Pro-Tec Welding G1621500, Operating Manual

Page 1: ...250MP 001 6 13 2019 PRODUCT PRO TEC 215 MP MULTI PROCESS SYSTEM PART NO G1621500 PRODUCT PRO TEC 250 MP MULTI PROCESS SYSTEM PART NO G1625000 215 AMPS 3 YEAR 250 AMPS 250MP ONLY Approvals CAN CSA E60974 1 12 ANSI IEC 60974 1 2008 120 208 240 VAC ...

Page 2: ...l especially the Safety Precautions They will help you to avoid potential hazards when working with this product Also check out our website for YouTube video of this product in action PRO TEC is a brand of Welding and Cutting systems from Global Welding LLC We develop optimized solutions for major welding industry sectors including Manufacturing Construction General Fabrication Automotive Rural an...

Page 3: ...bal Welding LLC Box 250 17209 Chesterfield Airport Road Chesterfield 63005 Missouri USA Website www protecwelding com Copyright 2018 PRO TEC is a Registered Brand of Global Welding LLC All rights reserved Reproduction of this Operating Manual in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party f...

Page 4: ...Package 15 3 7 PRO TEC 250MP Multi Process Package 15 3 8 Definitions of Terms Used 15 3 9 Specifications PRO TEC 215MP 16 3 10 Specifications PRO TEC 250MP 17 SECTION 4 INSTALLATION 18 4 1 Environment 18 4 2 Location 18 4 3 Explanation of Supply Voltages 18 4 4 Electrical Input Power Guide 18 4 5 Extension Cord Recommendations 18 4 6 Connecting 120 VAC Power 19 4 7 Connecting 208 230 240 VAC Powe...

Page 5: ...ng On metal structures such as floors gratings or scaffolds When in cramped positions such as sitting kneeling or lying When there is a high risk of unavoidable or accidental contact with the workpiece or ground For these conditions use the following equipment 1 A semiautomatic DC constant voltage wire welder or 2 A DC manual stick welder In most situations a DC welder is recommended Disconnect In...

Page 6: ...umes If inside ventilate the area and or use local exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Safety Data Sheets SDSs and the manufacturer s instruction for metals consumables coatings cleaners coolants degreasers and fluxes Work in a confined space only if it is well ventilated or while wearing an air supplied respi...

Page 7: ...igh pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinder s in an upright position by chaining cylinder s to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away fro...

Page 8: ...ified Tradesperson promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using the equipment immediately Have the installation regularly checked and maintained Keep spark gaps at correct setting if applicable and use ground ing and shielding to minimize the possibility of interference To reduce possible interference keep weld cable...

Page 9: ...s concernant les recommandations de fonctionnement de cet équipement de soudage et de découpage L équipement et les procédés de soudage et de découpage peuvent causer des blessures graves ou mortelles ou endommager d autres équipements ou biens si l opérateur n observe pas strictement toutes les consignes de sécurité et prend des précau tions Toute personne qui n est pas formée aux méthodes de sou...

Page 10: ...u un câble de travail à une seule borne de sortie de soudage Débranchez le câble quand il n est pas utilisé Utilisez un disjoncteur de fuite de terre GFCI lorsque vous utilisez des appareils auxiliaires dans des endroits humides ou mouillés PROJECTIONS DE MÉTAL ou PARTICULES peuvent blesser les yeux Le soudage l écaillage le brossage des fils et le broyage provoquent les étincelles et les projecti...

Page 11: ...u de découpage sans être inférieure au minimum Ce guide de sélection de lentille a été adapté d ANSI Z49 1 2012 LE SOUDAGE DÉCOUPAGE peut provoquer un incendie ou une explosion Les étincelles et les éclaboussures giclent de l arc de soudage découpage Les étincelles et le métal en fusion les éclaboussures de métal les pièces de travail et les équipements chauds peuvent provoquer des incendies et de...

