ESAB | MIGMASTER 250 | Instruction manual | ESAB MIGMASTER 250 Instruction manual

ESAB MIGMASTER 250 Instruction manual
MigMaster 250
Welding Package
Instruction Manual
F15-087-P
03/2008
Be sure this information reaches the operator.
You can get extra copies through your supplier.
caution
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
2
TABLE OF CONTENT
SECTION NO...................................................................................................................................................................................................PAGE NO.
SECTION 1 - SAFETY PRECAUTIONS ..................................................................................................................................................................... 3
SECTION 2 - INTRODUCTION..................................................................................................................................................................................11
2.1
2.2 2.3
2.4
2.5
GENERAL.........................................................................................................................................................................................................11
RECEIVING-HANDLING...............................................................................................................................................................................11
DESCRIPTION, Available Packages/Contents.....................................................................................................................................11
OPTIONAL ACCESSORIES..........................................................................................................................................................................12
SAFETY.............................................................................................................................................................................................................14
SECTION 3 - INSTALLATION.....................................................................................................................................................................................15
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
LOCATION.......................................................................................................................................................................................................15
ELECTRICAL INPUT CONNECTIONS.......................................................................................................................................................15
SECONDARY OUTPUT CONNECTIONS..................................................................................................................................................18
TORCH CONNECTIONS...............................................................................................................................................................................18
WIRE FEEDER MECHANISM.......................................................................................................................................................................18
CONNECTION OF THE SHIELD GAS........................................................................................................................................................19
WELDING CABLE CONNECTIONS...........................................................................................................................................................20
ASSEMBLE REAR WHEELS..........................................................................................................................................................................20
INSTALLING OPTIONAL SPOT/STITCH/ANTI-STICK MODULE.......................................................................................................20
INSTALLING OPTIONAL DIGITAL METER..............................................................................................................................................21
SECTION 4 - OPERATION..........................................................................................................................................................................................23
4.1
4.2
4.3
CONTROLS......................................................................................................................................................................................................23
PROCESS SETUP............................................................................................................................................................................................24
OPERATING PROCEDURES........................................................................................................................................................................27
SECTION 5 - SERVICE.................................................................................................................................................................................................31
5.1 5.2
5.3
MAINTENANCE..............................................................................................................................................................................................31
INSPECTION AND SERVICE.......................................................................................................................................................................31
TROUBLESHOOTING...................................................................................................................................................................................32
SECTION 6 - REPLACEMENT PARTS......................................................................................................................................................................41
6.1
6.2
6.3
SPARE PARTS . ...............................................................................................................................................................................................41
REPLACEMENT PARTS.................................................................................................................................................................................41
ORDERING......................................................................................................................................................................................................41
3
TABLE OF CONTENT
4
section 1
safety precautions
1.0Safety Precautions
1.1Safety - English
WARNING: These Safety Precautions are for your
protection. They summarize precautionary information from the references
listed in Additional Safety Information
section. Before performing any installation or operating procedures, be sure to read and
follow the safety precautions listed below as well
as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions
can result in injury or death.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1.Remove all combustible materials well away from
the work area or cover the materials with a protective non-flammable covering. Combustible
materials include wood, cloth, sawdust, liquid
and gas fuels, solvents, paints and coatings,
paper, etc.
2.Hot sparks or hot metal can fall through cracks
or crevices in floors or wall openings and cause a
hidden smoldering fire or fires on the floor below.
Make certain that such openings are protected
from hot sparks and metal.“
3.Do not weld, cut or perform other hot work until
the work piece has been completely cleaned so
that there are no substances on the work piece
which might produce flammable or toxic vapors.
Do not do hot work on closed containers. They
may explode.
4.Have fire extinguishing equInches per
minute (ipm)ent handy for instant use, such as a
garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained
in its use.
5.Do not use equInches per
minute (ipm)ent beyond its ratings. For example,
overloaded welding cable can overheat and create a fire hazard.
6.After completing operations, inspect the work
area to make certain there are no hot sparks or
hot metal which could cause a later fire. Use fire
watchers when necessary.
7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and
Welding Processes", available from the National
Fire Protection Association, Battery
march Park, Quincy, MA 02269.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equInches per
minute (ipm)ent is essential to prevent accidents.
Therefore:
1.Always wear safety glasses with side shields in
any work area, even if welding helmets, face
shields, and goggles are also required.
2.Use a face shield fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating or observing operations. Warn bystanders
not to watch the arc and not to expose themselves
to the rays of the electric-arc or hot metal.
3.Wear flameproof gauntlet type gloves, heavy
long-sleeve shirt, cuffless trousers, high-topped
shoes, and a welding helmet or cap for hair
protection, to protect against arc rays and hot
sparks or hot metal. A flameproof apron may
also be desirable as protection against radiated
heat and sparks.
4.Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars
should be kept buttoned, and open pockets
eliminated from the front of clothing.
5.Protect other personnel from arc rays and hot
sparks with a suitable non-flammable partition
or curtains.
6.Use goggles over safety glasses when chipping
slag or grinding. Chipped slag may be hot and
can fly far. Bystanders should also wear goggles
over safety glasses.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined,
or if there is danger of falling.
5
section 1
safety precautions
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
3. Welders should use the following procedures to
minimize exposure to EMF:
2. Connect the work piece to a good electrical
ground.
A.Route the electrode and work cables together.
Secure them with tape when possible.
3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.
B. Never coil the torch or work cable around your
body.
C.Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
4. Use well-maintained equInches per
minute (ipm)ent. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
D.Connect the work cable to the work piece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
Therefore:
9. Turn off the power before removing your gloves.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommendations. Do not mistake the work lead for a ground
cable.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
2. Exposure to EMF may have other health effects which
are unknown.
6
section 1
safety precautions
5.WARNING:This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and fittings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equipment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
7
section 1
safety precautions
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
Meaning of symbols - As used
throughout this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in immediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
8
section 1
sEGURIDAD
1.2Safety - Spanish
La escoria puede estar caliente y desprenderse
con velocidad. Personas cercanas deberán usar
gafas de seguridad y careta protectora.
ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas
hacen resumen de información proveniente de las referencias listadas en la sección
"Información Adicional Sobre La Seguridad". Antes
de hacer cualquier instalación o procedimiento
de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación
así como también todo manual, hoja de datos de
seguridad del material, calcomanias, etc. El no
observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1.Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases flamables, solventes,
pinturas, papel, etc.
2.Chispas y partículas de metal pueden introducirse
en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3.No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente
limpia y libre de substancias que puedan producir
gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inflamables.
4.Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5.No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en los
cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco, como
el sol , emite rayos ultravioleta (UV) y otras radiaciones
que pueden dañar la piel y los ojos. El metal caliente
causa quemaduras. EL entrenamiento en el uso propio
de los equipos y sus procesos es esencial para prevenir
accidentes. Por lo tanto:
1.Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2.Use una careta que tenga el filtro correcto y lente
para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a
los rayos del arco eléctrico o el metal fundido.
3.Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido. En
ocaciones un delantal a prueba de fuego es necesario
para protegerse del calor radiado y las chispas.
4.Chispas y partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable
como división.
6.Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo.
CHOQUE ELECTRICO -- El contacto con
las partes eléctricas energizadas y tierra
puede causar daño severo o muerte.
NO use soldadura de corriente alterna
(AC) en áreas húmedas, de movimiento
confinado en lugares estrechos o si hay
posibilidad de caer al suelo.
9
section 1
sEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones específicas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
3.Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A.Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C.Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D.Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno. Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.
CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente
eléctrica fluye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2.Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
10
section 1
sEGURIDAD
5.ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualificado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modifique el equipo en ninguna
manera.
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
section 1
sEGURIDAD
SIGNIFICADO DE LOS sImbolOs
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Significa el posible riesgo que
puede resultar en menores daños
a la persona.
12
section 1
sÉCURITÉ
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1.3Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de précaution provenant des références dans
la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser
l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les
fiches d'information sur la sécurité du matériel et
sur les étiquettes, etc. Tout défaut d'observer ces
précautions de sécurité peut entraîner des blessures
graves ou mortelles.
1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les
solvants, les peintures et les revêtements, le papier,
etc.
2.Les étincelles et les projections de métal incandescent
peuvent tomber dans les fissures dans les planchers
ou dans les ouvertures des murs et déclencher un
incendie couvant à l'étage inférieur Assurez-vous que
ces ouvertures sont bien protégées des étincelles et
du métal incandescent.
3.N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire des
vapeurs inflammables ou toxiques. N'exécutez pas
de travail à chaud sur des contenants fermés car ces
derniers pourraient exploser.
4.Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5.Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.
6.Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection
de métal incandescent ne risque de provoquer un
incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et exige l'emploi d'une
protection auditive. L'arc, tout comme le soleil, émet des
rayons ultraviolets en plus d'autre rayons qui peuvent
causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à
l'usage des processus et de l'équipement est essentielle
pour prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de
plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes afin de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé de
porter un tablier ininflammable afin de vous protéger
des étincelles et de la chaleur par rayonnement.
4.Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées, les
rebords de pantalons ou les poches. Il est recommandé
de garder boutonnés le col et les manches et de porter
des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes de
sécurité lors des opérations d'écaillage ou de meulage
du laitier. Les écailles de laitier incandescent peuvent
être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également
porter des lunettes étanches par dessus leur lunettes
de sécurité.
CHOC ÉLECTRIQUE -- Le contact avec des
pièces électriques ou les pièces de mise
à la terre sous tension peut causer des
blessures graves ou mortelles. NE PAS
utiliser un courant de soudage c.a. dans
un endroit humide, en espace restreint
ou si un danger de chute se pose.
13
section 1
sÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion afin d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endommagés. 5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A.Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C.Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D.Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conducteur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour
la santé.
14
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.
section 1
sÉCURITÉ
5.AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualifié. N'effectuez aucune réparation
électrique à moins d'être qualifié à cet effet.
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.
3. Maintenez les câbles, les fils de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des flaques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.
6. Utilisez l'équipement conformément à son usage
prévu et n'effectuez aucune modification.
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
15
section 1
sÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signifie un danger qui peut entraîner des blessures
corporelles mineures.
16
section 2
INTRODUCTION
2.1 GENERAL
Depending on the primary input voltage of the MM-250, and
the torch length, each package includes the following:
This manual has been prepared especially for use in familiarizing personnel with the design, installation, operation,
maintenance, and troubleshooting of this equipment.
All information presented here in should be given careful consideration to assure optimum performance of this
equipment.
- One (1), Migmaster 250 Power Supply/Wire Feeder equipped with
a dual-groove feed roll (for .035/.045 wire), a 6'-0" ft. primary input
power cable and plug (plug is installed for 208/230-V. units only), a
mating input power receptacle rated @ 50A./250-V. (packed loose
for 208/230-V. input packages only), 10-ft. work cable w/clamp, a
6'-0" shielding gas supply hose w/fittings and running gear w/gas
(cylinder) support, as follows:
2.2 RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
-- Migmaster 250 for 208/230-Volt input.........................P/N 32851
-- Migmaster 250 for 208/230/380/400/460/575-Volt
input.........................................................................................P/N 32852
- One (1), Migmaster 250 Kit as follows:
-- 12-ft. Pkg.
Includes:
GUNMASTER 250, ready-to-weld, 12-ft. lg. torch
for .035/.045 wire........................................................................P/N 21116
R-33-FM-580 Regulator, (F-15-173).......................................P/N 21557
Mig Welding Process Handbook......................................... P/N 791F18
10 # Sample Spool Wire .035 87 HP Wire
When requesting information concerning this equipment,
it is essential that Part, Serial and Model Numbers of the
equipment be supplied.
2.3 -- 15-ft. Pkg.
Includes same accessories as 12-ft. Kit except for torch,
which is:
GUNMASTER 250, 15-ft. lg. for .035/.045 wire,..................P/N 21117
DESCRIPTION
The Migmaster 250 is a portable Welding System designed
for fine wire, (0.023, 0.030, 0.035 and 0.045 in.) welding using the short arc method, as well as for spray arc aluminum,
short arc and spray arc stainless steel and spray arc cored
wires. It incorporates a running gear with provisions for one
gas cylinder, and a ST-23A spool-on-gun control.
