MigMaster 250
Welding Package
Instruction Manual
F15-087-M
12 / 2003
BE SURE THIS INFORMATION REACHES THE OPERATOR
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.
Copies of this manual can be obtained by any of the following;
Contacting your local ESAB supplier.
Downloading a copy from the ESAB web site at
www.esabna.com
Sending a written request to
ESAB WELDING & CUTTING PRODUCTS
ATTN: LITERATURE DEPT.
411 S EBENEZER ROAD
FLORENCE SC 29501
2
TABLE OF CONTENTS
SECTION NO.
PAGE NO.
SECTION 1 - SAFETY PRECAUTIONS FOR WELDING
AND CUTTING ........................................................................................................... 3
SECTION II - 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 III - 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 IV - OPERATION ................................................................................................ 23
4.1
4.2
4.3
CONTROLS ............................................................................................................................. 23
PROCESS SETUP .................................................................................................................. 24
OPERATING PROCEDURES .................................................................................................. 27
SECTION V - SERVICE ...................................................................................................... 31
5.1
5.2
5.3
MAINTENANCE ........................................................................................................................ 31
INSPECTION AND SERVICE .................................................................................................. 31
TROUBLESHOOTING ............................................................................................................. 32
SECTION VI - PARTS ......................................................................................................... 41
6.1
6.2
6.3
SPARE PARTS ........................................................................................................................ 41
REPLACEMENT PARTS .......................................................................................................... 41
ORDERING .............................................................................................................................. 41
3
TABLE OF CONTENTS
4
SECTION 1
SAFETY PRECAUTIONS
5. Do not use equipment 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, Batterymarch Park, Quincy, MA 02269.
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.
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 equipment is essential to prevent accidents. Therefore:
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.
1. Be sure the power source frame (chassis) is connected to
the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
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.
9. Turn off the power before removing your gloves.
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.
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.
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:
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
workpiece has been completely cleaned so that there are
no substances on the workpiece which might produce
flammable or toxic vapors. Do not do hot work on closed
containers. They may explode.
4. Have fire extinguishing equipment 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.
1. Welders having pacemakers should consult their physician
before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
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.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
5
SECTION 1
SAFETY PRECAUTIONS
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
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.
Therefore:
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.
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.
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.
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.
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.
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.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
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.)
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.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:
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"
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."
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, valve, or relief device can injure or
kill. Therefore:
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.
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.
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.
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.
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.
6
SECTION 1
PRECAUCION 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.
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:
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.
1. Utilice gafas de seguridad con protección a los lados siempre
1. Asegúrese de que el chasis de la fuente de poder esté conectado
que esté en el área de trabajo, aún cuando esté usando careta
de soldar, protector para su cara u otro tipo de protección.
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.
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.
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.
Proteja a otras personas de los rayos del arco y chispas
calientes con una cortina adecuada no-flamable como división.
Use careta protectora además de sus gafas de seguridad
cuando esté removiendo escoria o puliendo. La escoria puede
estar caliente y desprenderse con velocidad. Personas cercanas
deberán usar gafas de seguridad y careta protectora.
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.
ADVERTENCIA: Estas Precauciones de Seguridad
2.
3.
4.
5.
6.
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:
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:
2.
3.
4.
5.
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.
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.
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.
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.
No use el equipo fuera de su rango de operación. Por ejemplo,
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.
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.
7
SECTION 1
PRECAUCION DE SEGURIDAD
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:
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede causar
daño o muerte. Por lo tanto:
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.
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.
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.)
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.
Las siguientes publicaciones, disponibles através de la
American Welding Society, 550 N.W. LeJuene Road, Miami,
FL 33126, son recomendadas para usted:
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"
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."
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.
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.
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.
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
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.
8
SECTION 1
AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1.
a.
b.
c.
d.
e.
f.