Page 12: ...rancher les câbles de la batterie Ne laissez pas les outils créer des étincelles lorsque vous travaillez sur une batterie Ne vous servez pas du soudeur pour recharger des batteries ou démarrer des véhicules Observez la polarité correcte et sur les batteries SOUDERSOUS LA PLUIE ou DANS L EAU peut donner un choc électrique Souder sous la pluie ou dans l eau ou près de l eau peut augmenter le risque ...

Page 13: ... National Electrical Code NFPA Standard 70 from National Fire Protection Association Quincy MA 02269 Website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Sta...

Page 14: ...ated duty cycle of the Power Source is a statement of the time it may be safely operated at its rated Welding Amperage output MIG GMAW FCAW 120 VAC 15 A Outlet 35 Duty Cycle at 110 A 3 5 Minutes Welding in any 10 Minute Period 6 5 Minutes Non Welding in any 10 Minute Period MIG GMAW FCAW 120 VAC 20 A Outlet 35 Duty Cycle at 140 A 3 5 Minutes Welding in any 10 Minute Period 6 5 Minutes Non Welding ...

Page 15: ... ters for easy setup the selected STICK electrode type and size Fe Mild steel MIG welding Ss Stainless steel MIG welding Al Aluminum MIG welding FCAW S Flux Cored Arc Welding self shielded FCAW G Flux Cored Arc Welding gas shielded Arc Force DIG Additional amperage during low voltage short arc length conditions while welding Downslope The gradual ramping down of weld amperage over a period of time...

Page 16: ...ycle Rated Maximum Input 2 9 KVA 4 0 KVA 5 7 KVA Wirefeed Speed Range 120 980 IPM 120 980 IPM Wire Type and Diameter Aluminum 035 040 in 035 040 in Mild Steel 023 040 in 023 040 in Stainless Steel 030 040 in 030 040 in Flux Cored 035 045 in 035 045 in Output Welding Power with Stick 120 VAC 15 A Outlet 120 VAC 20 A Outlet 208 VAC 230 VAC 240 VAC Welding Amperage Range 10 110 A 10 200 A Nominal DC ...

Page 17: ... V 35 Duty Cycle 250 A 26 5 V 25 Duty Cycle Rated Maximum Input 2 9 KVA 4 0 KVA 7 8 KAV Wirefeed Speed Range 120 980 IPM 120 1180 IPM Wire Type and Diameter Aluminum 035 040 in 035 045 in Mild Steel Stainless Steel 023 040 in 023 045 in Flux Cored 035 045 in 035 045 in Output Welding Power with Stick 120 VAC 15 A Outlet 120 VAC 20 A Outlet 208 VAC 230 VAC 240 VAC Welding Amperage Range 10 110 A 10...

Page 18: ...e Section 3 9 or 3 10 regarding usage at this voltage 4 4 Electrical Input Power Guide Failure to follow these electrical input power guide recommendations could create an electric shock or fire hazard These recom mendations are for a dedicated circuit sized for the rated output and duty cycle of the power source In dedicated circuit installations the National Electrical Code allows the receptacle...

Page 19: ... Input Supply Voltage and Fuse Size 120 Volts AC Input Supply Voltage with Individual Branch Circuit Delay Fuse or Circuit Breaker Size 120VAC 15 A Outlet 30 Amps 120VAC 20 A Outlet 40 Amps Table 1 120VAC Electrical Fuse or Circuit Breaker Size NOTE 5 The time delay fuse or circuit breaker of an individual branch circuit may have nuisance tripping when welding with this Power Source due to the am ...

Page 20: ...WHITE or BLACK cable to the ground terminal NOTE 8 DO NOT connect an Input Power Cord ground GREEN cable to the Input Primary Supply terminal Input Supply Voltage PRO TEC 215MP Normal Fuse UL class K5 PRO TEC 250MP Normal Fuse UL class K5 208 230 240 VAC 40 35 35 Amps 50 45 45 Amps Table 2 208 230 240 VAC Electrical Fuse Sizes Use established Lockout Tagout procedures refer to OSHA 29 CFR 1910 147...