CO2 Kits are the same as 12-ft. Pkg. except Regulator is R-33-FM-320.
P/N 21558.
2.3.2 2.3.1 AVAILABLE PACKAGES AND CONTENTS
POWER SUPPLY
The power supply consists of a tapped single phase transformer, tap selection switches, secondary contactor, single
phase full wave rectifier, stabilizing reactor, slope resistor,
filtering capacitors and internal output connections for
polarity reversal.
The following Migmaster 250 Packages are available with
Argon Regulator:
MM-250 for 208/230-V.
Input w/12-ft. Pkg........................................................... P/N 604560
MM-250 for 208/230-V.
Input w/15-ft. Pkg........................................................... P/N 604561
MM-250 for 208/230/380/400/460/575-V.
Input w/12-ft. Pkg........................................................... P/N 604563
MM-250 for 208/230/380/400/460/575-V.
Input w/15-ft. Pkg........................................................... P/N 604570
2.3.3 WIRE FEEDER
The wire feeder pushes 0.023, 0.030, 0.035 and 0.045 in.
wire at speeds up to 650 IPM. Dynamic braking prevents
excessive wire overrun. A double grooved drive roll (0.035
and 0.045 in. - supplied) provides a convenient means of
changing the setup for either wire size.
The following Migmaster 250 packages are available with CO2
Regulator:
The wire feeder is built into the power supply cabinet, and
is housed in a compartment separated from the welding
machine components. Machine ventilation is not drawn
through this compartment, thus helping to keep the wire
and feeding mechanism clean.
MM-250 for 208/230-V
Input w/12-ft. Pkg..............................................................P/N 35678
MM-250 for 208/230/380/400/460/575-V
Input w/12 ft. Pkg..............................................................P/N 35763
17
section 2
INTRODUCTION
TABLE 1. SPECIFICATIONS
POWER SOURCE
MIGMASTER 250
Rated Output
Duty Cycle, 208/230V Unit
208/230/380/400/460/575V Unit
Primary Input
Primary Input Amperes
Output Current Range
Maximum Open Circuit Volts
250 Amps @ 27 Volts d.c.
50% @ 60 Hz.; 40% @ 50 Hz.
35% for 208 through 400V; 50% for 460 & 575V
Single Phase 208/230; 208/230/380/400/460/575 Volts 50 60 Hz
208-71, 230-62, 380-37,400-36, 460-31, 575-25
30 to 280 Amps.
55 v.d.c.
FEEDER
Feed Type
Wire Sizes: Hard
Cored
Soft
Push
0.023" (0.6mm) through 0.045" (1.2mm)
0.030" (0.8mm) through 1/16" (1.6mm)
0.035" (0.9mm) and 3/64" (1.2mm)
Feed Rate
20-650 IPM
GUNMASTER 250 TORCH
Cooling
Air
Gooseneck Angle
45 degrees
Rated 60% Duty Cycle
(DCRP) Amps:
200 w/Argon Mixtures, 300 w/CO2
Conduit Length
see section 2.3.1
PHYSICAL
Net Weight
*210 lbs (95 Kg.)
Height
*32.25 inches (819 mm)
Width
*19.5 inches (495 mm)
Depth
*40.0 inches (1016 mm)
*Includes running gear & bottle tray.
2.3.6 RUNNING GEAR
2.3.4 GUNMASTER 250 WELDING TORCH
(F15-612)
The Migmaster 250 is equipped with a running gear w/
swiveled front wheels and a gas cylinder support. The rear
wheels are packed loose for shipping, but are easily installed,
see Section 3.8.
The lightweight air cooled welding gun included in selected
systems is supplied complete and ready to weld 0.035 in.
steel wire. It is built with a one piece service conduit and
includes a 45 degree gooseneck. Changing the contact tip
to 0.045 in. allows the use of the larger wire.
2.4 OPTIONAL ACCESSORIES
Fan-on-demand (autofan) Kit, P/N 16781
2.3.5 CONTROLS
2.4.1 SPOT/STITCH/ANTI-STICK MODULE,
P/N 32858.
This easy-to-install, plug-in module mounts in place of
the lower blank cover plate of the upper-right front panel
location in the 250 unit. It enables the operator to use the
250 for Spot or Stitch or Continuous welding operations.
It also includes an adjustable Anti-Stick feature that allows
you to select various wire burnback times to prevent wire
from sticking in the puddle after a weld. For installation, see
Section 3.9 and for operating instructions see Section 4.2.
The Migmaster 250 System can be used to weld hard and
aluminum wire with an optional ST-23A spool-gun torch.
An optional spot/stitch control allows a welder to spot or
stitch weld within a range of 0.4 to 3.5 seconds. The built-in
spool-on-gun adaptors and control, when used in conjunction with the optional ST-23A torch, permits aluminum wire
welding with the machine.
18
section 2
INTRODUCTION
5.0 - OPTIONS
If a5.1
Spotwelding
operation is to be used, it is recommended
Liner Selection
that you also order a #12S Spotweld Nozzle,
& Flux Core
P/NSteel
999625.
0558001675 ........ .023 x 10,12,15' Liner*
2.4.2 DIGITAL
MODULE,
37031VOLT/AMMETER
........ .030 x 10,12,15'
Liner*
P/N 32857......... .045 x 25' Liner
0558002137
37032 ........ .035-.045 x 10,12,15' Liner*
This easy-to-install,
module mounts
in place ofLiner*
the
37033 plug-in
........ .045-.052-1/16
x 10,12,15'
top blank
cover plate........
of the.052-1/16
upper-right
front
panel location
0558002138
x 25'
Liner
in the 250 unit. This unique meter module alternately displays
0558001676 ........ 5/64 x 10,12,15' Liner*
welding voltage and current (of the dial-set welding condi0558002139
........
x ’25'
Liner Amps and Volts
tion) every
4-seconds.
Two5/64
L.E.D.
s labeled
37034
........
3/32
x
10,12,15'
Liner*illuminate
provided below the meter windows, alternately
0558002140
........
3/32
x
25'
Liner
to indicate which condition is being displayed. The voltage
952948
........
10,12,15' Liner*
indication is
displayed
in 7/64-1/8
1/10-voltxincrements
(e.g.: 20.5),
while
the current indication is usually displayed in threeAluminum
whole digits37039**
(e.g.: 225).
After
the torchxtrigger
is released,
........
.035-3/64
15' Poly
Liner the
meter will continue
to
flash
for
20-seconds
the
last
condition
37040** ........ 3/64-1/16 x 15' Poly Liner
used
during
welding.
time,tothe
*NOTE:
Liner
supplied At
15'the
— end
mustof
bethis
trimmed
fit. meter will
reset
to zero.Jumper
For installation
Section 3.10.
** Requires
Liner Sleevesee
0558003050
5.2 ST-23A
Power Pin
Adaptors (Options)
2.4.3
SPOOL-ON-GUN
TORCH, P/N 19164 (see F-14-353).
0558001862
Lincoln
The0558002313
Migmaster 250 unit is equipped
L-TEC with a built-in control
for the ST-23A Spool-On-Gun welding torch. The ST-23A is
a high performance, 250 ampere continuous duty spoolon-gun torch designed for the mig welding process. It is
completely portable (up to 30-ft.), air-cooled and hand
operated, and weighs less than three (3) pounds. The gun
is5.3
equipped
withPlugs,
(30) footTrigger
lines. For Leads
installation
and operaControl
(Options)
tion, see Section 4.2.2.
0558001815
............................................................P/N
Trigger Lead 7”, ESAB 36779
MT-250SG
Spool-On-Gun.
0558002583
.................
24”, ESAB
(Requires Adapter, P/NTrigger
36833)Lead
See F-15-380.
0558001864 ................. Lincoln (LN 7,8,9,NAZ)
2.4.4 TORCH NOZZLES - See table below:
Nozzles
Gun Master 250
Tip Relationship Using All Sizes
Standard and 5/64 & 3/32"
Heavy Duty Tips
Tip Relationship Using
All Sizes Heavy Duty Tips
Except 5/64 & 3/32".
Standard Duty
0558001610
0558001609
3/8" Standard
3/8" Standard
1/8" Recess
Flush
Flush
1/8" Recess
0558001612
0558001611
0558001613
1/2" Standard
1/2" Standard
1/2" Standard
1/8" Recess
Flush
1/8" Stick Out
Flush
1/8" Stick Out
1/4" Stick Out
0558001614
0558001615
5/8" Standard
5/8" Standard
Flush
1/8" Stick Out
1/8" Stick Out
1/4" Stick Out
Spot
0558001602
Spot Nozzle
Brass
3/8"
Std. Duty Tip/Noz. Adapter
0558001608
Heavy Duty
0558001599
0558001600
0558001598
0558001601
5/8" Heavy Duty
5/8" Heavy Duty
5/8" Heavy Duty
5/8" Heavy Duty
1/8" Recess
1/4" Recess
Flush
1/8" Stick Out
Flush
1/8" Recess
1/8" Stick Out
1/4" Stick Out
0558001603
3/4" Heavy Duty
1/4" Recess
1/8" Recess
Spot
0558001602
Spot Nozzle
Brass
1/4"
Heavy Duty Tip/Noz. Adapter
0558001888
All Tips are the Medium Length to give these relationships.
19
15
No. 10 XL Nozzle, (MT HS) ................ P/N 999472XL
n torch designed for the mig welding prompletely portable (up to 30-ft.), air-cooled
perated, section
and weighs2less than three (3)
e gun is equipped with (30) foot lines. For
nd operation, see Section 4.2.2.
2.4.5
TORCH/WIRE FEED ACCESSORIES -- See
INTRODUCTION
Tables 2.4.5.1 and 2.4.5.2.
2.4.6SPOOL
SPACER
2.4.6
SPOOL
SPACER
For
8"
dia.
spools.
.........................................................P/N
17511
For 8" dia. spools .....................................
P/N 17511
For 10" dia. spools.......................................................P/N 34330
For 10" dia. spools .................................... P/N 34330
2.4.5 TORCH / WIRE FEED ACCESSORIES
5.0 - ........................
OPTIONS
See
following tables:
Spool-On-Gun
P/N 36779
es Adapter, P/N 36833) See F-15-380.
TIPS
Drive Roll & Guide Tube Selection
Heavy Duty Tips
Standard Duty Tips
.1 Recommended
GUNMASTER
250 Torch
0558002367
20543
........... .023 Standard
DutyAccessories
Tip
20544 ........... .030 Standard Duty Tip
Contact Tips
Liners
996995 ........... .035 Standard Duty Tip
Short (S) Medium (M) Long (L)
10'
12'
37290 ........... .045 Standard Duty Tip
996999
........... 3/64 (Alum.) Standard Duty Tip
Cored Wires
2075349
.052 Standard
Duty Tip 20543 ...........
999742
999743*
20544 ...........
996994
948850
996997
1/16 Standard
Duty Tip17717
996995 ...........
996996
2075237
2075230
5/64 Standard
Duty Tip17718
999578‹
948340‹
948341‹
37287
37290‹
2075349‹
37289‹
37288
996998‹
-
2075237
2075239
2075239
17718
17719
17719
Upper
Lower
Pressure
Heavy
Duty
Drive
Roll Tip Roll
Guide
Tube
0558002368 .......... .035 Heavy Duty Tip
Wires.040
(“V” Heavy
groove) Duty Tip
0558002369Hard
..........
15'
37286.023
...........
.045
Heavy
Duty Tip
in. (0.6mm)
21155
23612397
21163
17765.030
...........
3/64
(Alum.)
Heavy23612397
Duty Tip
in. (0.8mm)
21155
21164
...........
.052 Heavy
Duty Tip
- 17778.035
in. (0.9mm)*
21156
23612397
21165
- 37291 ........... 1/16 Heavy Duty Tip (Hard or Cored Wire)
.040 in. (1.0mm)*
21156
23612397
21165
2075238
948835.045
...........
1/16 (Alum.)
Heavy23612397
Duty Tip
in. (1.2mm)*
21156
21165
948832 ........... 5/64 Heavy Duty Tip
2075238
(aluminum)
Wires (“U”
groove)
948833Soft
...........
3/32 Heavy
Duty
Tip
2075240
2075240
5.6 Nozzle/Tip
Heavy
Duty Tips Relationship
Wire Type /
..........