2
PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles résultant
d’une exposition prolongée au soleil. Aussi convientil d’observer les précautions suivantes:
Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les
oreilles des étincelles et du rayonnement de l’arc
électrique lorsque vous effectuez des soudures ou
des coupes ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.
Les étincelles ou les projections de métal incandescent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.
Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.
Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent provoquer
de graves incendies au contact de matériaux combustibles solides, liquides ou gazeux. Aussi faut-il
PRÉCAUTIONS DE SÉCURITÉ
observer les précautions suivantes:
a. Éloigner suffisamment tous les matériaux combustibles
du secteur où l’on exécute des soudures ou des coupes
à l’arc, à moins de les recouvrir complètement d’une
bâche non-inflammable. Ce type de matériaux comprend
notamment le bois, les vêtements, la sciure, l’essence,
le kérosène, les peintures, les solvants, le gaz naturel,
l’acétylène, le propane et autres substances combustibles semblables.
b. Les étincelles ou les projections de métal incandescent
peuvent tomber dans des fissures du plancher ou dans
des ouvertures des murs et y déclencher une ignition
lente cachée. Veiller à protéger ces ouvertures des
étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface de
barils, bidons, réservoirs ou autres contenants usagés,
avant de les avoir nettoyés de toute trace de substance
susceptible de produire des vapeurs inflammables ou
toxiques.
d. En vue d’assurer la prévention des incendies, il convient
de disposer d’un matériel d’extinction prêt à servir
immédiatement, tel qu’un tuyau d’arrosage, un seau à
eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur de
façon à vous assurer qu’aucune étincelle ou projection
de métal incandescent ne risque de provoquer
ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc au
plasma exige l’emploi de tensions à vide relativement
importantes; or, celles-ci risquent de causer des
dommages corporels graves et même mortels en cas
d’utilisation inadéquate. La gravité du choc électrique
reçu dépend du chemin suivi par le courant à travers le
corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous tension
venir au contact direct de la peau ou de vêtements
humides. Veillez à porter des gants bien secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assu-rer
votre isolation corporelle en portant des gants secs et
des chaussures à semelles de caoutchouc et en vous
tenant sur une planche ou une plate-forme sèche.
c. Mettez toujours à la terre le poste de soudage/coupage
en le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un danger
d’incendie. Ne pas enrouler ou passer le câble autour
d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce en
un point aussi proche que possible de la zone de travail.
Le branchement des câbles de masse à l’ossature du
bâtiment ou en un point éloigné de la zone de travail
augmente en effet le risque de passage d’un courant de
sortie par des chaînes de
9
SECTION 1
g.
4.
a.
b.
c.
d.
e.
f.
5.
PRÉCAUTIONS DE SÉCURITÉ
qualité mais, chose plus grave encore, d’entraîner des
dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qualifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien quelconque
à l’intérieur du poste de soudage/coupage, avant
d’avoir débranché l’alimentation électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et
des équipements accessoires. Gardez-les à l’écart
des sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri
des traces d’huile ou de graisse, des atmosphères
corrosives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de l’armoire de commande en
veillant à les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément
à son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ-Pour obtenir des informations complémentaires sur
les règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc
Cutting” AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc
Welding” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting” CSA-Standard
W117. 2.
levage, des câbles de grue ou divers chemins
électriques.
Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.
VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.
Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.
Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande
est munie d’un ventilateur destiné à empêcher la
formation de poches d’hydrogène, lesquelles
présentent un danger d’explosion; ce ventilateur ne
fonctionne que si l’interrupteur correspondant du
panneau avant se trouve placé en position ON
(Marche). Veillez à manœuvrer cette commande en
vérifiant si le couvercle est bien en place, de façon à
assurer l’efficacité de la ventilation ainsi réalisée. Ne
jamais débrancher le ventilateur.
Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’éliminer du voisinage de l’opérateur tout dégagement de
fumée visible.
Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
10
SECTION 2
II. INTRODUCTION
2.1
GENERAL
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.
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.