Page 21: ...he gas fittings 3 Plug the Power Source into Input Supply Voltage 4 Switch the Mains Power Supply ON Power Switch located on the rear panel ON This will immediately energize the Power Source 5 Rotate Knob then PUSH to SELECT a Welding Mode Selection to MIG SYN b Welding Material Selection to Fe or Ss or Al or FCAW S or FCAW G c Protective Gas Selection to Mix Gas or CO2 d Welding Diameter Selectio...

Page 22: ... Idle Roll Assembly to a vertical position 4 Check the Drive Roll groove size and type suits the Welding Wire 5 Fit the 8 200mm Spool as shown 6 Align locking pin on spool hub with hole in spool 7 Tighten the plastic Tension Screw to ensure spool rotates with slight tension NOTE 11 Check the MIG GUN Liner and Contact Tip are sized to match the Welding Wire 8 Hold the Welding Wire end on the Spool ...

Page 23: ... Terminal for FCAW b MIG Gun Lead to the MIG Gun Adaptor c 8 Pin Plug to 8 pin socket d Gas Hose to the Gas Input on rear panel then turn ON the shielding gas DO NOT over tighten the gas fittings 3 Plug the Power Source into Input Supply Voltage 4 Switch the Mains Power Supply ON Power Switch located on the rear panel ON This will immediately energize the Power Source 5 Rotate Knob then PUSH to SE...

Page 24: ... socket d Gas Hose to the Gas Input on rear panel then turn ON the shielding gas DO NOT over tighten the gas fittings e Fit a 4 100mm Welding Wire Spool into the Spool Gun refer to Spool Gun Operating Manual for details 3 Plug the Power Source into Input Supply Voltage 4 Switch the Mains Power Supply ON Power Switch located on the rear panel ON This will immediately energize the Power Source 5 Rot...

Page 25: ...trode Holder NOTE 15 Do not rest the Stick Electrode on the earth clamp or work piece Consult the electrode manufac tures packaging for the correct electrode polarity 3 Plug the Power Source into Input Supply Voltage 4 Switch the Mains Power Supply ON Power Switch located on the rear panel ON This will immediately energize the Power Source up to the output terminals including the Stick Electrode i...

Page 26: ...4 Switch the Mains Power Supply ON Power Switch located on the rear panel ON 5 Rotate Knob then PUSH to SELECT a Welding Mode Selection to TIG b Welding Diameter Selection to 1 16 3 32 215MP 250MP on 120 VAC 1 16 3 32 1 8 215MP 250MP on 208 230 240 VAC c Welding Type Selection to 2T or 4T d Thickness to Plate thickness to be welded 6 If needed adjust the Post Flow Gas time Control Knob 7 Grind the...

Page 27: ...Rotate Knob left or right to adjust Inductance Arc Control in MIG SYN or MIG MAN modes Adjusts the intensity of the MIG welding arc Lower Inductance settings give a softer arc with less weld spatter and low weld penetration Higher Inductance settings give a harsh arc with more spatter and increased weld penetration Post Flow Gas in LIFT TIG mode Post Flow Gas is the time Gas flows after the arc ha...

Page 28: ...chine amperage range Select Welding Material Selection Fe or Ss or Al or FCAW S or FCAW G Select Protective Gas Selection Mix Gas or CO2 Select Welding Diameter Selection Model Material 120 VAC 208 230 240 VAC 215MP Fe Ss Al FCAW S FCAW G 023 030 035 040 030 040 035 040 035 040 045 040 045 023 030 035 040 030 040 035 040 035 040 045 040 045 250MP Fe Ss Al FCAW S FCAW G 023 035 040 030 040 035 040 ...

Page 29: ... memory Select YES to Restore Factory Settings then YES again to com plete the restore 5 4 Memory Save Recall Frequently used welding parameters can be saved then re called as needed Memory Save Recall can be used for MIG SYN MIG MAN TIG or STICK parameters NOTE 19 A total of 9 memory locations are available to save recall welding parameters 1 SAVE Welding Parameters to Memory Adjust controls to a...