.030
Diameter
.035 in. (0.9mm)
3/64 in. (1.2mm)
21158
21159
23612397
23612397
21167**
21168**
Cored Wires (Serrated “V” groove - lower)
uminum)
.030 in. (0.8mm)
21160
23612369
21164
0558002367
..........
.030
Heavy
Duty
Tip
996996
948862
- is dictated
The996995
“Nozzle-to-Tip”
relationship
in semi-automatic
welding
by the welding
process
being used.
Under
.035 in. (0.9mm)
21160
23612369
21165
..........37288
.035 Heavy Duty Tip
- 0558002368
37287
ideal conditions the contact tip to work distance must be kept close
to(1.0mm)
the recommended
specification
to
ensure
.040 in.
21161
23612369
21165
0558002369
.040 Heavy948863
Duty Tip
999578
996999..........996998
.045 in. (1.2mm)
21161
23612369
21165
optimum performance for any given process. To make it easier for the welder to maintain proper contact tip to
37286 ........... .045 Heavy Duty Tip
.052 in. (1.4mm)
21161
23612369
21166
work distance the “Nozzle-to-Tip” relationship can be set according
to (1.6mm)
process and
application.
Shown below
are
1/16
in.
21161
23612369
21166
17765
...........
3/64
(Alum.)
Heavy
Duty
Tip
ty
Tip
ct tips are recommended
for propercombinations.
wire stick out for flux cored wire welding.
typical “Nozzle-to-Tip”
17778 ...........for
.052
Heavy
Duty
ntact tips are recommended
proper
wire
stickTip
out in spray transfer Mig
Cored Wires (Serrated “V” groove - upper and lower)†
37291 ........... 1/16 Heavy Duty Tip (Hard or Cored Wire)
.045 in. (1.2mm)
37319
37319
21165
ct tips are recommended
for good
proper
wire
37319
37319
21166
948835 ...........
1/16visibility
(Alum.)and
Heavy
Duty
Tipstick in dip transfer .052 in. (1.4mm)
1/16 in. (1.6mm)
37320
37320
21166
g.
948832 ........... 5/64 Heavy Duty Tip
Extended Tip Relationship
1/8”
upport liner for948833
.023" wire.
Order
P/N
999797.
*
Supplied with Migmaster 250.
........... 3/32 Heavy Duty Tip
improved arc performance on steel/flux cored wire.
Short
CircuitSupport
(Short
Arc)
Welding
**
Requires
Tube
21169.
5.0 - OPTIONS
Recommended for use with soft cored wires that are easy to
Tip†stick
out
1/8”
past
nozzle.
Used in thin materials in
flatten.
any
in the
vertical & overhead
13
Liner Selection
5.2position,
Powerthick
Pin materials
Adaptors
(Options)
position. Also where minimum distortion is a requireSteel
& Flux by
Core
omatic welding
is dictated
the welding process being used. Under ment or filling large gaps. Extended Tip/Nozzle Rela0558001862
Lincoln
0558001675
........
.023 x 10,12,15'
Liner*
ance must be kept
close to the
recommended
specification
to ensure tionship is normal in short arc or where you want to
0558002313
37031
.030
x 10,12,15'
Liner*contact tip to reach into a corner to makeL-TEC
ss. To make it easier for
the ........
welder
to maintain
proper
your weld.
0558002137
........ .045
25' Liner Shown below are
ip can be set according
to process
andxapplication.
37032 ........ .035-.045 x 10,12,15' Liner*
37033 ........ .045-.052-1/16 x 10,12,15' Liner*
Flush Tip Relationship
0558002138 ........ .052-1/16 x 25' Liner
0558001676 ........ 5/64 x 10,12,15' Liner*
High
Current Short
Arc
& Flux Core
5.3 Control
Plugs,
Trigger
Leads (Options)
Extended ........
Tip Relationship
0558002139
5/64 x 25' Liner
Characterized by higher currents and voltages than
1/8”
37034
........
3/32Arc)
x 10,12,15'
Liner*
short
arc. Typical
metalTrigger
transferLead
is accomplished
by
Short
Circuit
(Short
Welding
0558001815
.................
7”, ESAB
0558002140
3/32nozzle.
x 25' Liner
of
molten
metal
with
bigger
diameter
than
the
Tip stick out........
1/8” past
Used in thin materials in drops
0558002583 ................. Trigger Lead 24”, ESAB
x 10,12,15'
Liner*
itself. High
spatter Lincoln
and a relatively
erratic arc is
any952948
position,........
thick7/64-1/8
materials
in the vertical
& overhead wire
0558001864
.................
(LN 7,8,9,NAZ)
position. Also where minimum distortion is a require- normal. Most tubular wires have this kind of transfer.
Aluminum
ment
or filling
large
gaps. Extended
Rela- Should be worked Argon-CO2 mix.
37039**
........
.035-3/64
x 15' PolyTip/Nozzle
Liner
tionship
is normal
in short arc
where
you want to
37040**
........ 3/64-1/16
x 15'orPoly
Liner
*NOTE:reach
Liner supplied
15' — to
must
be trimmed
to fit.
into a corner
make
your weld.
** Requires Jumper Liner Sleeve 0558003050
5.4 Nozzles
Flush Tip Relationship
1/8”
Recessed Tip Relationship
Spray Arc Welding/Flux Core
High Current Short Arc & Flux Core
Tip Relationship Using
Sizes
Relationship
Using
Used All
when
high deposition Tip
rates
and high metal
deCharacterized by higher currents and Standard
voltages than
and 5/64
&
3/32"
All
Sizes
Heavy
Duty
Tips
posits
are
needed.
Typically
used
when
joining
materishort arc. Typical metal transfer is accomplished
Heavy by
Duty Tips
Except 5/64 & 3/32".
drops of molten metal with bigger diameter than the als of 1/8” and greater thickness. High heat transfer
Standard
Duty High spatter and a relatively erratic arc is and low splatter characterized this technique. Only poswire itself.
sible when 85% Argon or higher is Flush
used. Recessed
0558001610
3/8" Standard
1/8" Recess
normal. Most tubular
wires have this kind of transfer.
20
Tip/Nozzle
Relationship
is
normal
in
spray
arc.
0558001609
3/8"Argon-CO
Standard 2 mix.
Flush
1/8" Recess
Should be worked
0558001612
1/2" Standard
1/8" Recess
Flush
section 3
INSTALLATION
3.1 LOCATION (Figure 3.1)
A proper installation site should be selected for the welding
machine, if the unit is to provide dependable service and
remain relatively maintenance free.
A proper installation site permits freedom of air movement
into and out of the welding machine, and also least subjects the unit to dust, dirt, moisture, and corrosive vapors.
A minimum of 18 inches (46 cm) unrestricted space must
be maintained between the welding machine side and rear
panels and the nearest obstruction.
32.25"
Overall
The installation site should also permit easy removal of
the welding machine outer enclosure for maintenance
functions.
CAUTION: Do not place any filtering device over the
intake air passages of the welding machine
as this would restrict the volume of intake air
and thereby subject the welding machine
internal components to an overheating condition and subsequent failure. Warranty is
void if any type of filtering device is used.
If a forklift vehicle is used for lifting the unit, be sure that
the lift forks are long enough to extend completely under
the base.
19.50"
40.00"
Figure 3.1 Dimensional Drawing
Do not operate the machine without the running gear
installed.
3.2
others that the circuit is being worked on. If the plug-cap is
used, (see 3.2B) remove plug from receptacle.
ELECTRICAL INPUT CONNECTIONS
3.2.1
Models of this welding machine are designed to be operated from 208/230, or 208/230/380/400/460/575 volts single
phase 50/60 Hz, depending on model. The primary input
voltage requirements are shown on the welding machine
nameplate.
It is recommended that a line disconnect switch be installed
in the input circuit to the welding machine. This would provide a safe and convenient means to completely remove
all electrical power from the welding machine whenever it
is necessary to perform any internal function on the unit.
(See Figure 3.2A.)
Before making electrical input connections to the welding machine, “Machinery Lockout Procedures” should be
employed. If the connections are to be made from a line
disconnect switch, the switch should be padlocked in the
off position. If the connection is made from a fusebox, remove the fuses from the box and padlock the cover in the
closed position. If locking facilities are not available, attach
a red tag to the line disconnect switch (or fuse box) to warn
Input Electrical Requirements
3.2.2 Input Conductor Connections
The input power cord on 208/230 Volts primary input model
is provided with an attachment plugcap. The plugcap will
mate with a 250 Volts, 50 Ampere receptacle conforming to
NEMA 6-50 R configuration.
The receptacle should be wired to a separately fused disconnect or circuit breaker of the size listed in Table 3.1. This
disconnect or breaker can be wired to a single phase system
or to two conductors of a three phase system. A third conductor for grounding should also be connected between
the disconnect and the receptacle.
21
section 3
INSTALLATION
Figure 3.2A illustrates wiring to a single phase system and
Figure 3.2B illustrates wiring to a three phase system.
TABLE 3.1 Input Conductor and Fuse Size
Full
Primary
Load
Input
Line
Fuse
Volts
Amperes Size
The 208/230/380/400/460/575 primary input voltage unit is
provided with a three conductor primary input cable without
plugcap. The ground lead of this cable should be connected
to a reliable ground and the two remaining wires should be
connected to the separately fused lines of the disconnect
or breaker as shown in Figures 3.2C and 3.2D.
All machines leave the factory with their primary electrical
input requirements internally-connected for the highest
voltage rating available in each model (e.g.: 230-volt for
the 208/230-volt units; and 575-volt for the "multi-voltage"
units).
208
230
380
400
460
575
71
62
37
36
31
25
Fig. 3.3A shows the 230v and 208v connections for the
208/230 dual voltage model. Change over is made by removing the right side panel below the wire feed compartment
and switching the primary transformer tap at the top of the
power switch with the unused alternate voltage tap located
next to the main transformer (see Fig. 3.3B). Both voltage taps
(the one currently connected to the switch and the unused
alternate voltage) are marked with the input voltage requirement. All units are supplied from the factory connected for
the highest voltage (230 vac). Before switching the voltage
taps, verify the actual voltage requirement as well as the
current voltage connection to be certain re-connection
is necessary. If voltage tap re-connection is necessary, the
following paragraphs cover the procedure to switch the
voltage tap for either 208vac or 230vac input.
Fused GRD
Line
Disconnect
Switch,
or
Circuit Breaker
8
8
10
10
12
12
208/230/380/400/460/575-V. MODELS
THREE-PHASE
THREE-PHASE
SINGLE-PHASE
GRD
GRD
GREEN
Wall Receptacle
GREEN
CONDUCTOR
(GROUND)
MIGMASTER SYSTEM
CONNECTS HERE
Figure 3.2 A
8
8
10
10
12
12
The terminal labeled GRD is connected to the welding
machine chassis and is for ground purposes only. It must
be connected to a good electrical ground. Do not connect
a conductor from the terminal labeled GRD to any one of
the L1, L2 terminals as this will result in an electrically hot
welding machine chassis.
208/230 MODEL ONLY (With Plug-Cap)
SINGLE-PHASE
90
90
50
50
40
30
Figure 3.3A - Primary Reconnections at Switch For
208/230 Volt Models
Only qualified personnel should make these changes. Make
certain the primary power has been disconnected and all
safety procedures have been followed before proceeding
with these instructions.
GRD
Recommended
Primary
Input
Ground
Conductor Conductor
Size
Size
Figure 3.2 B
Figure 3.2 C
Figure 3.2 - Primary Connection
22
Figure 3.2 D
section 3
INSTALLATION
When changing the input voltage connections, the unused
lead must be insulated and positioned to prevent contact
with any other internal components of the machine or the
machine side panel. The clearance between the unused
lead and other components must be at least one inch (see
Fig. 3.3B for illustration of the proper position). FAILURE TO
INSULATE AND POSITION THIS LEAD PROPERLY WILL CAUSE
A SERIOUS SHOCK HAZARD.
3.2.3 Connecting for 208 vac input
After the panel is removed, locate the 208 Vac lead (Fig. 3.3B)
and cut the tie-wrap to remove the insulation sleeving (on
early models this lead may have been wrapped with black
electrical tape). Open the insulating cover around the power
switch (Fig. 3.3C.) to expose the terminals and disconnect
the 230 Vac lead from the top of the switch as shown in Fig.