When requesting information concerning this equipment,
it is essential that Part, Serial and Model Numbers of the
equipment be supplied.
2.3
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-ongun control.
2.3.1
AVAILABLE PACKAGES AND CONTENTS
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
The following Migmaster 250 packages are available
with CO2 Regulator:
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
INTRODUCTION
Depending on the primary input voltage of the MM-250,
and the torch length, each package includes the following:
z 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:
-- Migmaster 250 for 208/230-Volt input .... P/N 32851
-- Migmaster 250 for 208/230/380/400/460/575-Volt
input ....................................................... P/N 32852
z 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
-- 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
CO2 Kits are the same as 12-ft. Pkg. except Regulator is
R-33-FM-320. P/N 21558.
2.3.2
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.
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 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.
11
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
Feed Rate
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)
20-650 IPM
GUNMASTER 250 TORCH
Cooling
Gooseneck Angle
Rated 60% Duty Cycle
(DCRP) Amps:
Conduit Length
Air
45 degrees
200 w/Argon Mixtures, 300 w/CO
see section 2.3.1
2
PHYSICAL
Net Weight
Height
Width
Depth
*210 lbs (95 Kg.)
*32.25 inches (819 mm)
*19.5 inches (495 mm)
*40.0 inches (1016 mm)
*Includes running gear & bottle tray.
2.3.4
2.3.6
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.
GUNMASTER 250 WELDING TORCH
(F15-612)
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.
2.3.5
RUNNING GEAR
2.4
2.4.1
OPTIONAL ACCESSORIES
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.
CONTROLS
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 builtin spool-on-gun adaptors and control, when used in
conjunction with the optional ST-23A torch, permits aluminum wire welding with the machine.
12
SECTION 2
INTRODUCTION
If a Spotwelding operation is to be used, it is recommended that you also order a #12S Spotweld Nozzle,
P/N 999625.
2.4.2
DIGITAL VOLT/AMMETER MODULE,
P/N 32857.
This easy-to-install, plug-in module mounts in place of
the top blank cover plate of the upper-right front panel
location in the 250 unit. This unique meter module
alternately displays welding voltage and current (of the
dial-set welding condition) every 4-seconds. Two L.E.D.’s
labeled Amps and Volts provided below the meter windows, alternately illuminate to indicate which condition is
being displayed. The voltage indication is displayed in
1/10-volt increments (e.g.: 20.5), while the current indication is usually displayed in three-whole digits (e.g.:
225). After the torch trigger is released, the meter will
continue to flash for 20-seconds the last condition used
during welding. At the end of this time, the meter will
reset to zero. For installation see Section 3.10.
2.4.3
ST-23A SPOOL-ON-GUN TORCH, P/N 19164
(see F-14-353).
The Migmaster 250 unit is equipped 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
spool-on-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 is equipped with (30) foot lines. For
installation and operation, see Section 4.2.2.
MT-250SG Spool-On-Gun ........................... P/N 36779
(Requires Adapter, P/N 36833) See F-15-380.
2.4.4
TORCH NOZZLES - See table below:
Nozzles
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.
13
SECTION 2
2.4.5
INTRODUCTION
TORCH / WIRE FEED ACCESSORIES
See following tables:
2.4.6 SPOOL SPACER
For 8" dia. spools ...................................... P/N 17511
For 10" dia. spools .................................... P/N 34330
TIPS
2.5
Standard Duty Tips
20543 ........... .023 Standard Duty Tip
20544 ........... .030 Standard Duty Tip
996995 ........... .035 Standard Duty Tip
37290 ........... .045 Standard Duty Tip
996999 ........... 3/64 (Alum.) Standard Duty Tip
2075349 ........... .052 Standard Duty Tip
996997 ........... 1/16 Standard Duty Tip
2075230 ........... 5/64 Standard Duty Tip
SAFETY
Before the equipment is put into operation, the safety
section at the front of this manual should be read completely. This will help avoid possible injury due to misuse
or improper welding applications.
