mm x 12mm bolts and 6mm lock wash-
ers, attach the tank deck to the welder as shown in fig-
ure 5.
3. Slide the wheel axle through the two holes in the tank
deck, slide one washer on each end followed by a 10”
wheel and a second washer. Then place a cotter pin
through the hole at each end of the axle and bend it to
hold in place.
4. Attach a plug rated for 50 Amps/250 Volts (not includ-
ed) to the end of the power cord according to the in-
structions supplied with the plug. Note: Green jacketed
wire is neutral (ground).
Warning Always unplug the welder before connecting or disconnecting accessories.
Welding Set Up
Arc Welding
1. Insert the male connector on the electrode holder cable
into the positive (+) quick connect port (1). (Figure 6)
2. Insert the male connector on the ground clamp cable into
the negative (-) quick connect port (2). (Figure 6)
MIG Welding
1. Insert male connector on the ground clamp cable into the
negative (-) quick connect port (2). (Figure 6)
2. Insert the male connector on the gun cable into the gun
cable connection port (3), labeled “MIG.” Figure 6)
3. With the connector all the way in the connector block,
tighten the wing nut (4) to secure the gun. (Figure 7)
4. Connect the gun lead terminal to the gun lead connector
(5). (Figure 6)
TIG Welding
1. Insert the male connector on the ground clamp cable into
the positive (+) quick connect port (1). (Figure 6)
2. Connect foot pedal lead terminal A to the foot pedal lead
connector A (5). (Figure 6)
3. Connect foot pedal lead terminal B to foot lead connect B
(6). (Figure 6)
4. Connect TIG gun torch assembly to TIG connector (7).
2
3
Figure 5
Figure 6
1
2
3
4
5
Figure 7
67
Installation/Setup
KDAR Company 8
Cylinder can explode if damaged. Keep cylinder chained upright to a secure support.
Keep cylinder away from areas where it could be damaged.
Never lift or move the welder with the cylinder attached.
Do not let the welding electrode touch the cylinder.
Keep the cylinder away from welding or other live circuits.
Shielding Gas may be harmful to health or cause death.
Turn off gas supply when not in use.
Refer to American National Standard Z-49.1, “Safety in Welding and Cutting” from the
American Welding Society for more information.
Warning
Gas Hook Up
When using the MIG or TIG welding process, a cylinder of shielding gas
must be used. Shielding gas cylinders and gas can be obtained at a local
gas supply company or some farm supply stores. The recommended gas-
es for MIG welding are either welding grade CO2 or a Argon/CO2 blend
with 75-80% Argon and 20-25% CO2. For TIG welding pure Argon must
be used.
1. Insure the cylinder is properly secured to the welder, a wall or other
stationary support to prevent it from falling over during setup or oper-
ation. Be sure the cylinder is insulated from the work circuit and
ground.
2. Once the cylinder is properly secured, remove the cylinder cap.
Standing to one side, slowly open the cylinder valve for an instant to
blow away any debris that may have accumulated in the valve outlet.
3. Attach the flow regulator to the cylinder valve and tighten with a
wrench.
4. Attach one end of the gas hose to the output fitting of the regulator
and tighten securely with a wrench.
5. Test to insure the flow regulator is closed by opening cylinder valve
slightly. If the regulator is not closed turn the black knob counter
clockwise until the flow of gas has stopped.
6. Connect the other end of the hose to the appropriate gas inlet fitting
on the welder making sure that the hose is not kinked or twisted.
Gas Connection
Figure 8 Figure 9 Figure 10
3
5
5
6
7
Figure 11
MIG
TIG
Operation
KDAR Company 9
Electric Shock Can Kill
Do not touch live electrical parts of the electrode with skin or wet clothing.
Insulate yourself from work and ground.
Always wear insulated gloves and keep them dry.
Safety Considerations
Warning
Fumes & Gases Can Be Hazardous
Plasma cutter should only be used in a well ventilated area or with an exhaust
system.
Keep your head away from the fumes.
Arc Rays Can Burn Skin and Eyes
Always were eye, ear and body protection.
Cutting Sparks Can Cause Injury, Fire , or Explosion
Do not use near flammable material.
Do not cut or gouge on containers that have held combustibles.
Gas Hook Up (cont.)
7. Reopen the regulator valve until the flow indicator shows
15 L/min (initial flow setting). The setting may need to be
adjusted by the operator to compensate for welding condi-
tions.
8. Always close the cylinder valve and open the regulator
valve when not in use.
Properly
Secured
Tank
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