3.3A. Insulate the 230 Vac lead that was removed from the
power switch with sleeving or approved electrical tape
and re-position to a safe area beside the transformer (see
Fig. 3.3B), leaving a minimum of one inch clearance from
other components and the side panel.
Fig. 3.3B - Position of Alternate Voltage Tap
3.2.4 connectING for 230 vac input
After the panel is removed, locate the 230 Vac lead (Fig. 3.3B)
and cut the tie-wrap to remove the insulation sleeving (on
early models this lead may have been wrapped with black
electrical tape). Open the insulating cover around the power
switch (Fig. 3.3C.) to expose the terminals and disconnect
the 208 Vac lead from the top of the switch as shown in Fig.
3.3A. Insulate the 208 Vac lead that was removed from the
power switch with sleeving or approved electrical tape
and re-position to a safe area beside the transformer (see
Fig. 3.3B), leaving a minimum of one inch clearance from
other components and the side panel.
Connect the proper voltage (208 Vac or 230 Vac) tap to the
power switch and tighten securely. Check all other leads
connected to the power switch for tightness and clearance
from internal components before securing the insulating
cover around the power switch. Replace the side panel.
23
Fig. 3.3C - Power Switch Connection
section 3
INSTALLATION
3.2.5Reconnecting from 575 VAC Input
3.4 TORCH CONNECTIONS
Figure 3.3.1 shows you how to reconnect the "multi-voltage"
model from a 575-volt input to any of the remaining available voltage inputs 200 or 380 or 400 or 460-volts. These
connections are made by unscrewing the right side panel
below the wire feeding compartment, and locating the
primary voltage changeover terminal board handing in the
center of the lower compartment. This board contains copper
links which must be reconnected to match the silk-screened
voltage designations for the input you plan to use (it comes
factory-connected for a 575-volt input), see Figure 3.3.1.
The torch (GUNMASTER 250), which is supplied as standard
equipment with the Migmaster 250 System, is provided
with a euro-type adapter which directly connects to the
torch fitting mounted on the front panel. Line up matching
holes, push on and tighten locking collar. As shipped from
the factory, the euro or common connector type torches
are set-up for D.C.R.P. welding polarity (see sections 3.3
or 4.1.3). To connect the spool-on-gun torch (ST-23A) see
Section 4.2.2.
3.5 WIRE FEEDER MECHANISM
3.5.1 DRIVE ROLLS
The drive roll has two grooves: the small groove feeds 0.035
in. diameter wire, the large groove feeds 0.045 in. wire. The
groove nearest the gear motor feeds the wire. If the required
groove is not in that position:
A. Release the pressure drive roll lever and lift the assembly upward.
B. Remove the two (2) screws holding the drive roll to the gear.
C. Reverse the drive roll on the drive roll shaft.
PRIMARY VOLTAGE CONNECTION CHART
VOLTAGE
CONNECTION
NO. OF STRIPS
1 - 2
1
6 - 7
1
7 - 8
FLEX
1 - 2
1
208
6 - 7
1
230
5 - 8
FLEX
3 - 7
2
380
4 - 8
FLEX
2 - 6
2
400
7 - 8
FLEX
2 - 6
2
460
4 - 8
FLEX
2 - 3
2
4 - 8
FLEX
575
D. Replace the screws and tighten.
E. Secure the pressure drive roll assembly.
3.5.2 WELDING WIRE SPOOL
As with any work area, make sure safety glasses with side
shields are worn when handling or changing wire or clipping wire off at the spool or at the end of the torch. Hold
onto the wire coming off the spool with one hand before
clipping. Serious eye injury can result due to the springiness of the wire which can quickly unravel, or a cut wire
end which may shoot across the room.
Figure 3.3.1-Primary Reconnections at Voltage Changeover Terminal
Board for 208/230/380/400/460/575Volt Models
Install a spool of welding wire on the hub as follows:
3.3 SECONDARY OUTPUT CONNECTIONS
A. Unscrew spool nut from hub.
B. Place wire spool on hub to rotate clockwise as wire is unwound; hub pin must engage hole in spool.
C. Replace nut.
The Migmaster 250 Welding System is completely selfcontained so that the front panel torch fittings (Euro-type
MT and Spool gun) are internally connected to the welding
polarity (D.C. Reverse or D.C. Straight) via the secondary
output terminals located inside the wire feeding compartment (see Fig. 4.1). The machine comes set up for D.C.R.P.
welding as described in Section 4.1.3.
24
section 3
INSTALLATION
3.5.3 THREADING WELDING WIRE
A. Turn off power switch.
Do Not adapt R-33-FM-580 for use with CO2. Relief device
may rupture if CO2 is used with the R-33-FM-580. For CO2
service, order R-33-FM-320, P/N 21558.
When the power switch is on, and gun trigger is depressed,
the electrode wire becomes electrically hot, and the wire
feed rolls are activated.
B. Release pressure drive roll assembly and lift up
ward. Check that proper wire diameter groove is in
the inner position.
CAUTION: Before threading welding wire through casing,
make sure chisel point and burrs have been
removed from wire end to prevent wire from
jamming in gun casing or liner.
C. Feed the wire from the spool through the inlet guide, across the drive roll groove and into gun outlet guide.
Make sure that the proper “outlet guide tube” is inserted
into the front-panel gun fitting for the size and type of
wire being used, see Table 2.4.5.2 for wire feed accessories
(Section 2.4.5).
a. With the cylinder cap in place CAREFULLY slide the cylinder of gas onto the Migmaster 250 cylinder rack.
b. Secure the cylinder to the unit, using the chain provided.
c. Unscrew the cylinder cap.
d. Open the cylinder valve slightly, just for an instant, to blow away any dirt or dust which may have ac- cumulated in the cylinder valve outlet. Be sure to keep your face away from the valve outlet to protect your eyes.
e. Attach the regulator to the cylinder valve, tighten
the union nut securely with a 1-1/8in. open end or an
adjustable wrench.
CYLINDER
VALVE
To insure proper wire feeding, it is important that the wire
be kept clean and that the drive rolls be periodically cleaned
of any chips or scale that might be carried into the gun liner
and cause sticking.
CYLINDER
PRESSURE
GAUGE
OUTLET
CONNECTION
D. Lower pressure roll assembly and secure. Check that the gears mesh. Feed wire through to gun tip
with gun trigger (power ON).
Fig. 3.6 R-33-FM-580 Regulator (Illustrated)
3.5.4 BRAKE DRAG ADJUSTMENT
f. Attach the gas hose from the rear of the Migmaster 250
to the regulator outlet connection (see Fig. 3.6).
Brake disc friction should provide enough drag to keep the
wire spool or core from spinning freely after wire feed stops.
If adjustment is required, turn adjusting screw clockwise to
increase drag, counterclockwise to decrease it. Drag should
be just low enough to limit wire
overrun.
g. Slowly open the cylinder valve a fraction of a turn.
When the regulator pressure gauge pointer stops
moving, open the cylinder valve fully.
3.6 CONNECTION OF SHIELDING GAS SUPPLY
The R-33-FM-580 Regulator-Flowmeter is designed for use
with an argon or argon-mix cylinder of shielding gas. It is
adjustable for delivering up to 50 cfh through the torch. To
set up the system do the following:
Never stand directly in front of or behind the regulator when
opening the cylinder valve. Always stand to one side.
25
section 3
INSTALLATION
h. Using a leak test solution, such as P/N 998771 (8 oz. container) or soapy water, test for leakage about the cylinder
valve stem, the regulator inlet connection, and the hose
connections at the regulator and at the Migmaster 250
for leakage. Correct any leaks before starting work.
i. If work is to be stopped for a half-hour or more, or the
regulator is to be removed from the cylinder, shut down
the regulator as follows:
The proper operation of this equipment is to a large extent
dependent on the use of welding cables and connections
which are in good condition and of adequate size.
3.8 ASSEMBLE REAR WHEELS
a. Close the cylinder valve.
The unit's running board is factory assembled except for the
rear wheels which are packed loose in the shipping carton.
The rear gear consists of 2-wheels, 4-washers, 2-cotter pins,
and an axle. To install the gear, do the following:
b. Release gas from the regulator by closing the torch
trigger lever.
a. Insert the axle through the holes provided at the rear
of the gear.
c. When pressure gauge drops to zero, the regulator is
de-pressurized and shutdown.
b. Place a washer onto each end of the axle, then slip on
the wheels, then add another washer to the outside
of each wheel, and secure the whole assembly by
inserting a pin in each end of the axle.
j. Each regulator is equipped with a porous metal inlet
filter, P/N 71Z33, pressed into the regulator inlet nipple.
No. regulator should be connected to a cylinder or station
valve unless it contains this filter. You can replace the filter
if you have reason to do so. To remove a filter refer to the
regulator instruction literature for details.
k. Regulators in need of repair should be returned to your
Welding Equipment distributor or to an authorized Remanufacturing Center.
If welding is performed in a confined area, shielding gas leaks
could result in a buildup of shielding gas concentration, displacing oxygen, thereby endangering personnel enter the area.
3.7 WELDING CABLE CONNECTIONS
Connect the work clamp solidly to the workpiece or work table.
Clamp onto a bare metal area.
A good electrical connection to the work is essential to proper
welding operation and to prevent electric shock.
Welding cables should be kept as short as possible and be of
adequate current carrying capacity. Resistance of the welding
cables and connections causes a voltage drop which is added
to the voltage drop of the arc. Excessive cable resistance may
result in a reduction of the maximum usable current output
of the equipment.
26
c. Remove the existing shipping supports by unscrewing from chassis.
3.9 INSTALLING OPTIONAL SPOT/STITCH/ANTI-
STICK MODULE
a. Remove lower blank-cover plate from upper-right
front panel of power supply -- save the four mounting screws.
b. Locate the harness-connected 15-pin plastic plug,
P3, inside the mounting cavity. Note that this plug
will have a jumper plug with jumper wires connected to it -- remove (and save) the jumper plug.
(The jumper plug must be reinstalled if the module
is ever removed.
c. Connect the 15-pin plug into the matching receptacle
on the rear of the optional control module. The plug
will only fit one way.
d. Install the control module in place of the blank panel
removed in Step a., using the same four screws that
you saved.
section 3
INSTALLATION
3.10 INSTALLING OPTIONAL DIGITAL METER
a. Remove the top blank-cover plate from the upperright front panel of the power supply -- save the four
mounting screws.
b. Locate the harness-connected 10-pin plastic plug, PL1, inside the mounting cavity. This plug does not have a jumper plug connected to it.
c. Connect the 10-pin plug into the matching recep-
tacle on the rear of the optional meter module.
d. Install the meter module in place of the blank-
panel removed in Step a., using the same four screws that you saved.
27
section 3
INSTALLATION
28
section 4
4.1
OPERATION
CONTROLS (See Figure 4.1)
4.1.1 POWER SWITCH
4.1.2
A line toggle switch on the front panel energizes the primary of the main transformer. This switch also turns on the
fan, which is connected across a portion of the primary
winding.
Voltage control is by means of two high current tap switches
which connect the rectifier bridge to various secondary
taps.
Two transformer secondary windings also become energized:
The COARSE VOLTAGE RANGE Selector is a three-position
switch, LOW/MED/HIGH, by which the operator selects the
approximate range of voltage (or heat, that determines the
arc length) to be applied to the weld. It is a coarse selection
control and is used in conjunction with the Fine Voltage
Adjustment selector following. It must not be switched
under load.
A. Gun trigger circuit 24 volts AC.
Wire feeder circuit 24 volts DC.
B. Main welding secondary circuit. Depending upon the tap switch position, various secondary volt-
ages can be obtained. Then rectified, open circuit voltages can be selected between 18 and 56 volts DC when the secondary contactor is energized.
4.2.3
4.1.5
2.4.2
VOLTAGE CONTROL (Coarse Range Selector
and Fine Adjustment Range Selector)
4.2.2
Secondary Output Terminals
for Welding Polarity Change-over,
see 4.1.3.