The symbol
which precedes safety notes appearing throughout this manual means “Attention! Be Alert!
Your safety is involved.” The definitions relating to the
DANGER, WARNING and CAUTION safety notations are
described at the end of the Safety Section in the front of
this manual -- read them and their specific text references
carefully.
Heavy Duty Tips
0558002367 ..........
0558002368 ..........
0558002369 ..........
37286 ...........
17765 ...........
17778 ...........
37291 ...........
948835 ...........
948832 ...........
948833 ...........
.030 Heavy Duty Tip
.035 Heavy Duty Tip
.040 Heavy Duty Tip
.045 Heavy Duty Tip
3/64 (Alum.) Heavy Duty Tip
.052 Heavy Duty Tip
1/16 Heavy Duty Tip (Hard or Cored Wire)
1/16 (Alum.) Heavy Duty Tip
5/64 Heavy Duty Tip
3/32 Heavy Duty Tip
Drive Roll & Guide Tube Selection
Wire Type /
Diameter
Lower
Drive Roll
Upper
Pressure
Roll
Guide
Tube
21163
Hard Wires (“V” groove)
Liner Selection
Steel & Flux Core
0558001675
37031
0558002137
37032
37033
0558002138
0558001676
0558002139
37034
0558002140
952948
........
........
........
........
........
........
........
........
........
........
........
.023 x 10,12,15' Liner*
.030 x 10,12,15' Liner*
.045 x 25' Liner
.035-.045 x 10,12,15' Liner*
.045-.052-1/16 x 10,12,15' Liner*
.052-1/16 x 25' Liner
5/64 x 10,12,15' Liner*
5/64 x 25' Liner
3/32 x 10,12,15' Liner*
3/32 x 25' Liner
7/64-1/8 x 10,12,15' Liner*
Aluminum
.023 in. (0.6mm)
21155
23612397
.030 in. (0.8mm)
21155
23612397
21164
.035 in. (0.9mm)*
21156
23612397
21165
.040 in. (1.0mm)*
21156
23612397
21165
.045 in. (1.2mm)*
21156
23612397
21165
Soft (aluminum) Wires (“U” groove)
.035 in. (0.9mm)
3/64 in. (1.2mm)
.030 in. (0.8mm)
.035 in. (0.9mm)
.040 in. (1.0mm)
.045 in. (1.2mm)
.052 in. (1.4mm)
1/16 in. (1.6mm)
1/16 in. (1.6mm)
*
**
†
14
21167**
21168**
21160
21160
21161
21161
21161
21161
23612369
23612369
23612369
23612369
23612369
23612369
21164
21165
21165
21165
21166
21166
Cored Wires (Serrated “V” groove - upper and lower)†
.045 in. (1.2mm)
*NOTE: Liner supplied 15' — must be trimmed to fit.
** Requires Jumper Liner Sleeve 0558003050
23612397
23612397
Cored Wires (Serrated “V” groove - lower)
r .052 in. (1.4mm)
37039** ........ .035-3/64 x 15' Poly Liner
37040** ........ 3/64-1/16 x 15' Poly Liner
21158
21159
37319
37319
37320
37319
37319
37320
21165
21166
21166
Supplied with Migmaster 250.
Requires Support Tube 21169.
Recommended for use with soft cored wires that are easy to
flatten.
SECTION 3
III.
INSTALLATION
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.
Do not operate the machine without the running gear
installed.
3.2
ELECTRICAL INPUT CONNECTIONS
19.50"
Figure 3.1 Dimensional Drawing
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 others
that the circuit is being worked on. If the plug-cap is
used, (see 3.2B) remove plug from receptacle.
3.2.1
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.)
40.00"
Input Electrical Requirements
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.
15
SECTION 3
3.2.2
INSTALLATION
TABLE 3.1 Input Conductor and Fuse Size
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.