Page 30: ...nt heat input into weld puddle A Joint design must allow access to the bottom of joint with a welding wire stick out length of 3 8 1 2 B Requires a MIG Gun angle of 0 15 for maxi mum penetration Keep arc on leading edge of weld puddle C Set higher Wirefeed Speed and or higher Voltage or reduce MIG Gun travel speed 5 Excessive Spatter molten metal particles solidify onto base metal A Wirefeed Speed...

Page 31: ... sure Device counter clockwise B Fit a suit size and type of Drive Roll that suits the welding wire C Replace the Drive Roll that suits the welding wire D Replace the Liner to suit the Welding Wire E Reduce the gaps at liner contact tip junction or wire guide junctions F Replace contact tip to suit Welding Wire G Replace contact tip to suit Welding Wire H Straighten out MIG Gun cable I Inspect Gro...

Page 32: ... is directed more into the base metal D Reduce travel speed of electrode E Clean surface before welding 5 Non metallic particles are trapped in the weld metal slag inclusion A Non metallic particles may be trapped in undercut from previous run B Joint preparation too restricted C Irregular deposits allow slag to be trapped D Lack of penetration with slag trapped beneath weld bead E Rust or mill sc...

Page 33: ... right size electrode 0 040 in 1 0 mm 5 to 30 Amps 1 16 in 1 6 mm 10 to 70 Amps 3 32 in 2 4 mm 15 to 150 Amps 1 8 in 3 2 mm 20 to 230 Amps 10 Welding arc cannot be established A Work clamp is not connected to work piece or ground torch leads are not connected to the correct welding terminals B Torch lead is disconnected C Gas flow incorrectly set cylinder empty or the torch valve is off A Connect ...

Page 34: ... techniques If major complex subassemblies are faulty then the Power Source must be returned to a PRO TEC Service Provider for repair Refer to SECTION 7 PRO TEC WARRANTY POLICY Suitably Trained and Qualified Tradesperson must DISCONNECT the Input Power Supply from the Power Source before opening the enclosure Wait at least 5 minutes before opening the enclosure to allow the primary capacitors to d...

Page 35: ...vider inspect then repair the weld er Refer to SECTION 7 PRO TEC WARRAN TY POLICY 3 Maximum output Welding Amperage cannot be achieved with nominal Input Supply Voltage Defective control circuit Have an approved Service Provider inspect then repair the welder Refer to SECTION 7 PRO TEC WARRANTY POLICY 4 Welding Amperage reduces when weld ing Poor work lead connection to the work piece Ensure that ...

Page 36: ... Welding Arc D Replace the Liner to suit the Welding Wire E Replace contact tip F Straighten out MIG Gun cable 12 Erratic Wire Feeding or Welding Arc A Excessive Drive Roll pressure B Incorrect Drive Roll size C Worn Drive Roll D Incorrect or blocked liner E Gaps at liner contact tip junction or wire guide junctions F Incorrect or worn contact tip size or contact tip overheating G Spatter adhesion...

Page 37: ...her warranties 2 Global Welding LLC will not accept responsibility or li ability for repairs made by a non authorized service fa cility 3 PRO TEC liability under this Limited Warranty shall not exceed the original cost of the Goods to correct the de fect of the Goods 4 Global Welding LLC will not be liable for incidental or consequential damages such as loss of business etc caused by the defect or...

Page 38: ...NOTES Operating Manual No PWOM 215 250MP 001 Page 38 2018 Global Welding LLC ...

Page 39: ...NOTES 2018 Global Welding LLC Page 39 Operating Manual No PWOM 215 250MP 001 ...

Page 40: ... Printed in USA Global Welding LLC Copyright 2018 PRO TEC is a Registered Brand of Global Welding LLC Box 250 17209 Chesterfield Airport Road Chesterfield MO 63005 USA ...