10A. Fuse
4.1.3
4.1.2
Work
Cable
Torch
Cable
4.1.1
29
4.1.6
section 4
OPERATION
4.1.5 WIRE FEED SPEED CONTROL
The FINE VOLTAGE ADJUSTMENT Selector is an eightposition switch by which the operator selects the exact
amount of arc voltage (or heat) to be applied to the weld
(within the coarse range selected above). This allows you
to fine-tune the voltage required; the higher the number
selected (1-8), the hotter the weld. The Fine Voltage Selector
switch also has an "open" detent at the six o'clock position.
Placing the switch in this position allows operation of the
torch trigger to feed electrode wire without the wire being
electrically "hot". This switch also, must not be switched
under load.
Wire feed speed is controlled by the wire speed potentiometer knob on the front panel. The solid state control allows
for infinitely variable speeds up to 650 IPM.
This wire speed pot is used to set the speed at which the
welding wire is fed out from the torch and hence the welding amperage. The panel-face numbers on the dial (0-10)
are used for reference and do not directly indicate wire feed
speed; the higher the number, the faster the speed.
4.1.6 STD./SPOOL GUN SELECTOR
These tap switches carry several hundred amperes, and must not be switched under load, as
this will cause the contacts of the switches to arc.
This two-position toggle switch is located inside the unit
on the mid-wall of the wire feeding compartment and is
labeled Standard and Spool Gun. It is used to select standard
metal inert gas welding (MIG) with the GUNMASTER 250, or
welding with the ST-23A (spool-on-gun) torch.
4.1.3 SECONDARY WELDING CONNECTIONS
4.2 The secondary contactor, with parallel poles, is used to make
and break the circuit between the transformer secondary
and the rectifier. This contactor is turned on and off when
the torch trigger (in the 24 volt circuit) is operated.
4.2.1 STANDARD MIG SEAM WELDING W/
GUNMASTER 250
PROCESS SETUP
Refer to Sections 4.3.1, 4.3.2, 4.3.3, 4.3.4, and Table 4.3.3.
The secondary output welding terminals, POS.(+) and
NEG(-), are located in the right side wire feeding compartment and are used to set the welding polarity (D.C.R.P. or
D.C.S.P.) in which the machine will operate (see Fig. 4.1).
As shipped from the factory, the 250 is set up to operate
in D.C.R.P. (TORCH fitting is connected to Positive, and
WORK cable/clamp is connected to Negative output). To
weld using D.C.S.P., simply mount the WORK cable to the
Positive output and the TORCH fitting cable to the Negative output terminal.
4.2.2 ST-23A SPOOL-ON-GUN CONTROL
CONNECTION/OPERATION
The Migmaster 250 is equipped with a built-in control for
the Spool Gun which operates via the amphenol control
receptacle and a screw adaptor that provides Gas and Power.
The ST-23A Torch (see Section 2.4.3) has a amphenol-plug
control cable connection, and a gas/power cable, see Figure
4.2.2.
To operate the unit with the ST-23A Torch connected, do
the following (refer to Fig. 4.2.2):
4.1.4 CONTACTOR CONTROL
A. Place the STD./Spool Gun selector toggle switch (4.1.6)
in the 250 to its Spool Gun position.
Refer to the schematic diagrams. Note that the coil of the
24 volt contactor is activated with the torch trigger and is
energized when the trigger is pulled. The gas solenoid is
in parallel with the contactor coil and is energized at the
same time.
B. Connect the ST-23A control cable amphenol to the receptacle labeled CONTROL on the 250’s front panel.
C. Remove the threaded plastic plug from the Gas/Power
adaptor (on the 250's front panel) using a clockwise
rotation. Connect the ST-23A gas/power cable to the
panel adaptor using a counter-clockwise rotation. As
shipped from the factory, the 250's secondary output
power terminals are set-up for D.C.R.P. welding polarity (see Section 4.1.3).
When the trigger switch is released, the contactor drops
out and disconnects the load.
Because of the charged capacitor bank in the secondary circuit, the output voltage will take a few seconds
before falling to zero volts.
The gas valve shuts off when the contactor opens.
30
section 4
OPERATION
MT-250SG Requires
Adapter 36833
Figure 4.2.2 - Connecting Spool-On-Gun to Services
IMPORTANT -- Always make sure that the plastic plug is
screwed back into the adaptor when the ST-23A gas/
power cable is disconnected, because shielding gas
will escape from the adaptor unless the gas cylinder
is shut off.
4.2.3.1 ANTI-STICK WELDING OPERATION
Anti-Stick feature provides a time delay at the end of a weld
from the time the torch trigger is released until the main
contactor is deenergized. This delay allows the welding
wire to burn back, away from the work, so it won’t “stick”
in the weld puddle.
D. Connect the 250’s WORK cable to the workpiece.
E. Set Migmaster 250 voltage tap switches to RANGE
and FINE ADJUSTMENT VOLTAGE settings desir- ed.
This delay time, controlled by the“anti-stick”potentiometer,
is variable from approximately 0.05 seconds to 0.5 seconds.
The required delay time generally depends on the WIRE
SPEED Adjustment setting on the front panel - the higher
the setting, the faster wire will feed into the weld, and the
more delay time will be required.
F. Turn on the Migmaster 250’s power switch and
begin seam mig welding.
If the optional Spot/Stitch/Anti-Stick control module is installed, the MT-250SG and the ST-23A gun may be operated
using these optional features, see Section 4.2.3.
If, when using the Anti-Stick feature, the welding wire tends
to stick in the puddle at the end of a weld, the Anti-Stick
time should be increased; if, on the other hand, the wire
burns back into the torch tip, the anti-stick time should be
decreased. Setting the anti-stick time to “Min” effectively
cancels the anti-stick feature.
4.2.3 OPTIONAL SPOT/STITCH/ANTI-STICK
CONTROL MODULE
This optional control module allows the operator to use the
250 for Spot or Stitch or Continuous welding operations.
It also includes an adjustable Anti-Stick feature to select
various burnback times to prevent wire from sticking in the
puddle after a weld.
This Anti-Stick feature is available for all three welding
modes - Continuous, Spot, and Stitch.
4.2.3.2 CONTINUOUS WELDING MODE
OPERATION
The module consists of three pots (one for Spot-Stitch Weld
Time "ON", one for Stitch Weld Time "OFF", and one for AntiStick Time modes) and one three-position toggle switch to
select the welding operation desired (Spot, Continuous or
Stitch). For installation, see Section 3.9; for operation, see
following:
A. Place the three-position toggle switch in “Continu-
ous” weld mode (center position) for mig seam welding.
B. Set the “Anti-Stick Time” as required (see 4.2.3.1).
31
section 4
OPERATION
C. Set the “coarse” and “fine” Voltage control switches
and wire speed pot to the desired settings and begin
welding operation as described in Sections 4.3.2 and
4.3.3.
B. Be sure a standard nozzle (and not a spot weld nozzle)
is installed on the torch.
C. Set the length of time the arc will be ON for each
sequence by adjusting the Spot-Stitch Weld Time
control  on  the  power  supply’s  front  panel. This
timer has an approximate range of from 0.4 seconds at
the minimum setting to 3.5 seconds at the maximum
setting. Set the length of time the arc will be OFF for
each sequence by adjusting the Stitch Weld
Time control on the front panel. This timer has an
approximate range of from 0.4 seconds at the minimum
setting to 3.5 seconds at the maximum setting.
4.2.3.3 SPOT WELDING MODE OPERATION
A. Place the three-position toggle switch in “Spot” position.
B. Replace the standard nozzle with the No. 12 Spot weld
Nozzle P/N 999625.
C. Trim the welding wire back so the end is slightly inside
the nozzle.
D. Set the “coarse” and “fine” voltage control switches
and wire speed as specified in Table 4.3 under
Continuous Weld Conditions for:
D. Set the “coarse” and “fine” voltage control switches,
wire speed, and the Spot-Stitch Weld Time see Table
4.3, for the thickness of the metal being welded
and the diameter of the weld wire being used.
i. The type weld being made (see diagrams to the
left of each column of figures).
E. To spotweld:
ii. The thickness of the metal being welded.
i. Press the torch nozzle squarely on the top plate.
Apply enough pressure to hold the two pieces of
metal firmly together, so there is no loose play
between them.
iii.The gap (if any) between the pieces being welded.
iv. The diameter of the welding wire being used.
E. When using the Stitch weld mode, before starting the weld the welding wire should extend about
1/2-in. beyond the end of the nozzle. Adjust this length by either clipping off the end of the wire with insulated cutters or by using the torch switch.
Fig. 4.2.3 - Cross Section of Good Spotweld
Power supply contactor becomes energized the moment
the torch trigger is depressed. Arcing can occur if the
wire is brought to a ground. Keep the torch always from
ground until welding is to begin.
ii. Pull the trigger, holding the gun motionless and
firmly. The electrode wire and shielding gas will be
fed to the work, and the arc will be maintained for
the length of time set in Step D. above. iii.After the preset time has elapsed, the wire will
stop feeding, the arc will be broken, and the
shielding gas will stop flowing.
F. During the welding, use the same welding techniques
as described in Section 4.3.3 and 4.3.4.
4.2.5
A good spotweld will penetrate through both layers of metal, and will have a small nugget on the
reverse side, (Fig. 4.2.3)
4.2.4
DUTY CYCLE (Figure 4.2.5)
The duty cycle of the equipment is the percentage of a 10
minute period which it can operate safely at a given output
current. The Migmaster system is rated at 50% duty cycle.
This means that the equipment can be safely operated at
250 amperes for five minutes out of every 10. This cycle can
be repeated indefinitely (See Figure 4.2.5).
STITCH WELDING MODE OPERATION
A. Place the three-position toggle switch in “Stitch”
position. The stitch weld mode uses a series of pretimed arc-on/arc-off time sequences to allow cooler
welding.
32
section 4
OPERATION
4.3 OPERATING PROCEDURES
4.3.1 OPERATING SAFETY PRECAUTIONS
Comply with all ventilation, fire and other safety requirements for arc welding as established in the SAFETY Section
at the front of this manual.
Also remember the following:
A. Because of the radiant energy of the welding arc
and the possibility of drawing an arc before the
helmet is lowered over the face, the operator should
wear flash goggles with filter lenses under his helmet.
The helmet filter plated should be shade number
11 (nonferrous) or 12 (ferrous). All those viewing the
arc should use helmets with filter plates, as well as
flash goggles. Nearby personnel should wear flash
goggles.
Fig. 4.2.5 Duty Cycle Curves
4.2.6 VOLT/AMPERE CURVES (Figure 4.2.6)
The Volt/Ampere curves show the output Voltage available
at any given output current for the various Voltage Selector
positions in each range low, medium, and high.
B. The radiant energy of the arc can decompose chlorinated solvent vapors, such as trichloroethylene and
perchlorethylene, to form phosgene, even when
these vapors are present in low concentrations. DO
NOT weld where chlorinated solvents are present in
atmospheres in or around the arc.
The actual operating point of load Voltage and Current is
determined by type of process, electrode, shield gas, wire
feed speed, and operating technique.
C. DO NOT touch the electrode, nozzle or metal parts in
contact with them when power in ON: all are electrically energized (HOT) and can cause a possibly fatal
shock. DO NOT allow electrode to touch grounded
metal: it will create an arc flash that can injure eyes.
It may also start a fire or cause other damage.
DUTY CYCLE
D. When working in a confined space, be sure it is
safe to enter. The confined space should be tested
for adequate oxygen (at least 19%) with an approved
oxygen measuring instrument. The confined space
should not contain toxic concentrations of fumes or
gases. If this cannot be determined, the
operator should wear an approved air supplied
breathing apparatus.
HIGH
Avoid gas leaks in a confined space, as the leaked gas can
dangerously reduce oxygen concentration in the breathing air.
MED.
DO NOT bring gas cylinders into confined spaces.
LOAD LINE
VOLTS = 14+ (.05 x AMPS)
50
100
When leaving a confined space, shut OFF gas supply at the
source to prevent gas from leaking into the space, if the
switch is accidently kept depressed. Check the breathing
atmosphere in the confined space to be sure it is safe to
reenter.
LOW
AMPERES
150
200
250
33
section 4
OPERATION
E. Never operate the equipment at currents greater than
the rated ampere capacity; overheating will occur.
b. Attempting to weld over grease or oil can cause weld defects.