Full
Primary Load
Input
Line
Fuse
Volts Amperes Size
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.
208
230
380
400
460
575
Figure 3.2A illustrates wiring to a single phase system
and Figure 3.2B illustrates wiring to a three phase
system.
71
62
37
36
31
25
Recommended
Primary
Input
Ground
Conductor Conductor
Size
Size
90
90
50
50
40
30
8
8
10
10
12
12
8
8
10
10
12
12
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 reconnection is necessary, the following paragraphs cover
the procedure to switch the voltage tap for either 208vac
or 230vac input.
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 "multivoltage" units).
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.
208/230/380/400/460/575-V. MODELS
208/230 MODEL ONLY (With Plug-Cap)
THREE-PHASE
SINGLE-PHASE
Fused GRD
Line
Disconnect
Switch,
or
Circuit Breaker
GRD
Wall Receptacle
Figure 3.2 A
MIGMASTER
SYSTEM
CONNECTS HERE
Figure 3.2 B
GRD
GRD
GREEN
GREEN
CONDUCTOR
(GROUND)
Figure 3.2 C
Figure 3.2 - Primary Connection
16
THREE-PHASE
SINGLE-PHASE
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.
Figure 3.3A - Primary Reconnections at Switch
For 208/230 Volt Models
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.
Fig. 3.3B - Position of Alternate Voltage Tap
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.
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
Fig. 3.3C - Power Switch Connection
17
SECTION 3
INSTALLATION
3.2.5
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.
RECONNECTING FROM 575 VAC INPUT
Figure 3.3.1 shows you how to reconnect the "multivoltage" 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.
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.
3.3 SECONDARY OUTPUT CONNECTIONS
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.
3.4 TORCH CONNECTIONS
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.
PRIMARY VOLTAGE CONNECTION CHART
VOLTAGE
208
230
380
400
460
575
CONNECTION
NO. OF STRIPS
1-2
1
6-7
1
7-8
FLEX
1-2
1
6-7
1
5-8
FLEX
3-7
2
4-8
FLEX
2-6
2
7-8
FLEX
2-6
2
4-8
FLEX
2-3
2
4-8
FLEX
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.
Figure 3.3.1-Primary Reconnections at Voltage
Changeover Terminal Board for 208/230/380/400/460/
575Volt Models
C. Reverse the drive roll on the drive roll shaft.
D. Replace the screws and tighten.
E. Secure the pressure drive roll assembly.
18
SECTION 3
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.
INSTALLATION
3.5.4 BRAKE DRAG ADJUSTMENT
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.
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:
Install a spool of welding wire on the hub as follows:
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.
3.5.3
Do Not adapt R-33-FM-580 for use with CO2. Relief
device may rupture if CO2 is used with the R-33-FM580. For CO2 service, order R-33-FM-320, P/N 21558.
THREADING WELDING WIRE
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 accumulated 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.
A. Turn off power switch.
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.
CYLINDER
VALVE
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).
CYLINDER
PRESSURE
GAUGE
OUTLET
CONNECTION
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.
f. Attach the gas hose from the rear of the Migmaster
250 to the regulator outlet connection (see Fig. 3.6).
D. Lower pressure roll assembly and secure. Check
that the gears mesh. Feed wire through to gun tip
with gun trigger (power ON).
g. Slowly open the cylinder valve a fraction of a turn.
When the regulator pressure gauge pointer stops
moving, open the cylinder valve fully.
Fig. 3.6 R-33-FM-580 Regulator (Illustrated)
19
SECTION 3
INSTALLATION
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.
Never stand directly in front of or behind the regulator when opening the cylinder valve. Always stand to
one side.
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.
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
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 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:
a. Close the cylinder valve.
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.
j.
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.
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.
c. Remove the existing shipping supports by unscrewing from chassis.
3.9
k. Regulators in need of repair should be returned to
your Welding Equipment distributor or to an authorized Remanufacturing Center.