F. Never operate equipment in a damp or wet area
without suitable insulation for protection against
shock. Keep hands, feet and clothing dry at all
times.
c. Before welding on aluminum, be sure to clean surface thoroughly using a stainless steel brush.
4.3.3 SET-UP PROCEDURE
A. Determine the material type, thickness and joint configuration to be welded from Table 4.3 and use the recommendations to set the following:
G. Whenever the equipment is left unattended, turn
all control and power supply switches and gas
supplies OFF and open the main line switch.
a. Coarse Voltage Range, LOW/MED/HIGH.
H. Wear dark substantial clothing to protect exposed
skin from arcburn, sparks and flying hot metal.
b. Fine Arc Voltage Setting, 1 thru 8 (the higher the
number, the hotter the weld).
I. Turn off welding power before adjusting or replacing
electrodes.
c. Wire Speed setting, 0 thru 10 (the higher the number, the faster the speed).
B. Set the two-position switch in the wire feeder compartment to STANDARD for seam welding with the
GUNMASTER 250 torch. (For ST-23A Spool-On-Gun
welding, see Section 4.2.2).
Never operate the welding machine with any portion of
the outer enclosure removed. In addition to a hazard,
improper cooling may result in damage to the welding
transformer and the welding machine components.
Warranty is void if the machine is operated with any
portion of the outer enclosure removed.
C. If optional Spot/Stitch/Anti-Stick Control module is
installed, refer to Section 4.2.3 for operation, settings
and welding condition table.
D. Make sure the GUNMASTER 250 torch fitting and
the “Work” cable are connected to the proper output
terminals (inside unit) for the polarity desired.
4.3.2 PRE-WELD REQUIREMENTS
Before welding commences, with all power OFF, check
the following:
A.All safety requirements have been read and understood.
B. All hoses and cables are in good condition, safely insulated and securely connected.
C. Turn on gas supply by slowly opening cylinder valve to full ON.
D.Correct size wire accessories have been installed on the wire feeder, drive gears are meshed, wire pressure set, and guide tube is installed for type and size wire you plan to use, refer to Tables 2.4.5, and 4.3.
Only qualified personnel should make these changes.
Make certain the primary power has been disconnected
and all safety procedures have been followed before
proceeding with these instructions.
Normally, you will set-up for “reverse polarity”; this
means the torch fitting is connected to the POS (+)
output terminal and the “Work” cable to the NEG (-)
output terminal.
For“straight polarity”, do just the opposite; torch fitting
to NEG (-) output terminal and “Work” cable to POS (+) output terminal.
4.3.4 WELDING OPERATION
E. Spool of correct size wire is locked in place, brake tension is set, and wire is properly threaded through the inlet guide to the gun tip.
F. The wire feeding compartment cover is closed
and secure.
G.Make sure that the metal to be welded is properly prepared:
a. Remove loose surface rust, scale or paint with wire brush or sander.
A. Turn Power switch (on unit) to ON position -- be
careful not to operate the torch switch.
B. Before starting the weld, the welding wire should
extend about 1/2-inch beyond the end of the nozzle.
Adjust this length by either clipping off the end of the
wire with insulated cutters or by using the torch
switch.
34
section 4
OPERATION
F. When welding in the vertical position, traveling either
up or down, it is very important to keep the arc on the
leading edge of the puddle to ensure complete penetration.
Power supply contactor becomes energized the moment
the torch trigger is depressed. Arcing can occur if the
wire is brought to a ground. Keep the torch away from
ground until welding is to begin.
G. Some welders who are accustomed to welding with stick
electrodes may tend to push the torch into the weld.
This is neither necessary nor desirable, since the wire
electrode is being mechanically fed into the weld.
C. To start the weld, hold the torch so the welding wire is
approximately 1/4-in. from the work, then press the torch trigger.
Please note that the Wire Speed control can be adjusted
for the gauge of metal to be welded. However, the
Coarse Voltage Range and Fine Voltage setting must
not be switched while welding.
D. The welding wire should be pointed into the joint
at angles of approximately 450 for fillet welds, and
approximately 900 for butt welds, (Fig 4.3.4.1).
H. To stop the weld, release the trigger and pull the torch
from the work. When leaving equipment unattended,
always shut OFF and disconnect all input power and
shut off shielding gas at source.
E. The torch angle relative to the length of the weld should
be approximately 100 from the vertical (Fig. 4.3.4.2).
TABLE 4.3, Continuous/Stitch Weld Conditions
Fig. 4.3.4.1 - Angle of Welding Wire with Joint
35
section 4
OPERATION
TABLE 4.3, Continuous /Stitch Weld Conditions
This equipment is provided with a thermostat (OL) in the transformer (T1) windings which will open and prevent the contactor (CON) from closing if the transformer windings are overheated. If the thermostat opens, allow the equipment to idle
with fan running for approximately 15-min. before attempting to weld again.
36
section 5
5.1
SERVICE
MAINTENANCE
If uninsulated cable and parts are not replaced, an arc
caused by a bared cable or part touching a grounded
surface may damage unprotected eyes or start a fire.
Body contact with a bared cable, connector, or uncovered
conductor can shock, possible fatally.
Be sure the branch circuit or main disconnect switch is
off or electrical input circuit fuses are removed before
attempting any inspection or work on the inside of
the welding machine. Placing the power switch on the
welding machine in the OFF position does not remove
all power from inside of the equipment.
Keep power cables dry, free of oil and grease, and protected
at all times from damage by hot metal and sparks.
Clean dirt and metal particles from drive roll groove weekly;
replace roll if badly worn.
Inspection, troubleshooting and repair of this equipment may ordinarily be undertaken by a competent
individual having at least general experience in the
maintenance and repair of semi-conductor electronic
equipment. Maintenance or repair should not be undertaken by anyone not having such qualifications.
5.2.1 5.2.1.1 RECTIFIER
It is recommended that the rectifier be cleaned occasionally
by blowing it out with compressed air. This cleaning operation
is necessary so that maximum cooling will be accomplished
by the air stream. This should be done periodically, depending upon the location of the unit and the amount of dust
and dirt in the atmosphere.
Shut OFF shielding gas supply at source.
To aid in checking and servicing, use Schematic, Figure
5.1.
5.2
POWER SOURCE
INSPECTION AND SERVICE
The hermetically sealed silicon diode rectifiers are specially
designed for welding machine use and will not age or deteriorate in use. The four diodes are mounted on heat sinks. A
periodic cleaning of dust and dirt from these is necessary to
insure cooling of the rectifiers. Access is by removal of top
cover and side panels. Should any diode accidentally be
damaged and need replacement, it can be quickly removed
from the heat sink. The replacement diode should be of
the same type as the one removed, and should be locked
securely to the sink, preferably with a torque wrench set for
maximum of 25 ft. lbs. and a minimum of 20 ft. lbs. Excessive torque will distort the mechanical structure and may
break the hermetic seal, whereas too little torque will result
in improper electrical connections.
Keep Equipment in clean and safe operating condition free
of oil, grease, and (in electrical parts) liquid and metallic
particles which can cause short-circuits.
Regularly check cylinder valves, regulators, hoses, and gas
connections for leaks with soap solution.
Check for and tighten loose hardware including electrical
connection. Loose power connections overheat during
welding.
Immediately replace all worn or damaged power cables
and connectors. Check for frayed and cracked insulation,
particularly in areas where conductors enter Equipment.
5.2.1.2 FAN MOTOR
All models are equipped with an exhaust fan and rely on
forced draft for adequate cooling for high duty cycles and
overloads. Lubricate the fan motor with a few drops of SAE-20
non-detergent oil every three months.
The electrode wire and all metal parts in contact with it are
electrically energized while welding. Inspect these parts
periodically for defective insulation and other electrical
hazards.
37
section 5
SERVICE
5.2.1.3 TRANSFORMER
Occasional blowing out of the dust and dirt from around
the transformer is recommended. This should be done
periodically depending upon the location of the unit and
the amount of dust and dirt in the atmosphere. The welding
machine case cover should be removed and a clean, dry air
stream should be used for this cleaning operation.
To avoid shock, do NOT touch electrode wire or parts in
contact with it, or uninsulated cable or connections.
B. Check all gas (and water) hoses and connections, flowmeters, and regulators for possible sources of
leakage, breakdown or intermittent failure.
C. Isolate trouble to one part of the welding installation:
primary power supply, power source, Feeder or wire
guide train (casing, drive rolls, liners and contact tip).
If this inspection indicates trouble in the Feeder, use
Troubleshooting Guide, Table II and schematic diagram
(Figure 5.1).
5.2.1.4 24 VOLTS WIRE FEEDER AND CONTROL CIRCUITS
The 24-volts circuit is protected by a 10 amp fuse in a panel
mounted fuseholder, accessible from the wire feeder compartment. Failure of this fuse will shut off the contactor,
shielding gas and wire feeder.
5.3.1 IF MOTOR DOES NOT RUN:
If it should become necessary to replace this or any other
fuse in the welding machine, ensure that the proper size
fuse is used as a replacement.
A. Check for blown fuse. If blown, check that motor is
not binding before replacing fuse.
B. Check for continuity across speed potentiometer (POT)
and wiper contact. Voltage from center tap to MIN end
should vary from 0 to 5.4 VDC as pot- entiometer is
rotated clockwise.
5.2.1.5 OVER-TEMPERATURE PROTECTION
The machine is equipment with a thermostat. On continued high current application, if the thermostat reaches an
abnormally high temperature, it will deenergize the contactor. This thermostat will reset itself automatically after
the transformer windings have cooled to a safe level. While
deenergized, neither the contactor, shielding gas nor wire
feeder can be operated.
5.2.2 C. Check wiring for continuity. Then turn power ON and
check for 30 volts d.c. across input terminals 8 and 9
on the feeder printed circuit board connector (PL1).
WIRE FEEDER
D. Press torch trigger, and check for voltage across motor
(Pins 4 to 7) of speed control board; should vary from
1 to 24 VDC as speed control potentiometer is rotated
clockwise.
When soft wire is fed, the drive rolls may pick up metal from
the wire surface. Accumulation on the rolls may score the wire
with resulting unwanted friction and improper feeding.
Inspect the rolls regularly and clean them with a fine-wire
power brush. Avoid roughening, or removing the hardness of
groove surfaces in grooved rolls. Any roughening may score
the wire, just as the accumulation being removed may do.
5.3.2
DRIVE ROLL PRESSURE ADJUSTMENT
Adjust the drive roll pressure knob until no wire slippage
occurs. DO NOT OVERTIGHTEN - EXCESSIVE PRESSURE CAN
CAUSE WIRE FEEDING PROBLEMS.
5.3 TROUBLESHOOTING
General Replacement
If welding equipment doesn’t work right despite compliance
with checklist inspect as follows:
The exploded views in the Parts Section indicate generally,
in numbered parts sequence, the disassembly of the wire
drive and feeder parts.
A. With all power controls ON and other operating controls at required settings, visually check all power cables and connections for evidence of overheating or sparking.
Reassemble in reverse order.
38
section 5
SERVICE
5.3.3 SOLENOID VALVE REPLACEMENT
When replacing the gas solenoid valve, the inlet (with the
word IN) must face the rear of the Unit.
Many troubleshooting situations require that the power
remain On and that power terminals in the equipment
carry voltage. Exercise extreme caution when working
on “LIVE” equipment. Avoid contact with electrical
components, except when testing with an appropriate
instrument.
Do not make any repairs to equipment unless you are
fully qualified, as described in the maintenance section.
TABLE II. TROUBLESHOOTING GUIDE
WELD CONDITION
POSSIBLE CAUSEREMEDY
1. No weld or control power.
a. Primary input power not available.
a. Check for Voltage at primary input.
b. Faulty connection, primary input
b. Repair or replace cable or switch
cable, or power switch (S3) (TGS1) as necessary.
c. Blown line fuse.
c. Replace fuse. If it blows again,
contact ESAB representative.
2. No welding power.
a. Thermostat has opened.
a. Wait 15 minutes with fan running. If
still no power, contact ESAB repre-
sentative.
b. Shorted diode in main rectifier.
b. Check diodes and replace if req’d.
c. Open in wiring
c. Check all wiring.
3. Fan does not run.
a. See Weld Condition 1.
a. Repair or replace cable or switch
as necessary.
b. Malfunctioning fan motor (M1)
b. Replace fan motor (M1).
4. Erratic welding current.
a. Poor workpiece connection.
a. Check workpiece grounding
connection.
b. Loose welding connections.
b. Check all connections.
c. Wrong polarity.
c. Check for correct polarity.
5. Welding output Voltage
a. Low line Voltage.
and/or current too low.
b. Welding cables too long or too
small.
39
a. Use correct Voltage.
b. Use correct cable size.
section 5
WELD CONDITION
SERVICE
POSSIBLE CAUSEREMEDY
c. Loose connection.
c. Check all welding cable
connections.
d. Malfunctioning capacitor bank.
d. Check capacitors for low
leakage resistance.
6. Stringy irregular bead,
a. Torch moved too fast.
poor penetration.
b. Controls are not set properly for
metal gauge thickness.
c. Wrong polarity.
a. Move Torch slower along seams.
b. Reset control properly.
c. Check for correct polarity.
7. Bead not centered.
a. Nozzle not aligned.
a. Move Torch nozzle parallel to
and centered over seam.
8. Bead too large.
a. Torch moved too slowly.
a. Move Torch faster along seam.
9. Unstable arc, excess
a. Incorrectly set controls.
a. Reset controls.
spatter, weld porous.
b. Shield gas flow is too low or
b. See Condition 10.
stopped.
c. Torch nozzle is too far from work.
c. Maintain 1/4" (.6 mm) wire
protrusion; hold closer to work.
d. Faulty regulator or adapter.
d. Check flow at outlet;
replace faulty item.
e. Faulty gas solenoid valve (SOL).
e. Replace solenoid valve.
f. Wrong polarity.
f. Check polarity.
10.Shield gas flow low or
a. Cylinder valve closed.
a. Turn off regulator, slowly open
stopped valve, until regulator reaches
35 c.f.h. pressure.
b. Cylinder empty.
b. Replace if gauge so indicates.
c. Faulty regulator or adaptor.
c. Check flow at outlet; replace
faulty item.
d. Faulty gas solenoid valve.
d. Replace solenoid valve.
11.Wire stubs on work
a. Controls not set properly for
while welding. metal gauge, thickness.
a. Reset controls properly.
12.Wire burns back into
a. Contact tip loose.
a. Firmly tighten with pliers.
contact tip.
b. Tip too close to work.
b. Maintain 1/4" (.6 mm) wire
protrusion; hold Torch further
from work.
c. Wire feed slipping.
c. Increase pressure on pressure
roll by adjusting pressure knob.
d. Contact tip damaged.
d. Trim back tip 1/16" (1.6 mm) max.
Replace if still faulty.
e. Voltage setting too high.
e. Adjust setting.
f. Drive or pressure roll dirty or worn.
f. Clean rolls or replace.
40
section 5
WELD CONDITION
SERVICE
POSSIBLE CAUSEREMEDY
13.Wire does not feed; motor
a. Kink, etc. in wire, or wire bound
a. Straighten; or feed wire until
running (drive roll turns). on reel. clear and cut off.
b. Wire freezing to contact tip
b. Free freeze, or remove contact
(burnback). tip feed wire until clear cut end free,
and replace tip.
c. Clogged liner.
c. Replace liner.
14.Wire does not feed;
a. Motor
a. With wire speed dial on 10,
motor NOT running press trigger. If voltage
(drive roll does not turn). appears across motor leads
but motor does not run, check
motor gears and commutator
areas.
b.Power switch S3 and fuses.
b. With S3 ON, if voltage
across terminal 1 and 3 is 24 VAC,
switch and fuses are good.
c. Speed Potentiometer (POT).
c. Check for 1K ohms across
POT outside terminals.
d. Malfunctioning speed control board. d. Check board voltages
(Para 5.3.1 b. and c.)
15.Wire feed does not stop.
a. Torch trigger switch.
a. Check continuity of Torch trigger
circuit; check to see if trigger lever
is stuck in “ON” position.
b. Malfunctioning relay (K3).
b. Check for proper action.
16.Gas continues to flow
a. Gas solenoid valve stuck open.
a. Tap solenoid or click on and off
after trigger release. to clear valve.
41
NOTE:
D-32860-D
42
Figure 5.1 - Schematic Migmaster 250 for 208/230 V. Model
Recent modifications to the power source may not be reflected in this schematic. For up-to-date information on your model, refer to the schematic on the inside cover of the power
source or contact the factory.
D-33310-C
NOTE:
43
6 - 7
1 - 2
6 - 7
3 - 7
2 - 6
2 - 6
4 - 8
2 - 3
575
4 - 8
460
7 - 8
400
4 - 8
380
5 - 8
230
7 - 8
FLEX
2
FLEX
2
FLEX
2
FLEX
2
FLEX
1
1
FLEX
1
1
NO. OF
STRIPS
Recent modifications to the power source may not be reflected in this schematic. For up-to-date information on your model, refer to the schematic on the inside cover of the power source or contact the
factory.
Figure 5.2 - Schematic Migmaster 250 for 208/230/380/400/460/575 V. Model
1 - 2
208
PRIMARY VOLTAGE
CONNECTION CHART
VOLTAGE
CONNECTION
D-32861-F
44
Figure 5.3 - Wiring Migmaster 250 for 208/230 V. Model
D-33311-D
45
Figure 5.4 - Wiring Migmaster 250 for 208/230/380/400/460/575 V. Model
section 5
SERVICE
46
section 6
REPLACEMENT PARTS
6.0Replacement Parts
6.1General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
6.2Ordering
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
Note
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
47
section 6
REPLACEMENT PARTS
11, 12
27
32, 34
6
33
7
21, 22, 23
8
13,14
5
15
18, 19
(Red Plug behind
Item 28)
10
2
25
16, 17
30
26
20
3, 29
24
28
31
FIGURE 6.1 MIGMASTER 250 SYSTEMS
48
section 6
REPLACEMENT PARTS
ITEM QTY
PARTCKT.
NO.REQ.NO.
DESCRIPTION (Figure 6.1)
DESIG.
2
3
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
1
1
2
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
33188YL
950769•
1373 0623
33192M
33291YL
33189M
33187YL
2360 3918
950584
32818
2062171
647233
2062171
32902
951069
680552
950721
21165
952924
2361 2350
2361 0696
2361 0528
23612590
33190
82F31
13730912
1
4
2
1
13735895
64304275
99510614
951574
26
2
950396
27
1
951672
950695
28
1
0558001651
1
0558001652
29
1
13732313
30
1
31
1
34886
32
1
2091514
33
1
13734588
34
1
13736753
PANEL, SIDE, RIGHT
STRAIN, RELIEF, BUSHING
LATCH, DOOR
PLATE, BLANK COVER*
COVER, HINGED
PANEL, CONTROL, SILKSCREENED
PANEL, SIDE, LEFT
POTENTIOMETER, 1K, WIRE SPEED CTRL, 2W
KNOB
SWITCH, FINE VOLTS ADJ., 8 POS.
KNOB
RECEPTACLE, 8 PIN
KNOB w/ SET SCREW
SWITCH, COARSE VOLTS ADJ., 3 POS, HI-MED-LO
PLUG, PLASTIC "C" SIZE (RED)
ADAPTOR, POWER & GAS (SPOOL GUN)
SWITCH, TOGGLE, (ON/OFF)
GUIDE TUBE OUTLET (035/045) (fits into conn. tube, 6" lg)
TORCH ADAPTOR ASSY. includes:
POWER LUG
ADAPTOR BLOCK ASSY (fem trigger pins/gas hose/2 wires)
HOUSING, GUN ADAPTOR (STRAIGHT) - molded blk plast
CONNECTION TUBE, 4" LG BRASS
BUSBAR, COPPER
WORK CLAMP
WHEEL
NOT SHOWN
AXLE
WASHERS
COTTER PINS
CYLINDER CHAIN
CASTER, SWIVELS 5"
HANDLE (From (1/1/94)
HANDLE (Before 1/94)
GUNMASTER 250cc 12'
GUNMASTER 250cc 15'
BUSHING
SET SCREW
CABLE AND CLAMP
WARNING LABEL
LABEL
WELD PARAMETER LABEL
* Photo shows optional Digital Volt/Ammeter Module, P/N 32857, and Spot/Stitch/Anti-Stick Control Module, P/N 32858.
• Was 97W63, changed to 950769, 6/95.
49
R1
S1
J3
S2
S3
section 6
REPLACEMENT PARTS
19,20
35
36
7
18
17
14
15,16
34
24
21
12
28
33
27
FAN ASSEMBLY
See Figure 6.4
26
1
31
30
4
5,25
6
22,23
8
29
FIGURE 6.2 MiGMASTER 250 Main Assembly (Left Side)
50
32
section 6
REPLACEMENT PARTS
ITEM QTY.
PARTCKT.
NO.REQ.NO.
DESCRIPTION (Figure 6.2)
DESIG.
1
1
33184M
4
1
672225
5
1
1373 6750
1
33176
6
1
951634
1373 0628
7
1
951633
2360 6726
8
7
1373 2230
12
3
1373 0222
14
1
31484
15
1
2360 8111
16
1
1373 5940
17
2
950760
2361 0322
18
1
1373 0469
19
1
952173
BASE
INSULATOR STANDOFF
TRANSFORMER, MAIN - for 208/230 v. model
TRANSFORMER, MAIN - for 208-575 v. model
VALVE, SOLENOID, 24 V(from 1/1/94)
VALVE, SOLENOID 24 V (before 1/94)
CONNECTOR, "Y" from 1/1/94)
HOSE CONNECTION (before 1/94)
CAPACITOR 10,000 MT, 50V & screws #10-32
BUSHING
P.C. BOARD, SPEED CONTROL
TERMINAL BLOCK, 8 PT 230 V
MARKER, TERMINAL
RELAY (from 1/1/94 to present)
*suggest 0558007736 3dpt 24 vac 10A
RELAY, 4 PDT, 24 VAC, 10A (prior to 1/1/94)
KUP 11A55-24
KUP 17A55-24
BRIDGE, RECTIFIER
CONTACTOR 60 amp 24V coil
T1
T1
SOL1
C 1-7
PCB1
TB1
K2, K3
BR1
K1
------------------------------------------------------HISTORY------------------------------------------
2
0558001290
CONTACTOR 60 amp E Busbar
952173
CONTACTOR FURNAS 42EF35A3L 2 7/8 x 3 11/16
2
13730665
CONTACTOR 40 amp E Busbar
13734781
CONTACTOR FURNAS 42CF35A3L 2 1/4 x 2.90
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
2
1
1
3
1
1
1
1
1
1
AR
1
1
2
1
1
1
1
1
0558001290
9951 2178
2360 9967
674216
1373 5289
1373 1989
951649
13736733
90862175
33818
2132496
13731597
31563
23610005
950253
13736749
13731780
13736752
33817
BUSBAR “E” STAMPING
RESISTOR, 50 OHM, 50W
TERMINAL, 3 POS
CAPICATOR .02uf 1KV
RESISTOR 1 OHM 25W
THERMOSTAT 145°
POWERCORD
HEATSHRINK RECTIFIER
3/4" HEATSHRINK TUBING
BUSBAR (9.94")
INSULATION (sold by FT)
SLOPE RESISTOR (2 pcs per side)
SHUNT
END BOARD
BRACKET
BUSBAR (13")
P/C CONN TO PCB1
COMPLETE HARNESS
BUSBAR (16")
R3
TB3
C9-11
R5
TS1
Capacitor C9-11 and R5 resistor were added 4/93 (starting with Serial No. B93H36548) to provide greater relay protection.
51
section 6
REPLACEMENT PARTS
work cable
6,7
19
5
18
3
11
2
1
gas hose
14
9,10
21
20
18" 2 AWG
w/
1/2" stud
3/8" stud
16
22
23
FIGURE 6.3 MiGMASTER 250 Main Assembly (Right Side)
52
section 6
REPLACEMENT PARTS
ITEM QTY
PARTCKT.
NO.REQ.NO.
DESCRIPTION (Figure 6.3)
DESIG.
1
1
2
1
3
1
5
1
6
1
7
1
9
1
10
1
11
1
14
1
15
1
16
1
17
1
18
1
19
2
20*
1
21 8' or 10'
1
1
1
22
6
23
1
1
33186M
2360 5057GY
2360 6237
634519
+ - 1373 5464
634709
2361 2348
+ - 2361 2479
33199M
952939
82F31
+ - 1373 2232
951649
1373 0583
676701
97W63
95195024
11N22
136Z08
950731
13732230
13736738
13736739
REAR, PANEL
SUPPORT, REEL
HUB, REEL (See Figure 6.5)
SWITCH, TOGGLE, 4 PDT
FUSE, 10A, TIME DELAY
HOLDER, FUSE
24V GEAR MOTOR, 50-675 IPM KSV 4030/182
KEY, MOTOR SHAFT COVER P.C. BOARD
DRIVE STAND ASSEM. (See Fig. 6.6)
WORK CLAMP
FILTER, CHOKE / INDUCTOR
POWERCORD
BUSHING, TERMINAL
TERMINAL ASS'Y., OUTPUT
STRAIN RELIEF
GAS HOSE
NIPPLE
NUT 5/8-18M RH
CLAMP
CAPACITORS
COPPER BUSBAR CAPACITOR STRAPS (+)
COPPER BUSBAR CAPACITOR STRAPS (-)
+ - DENOTES RECOMMENDED ON HAND SPARE PART
* - Added "D" Edition, 3/96
53
S4
F1
L1
TP
section 6
REPLACEMENT PARTS
15
5
6
4, 3
2
11,10, 9
2
14
12
6
13
FIGURE 6.4 MIGMASTER 250 FAN & CAPACITOR BANK
ITEM
QTY.
PARTCKT.
NO.REQ.NO.
DESCRIPTION (Detail "B" FAN)
DESIG.
2
3
4
5
6
9
10
11
12
13
14
15
2
4
4
2
2
1
1
1
1
2
1
1
99511916
1373 0680
1373 0681
1373 1597
1373 0378
951939
1373 2226
63311886
13736737
13736733
672225
23610005
DIODE, SILICON, STRAIGHT POLARITY
INSULATOR, COLLAR
INSULATOR, SHOULDER
WELDMENT, RESISTOR
DIODE, SILICON, REVERSE POLARITY
BLADE, FAN
MOTOR, FAN
HEX NUT 8-32
FAN BRKT (torque 19 lbs. max)
HEATSHRINK RECTIFIER
STANDOFF
RECTIFIER END BOARD
54
D1, D2
D3, D4
M1
section 6
REPLACEMENT PARTS
REF.
9
8
7
6 5
4
3
1
2
FIGURE 6.5a MIGMASTER 250 LEXAN HUB KIT (OBSOLETE)
ITEM
QTY.
PARTCKT.
NO.REQ.NO.
DESCRIPTION (HUB KIT)
DESIG.
2360 5780
REEL HUB KIT (INCLUDES 1-8)
1
2
2360 0255
BRAKE, DISC
2
1
2360 6237
HUB, REEL
3
1
2360 0982
SPRING
4
1
2360 0010
NUT, PLASTIC (OBSOLETE - USE NEW ASSY)
5
1
9204 0101
SCREW, R.H.M., 3/8-16 x .75
6
1
9205 6007
WASHER, PLAIN
7
1
2360 0952
WASHER, "D"
8
1
2360 5057GY
SUPPORT, REEL
9
1
SHELF (REF.)
REPLACEMENT PARTS:
0558005764
SPINDLE REPLACEMENT KIT
23600982
SPRING (USE EXISTING)
64304125
3/8" FLAT WSR
92044046
3/8" - 16 X 1" RH SCREW
55
section 6
REPLACEMENT PARTS
5
6, 7
4
9
10
8
11
2, 3
1
12
13
14
FIGURE 6.5b MIGMASTER 250 LEXAN HUB KIT
ITEM
QTY.
PARTCKT.
NO.REQ.NO.
DESCRIPTION (HUB KIT)
DESIG.
1
1
0558002993
D-Shaft, Wirefeeder, 5.75L
2
AR
61341133
Screw, HC, .375-16 x 1.00
3
AR
64302037
Washer, Lock, .375
4
1
0558002992
Bracket, Spool Support
5
1
33191M
Shelf, Silkscreened
6
AR
63300916
Nut, Hex, 10-24
7
AR
64302920
Washer, Lock, #8
8
2
948255
Pad, Braking
*
9
1
2360 0982
Spring
10
1
Pin, Hitch Clip
* 634347
11
1
8948258
Hub,
Reel
*
12
1
92044046
Screw, 10001 Stl ZPC, .375-16 x 1.00
13
1
64304125
Washer, 53001, Stl ZPC, .375
14
1
0558003320
Washer, D-Type
*
0558005764
SPINDLE REPLACEMENT KIT
Spindle Replacement Kit includes *items, order other items separately
56
addendum
section
history
57
2-Roll (Driven Upper) Drive Stand (original to mid-1999)
*1
20
*21
7
8
10
6
*4
*2
2
4
*8
*7
*3
5
*6,10
*21
9
19
18
14
*14
*18
12
11
*13,16
13,16
15
*12
* Items shown in exploded view for clarity.
ITEM
QTY.
PART
NO.REQ.NO.
DESCRIPTION
2 ROLL GEARED WIRE DRIVE SYSTEM, CONSISTS OF:
PRESSURE ARM ASSY., (incls. 2, 3, 4, 7, 8)
AXLE, PRESSURE
PRESSURE ARM
CIRCLIP, PRESSURE ROLL
PIVOT PIN
CIRCLIP
PRESSURE ROLL, SMOOTH (see Table 2.1) - has 2 holes for pins
GEARED ADAPTOR, PRESSURE ROLL - has pins
PRESSURE DEVICE ASSY.
LOCATING PIN
INLET GUIDE - w/ red plastic tube
DRIVE ROLL, (see Table 2.1)
GEARED ADAPTOR DRIVE ROLL - no pins
FEED ROLL RETAINING SCREW
FEED PLATE
FEED ROLL KEY
MOTOR SHAFT SNAP RING (Not Shown)
LOCATING SCREW m4 x 16 (952926)
SCREW, MOTOR MOUNTING
SPACER TUBE (Pressure Arm)
SPRING PRESSURE ARM
GEARED ADAPTOR w/ PINS - used w/ Drivestand 0558001796
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
2
9
1
10
1
11
1
12
1
13
1
14
1
15
1
16
1
17
1
18
2
19
3
20
1
21
1
22
1
0558001796
23612626
23612387
23612475
23612385
23612470
23612472
23612397
0459441880
23612460
23612473
23612461
21156
23612383
23612398
23612478
23612479
23612480
23612384
23612462
23612662
23612663
952985
58
2-Roll (Undriven Upper) Drive Stand (mid-1999 to mid-2000)
21
20
10
1 (Includes, 2,3,4,7,8)
*3
2
6
9
*7,8
*2,4
3
5
*10,6
7
4
*20
*21
8
* Items shown in exploded view for clarity.
11
18
*12
*14
17
*13
13
14
*17
12
hand tighten only !
19
ITEM
QTY.
PART
NO.REQ.NO.
DESCRIPTION
2 ROLL WIRE DRIVE SYSTEM, CONSISTS OF:
PRESSURE ARM ASSY., (incls. 2, 3, 4, 7, 8)
AXLE, PRESSURE
PRESSURE ARM
AXLE NUT
PIVOT PIN
CIRCLIP
PRESSURE ROLL, SMOOTH (see Table 2.1) - no pin holes
SPACER
PRESSURE DEVICE ASSY.
LOCATING PIN
INLET GUIDE
DRIVE ROLL, (see Table 2.1)
ADAPTOR DRIVE ROLL
FEED ROLL THUMB SCREW
FEED PLATE
WASHER RETAINING SCREW
FEED ROLL SPACER
THUMB SCREW M6X16
SCREW, MOTOR MOUNTING
SPACER TUBE (Pressure Arm)
SPRING PRESSURE ARM
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
2
9
1
10
1
11
1
12
1
13
1
14
1
15
1
16
1
17
1
18
2
19
3
20
1
21
1
952939
952704
23612477
23612475
23612474
23612470
23612472
23612368
23612476
23612460
23612473
23612461
21156
952944
952925
23612478
34608
952945
952926
23612462
23612662
23612663
59
15
2-Roll (Gear Driven) Tool-Free Drive Stand (mid-2000 to present)
*1
18
19
7
8
10
*7
*3
6
*8
*4
*2
5
2
*6,10
*19
4
9
12
17
*14
14
11
13
*13,16
16
*16
* Items shown in exploded view for clarity.
ITEM
QTY.
PART
NO.REQ.NO.
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
1
10
1
11
1
12
1
13
1
14
1
15
1
16
1
17
2
18
1
19
1
20
3
21
1
0558001796
23612626
23612387
23612475
23612385
23612470
23612472
23612397
23612386
23612460
23612473
23612461
21156
952985
952925
23612478
952945
952926
23612662
23612663
23612462
36880
15
*12
21
20
DESCRIPTION
2 ROLL GEARED WIRE DRIVE SYSTEM, CONSISTS OF:
PRESSURE ARM ASSY., (incls. 2, 3, 4, 7, 8)
AXLE, PRESSURE
PRESSURE ARM
CIRCLIP, PRESSURE ROLL
PIVOT PIN
CIRCLIP
PRESSURE ROLL, SMOOTH
GEARED ADAPTOR, PRESSURE ROLL
PRESSURE DEVICE ASSY.
LOCATING PIN
INLET GUIDE
DRIVE ROLL, .035" / .045" (see Table 2.4 & 5.2)
GEARED ADAPTOR DRIVE ROLL
FEED ROLL THUMB SCREW
FEED PLATE
CONE WASHER, FEED ROLL
THUMB SCREW M6X16
SPACER TUBE (Pressure Arm)
SPRING PRESSURE ARM
SCREW, MOTOR MOUNTING
SAFETY GUARD KIT
60
notes
61
notes
62
revision history
The "G" edition (6/99) of this manual covers the following:
1.
2.
3.
4.
5.
6. Added contact tips modified for improved arc performance on steel and cored wires in Table 2.4.5.1.
Added end drive roll/pressure roll combinations for use with soft cored wires in Table 2.4.5.2.
Added optional spool spacers for 8" and 10" dia. spools
Added the torch adaptor assy and copper busbar (33190) in the torch connection circuit to the replacement
parts list of Figure 6.2.
Changed the drive stand from 23612627 to 952939.
Added parts call out Figure 6-7. for drive stand with driven upper pressure roll (23612627).
The "H" edition (12/00) of this manual covers the following:
1.
2.
3.
4.
Renamed MT-200CC to GUNMASTER 250 throughout the manual.
Added GUNMASTER 250 to the parts lists.
Corrected Torch and Cable call out in Section 4 (Operation) diagram on page 16.
Made various text corrections.
The "J" edition (04/03) of this manual covers the following: Updated replacement parts section. Added new Hub Kit assembly. Changed color code of some items to metallic black.
The "J" edition (07/03) of this manual covers the following:Updated the photos on pages 15, 23, 42 and the cover page to
show the black front panels of the machine.
The "K" edition (08/03) of this manual covers the following: Updated Figure 6.5a and item listing to show quantity of 2 for
Item #1.
The "L" edition (09/03) of this manual covers the following: Updated Gunmaster 250 torch information on liners, nozzles
and tips on Pages 13 and 14 by replacing it with updated information from Gunmaster 250 torch manual F15612-D.
The "M" edition (12/03) of this manual covers the following: Updated part number 26 on Page 42 from 959396 to 950396.
The "N" edition (05/04) of this manual covers the following: Updated part number on Page 42 from 952929 to 23612590.
The "P" edition (03/08) of this manual makes many changes per B. Bitzky/ E. Shumate.
63
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A.
CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548
Hours: 8:00 AM to 7:00 PM EST
Order Entry
Product Availability
Pricing Order Information Returns
B.
ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C.
TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Specifications
Hours: 8:00 AM to 5:00 PM EST
Equipment Recommendations
D.
LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 7:30 AM to 4:00 PM EST
E.
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status
Hours: 7:30 AM to 3:30 PM EST
F.
WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
G.
WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H.
TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
F15-087-P
03/2008
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