INSTALLING OPTIONAL SPOT/STITCH/ANTISTICK 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.
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
ASSEMBLE REAR WHEELS
WELDING CABLE CONNECTIONS
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.
Connect the work clamp solidly to the workpiece or work
table. Clamp onto a bare metal area.
d. Install the control module in place of the blank
panel removed in Step a., using the same four
screws that you saved.
A good electrical connection to the work is essential
to proper welding operation and to prevent electric
shock.
20
SECTION 3
3.10
INSTALLATION
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 receptacle on the rear of the optional meter module.
d. Install the meter module in place of the blankpanel removed in Step a., using the same four
screws that you saved.
21
SECTION 3
INSTALLATION
22
SECTION 4
IV.
OPERATION
4.1.2 VOLTAGE CONTROL (Coarse Range Selector
and Fine Adjustment Range Selector)
OPERATION
4.1
CONTROLS (See Figure 4.1)
Voltage control is by means of two high current tap
switches which connect the rectifier bridge to various
secondary taps.
4.1.1 POWER SWITCH
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.
Two transformer secondary windings also become energized:
The COARSE VOLTAGE RANGE Selector is a threeposition 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 voltages 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
4.2.2
Secondary Output Terminals
for Welding Polarity Changeover, see 4.1.3.
2.4.2
10A. Fuse
4.1.3
4.1.2
4.1.6
Work
Cable
Torch
Cable
4.1.1
23
SECTION 4
OPERATION
The FINE VOLTAGE ADJUSTMENT Selector is an
eight-position 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.
4.1.5 WIRE FEED SPEED CONTROL
CAUTION: 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.
4.1.6 STD./SPOOL GUN SELECTOR
4.1.3
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.
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-ongun) torch.
SECONDARY WELDING CONNECTIONS
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.
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.
4.1.4
4.2
PROCESS SETUP
4.2.1
STANDARD MIG SEAM WELDING W/
GUNMASTER 250
Refer to Sections 4.3.1, 4.3.2, 4.3.3, 4.3.4, and Table
4.3.3.
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.
CONTACTOR CONTROL
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.
To operate the unit with the ST-23A Torch connected, do
the following (refer to Fig. 4.2.2):
A. Place the STD./Spool Gun selector toggle switch
(4.1.6) in the 250 to its Spool Gun position.
When the trigger switch is released, the contactor drops
out and disconnects the load.
B. Connect the ST-23A control cable amphenol to the
receptacle labeled CONTROL on the 250’s front
panel.
Because of the charged capacitor bank in the
secondary circuit, the output voltage will take a few
seconds before falling to zero volts.
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 counterclockwise 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).
The gas valve shuts off when the contactor opens.
24
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.
D. Connect the 250’s WORK cable to the workpiece.
E. Set Migmaster 250 voltage tap switches to RANGE
and FINE ADJUSTMENT VOLTAGE settings desired.
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.
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.
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.
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.
If, when using the Anti-Stick feature, the welding wire
tends to stick in the puddle at the end of a weld, the AntiStick 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.
This Anti-Stick feature is available for all three welding
modes - Continuous, Spot, and Stitch.
4.2.3.2
CONTINUOUS WELDING MODE
OPERATION
A. Place the three-position toggle switch in “Continuous” weld mode (center position) for mig seam
welding.
The module consists of three pots (one for Spot-Stitch
Weld Time "ON", one for Stitch Weld Time "OFF", and
one for Anti-Stick 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:
B. Set the “Anti-Stick Time” as required (see 4.2.3.1).
25
SECTION 4
OPERATION
B. Be sure a standard nozzle (and not a spot weld
nozzle) is installed on the torch.
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.
4.2.3.3
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.
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).
ii. The thickness of the metal being welded.
E. To spotweld:
iii. The gap (if any) between the pieces 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.
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.
F. During the welding, use the same welding techniques as described in Section 4.3.3 and 4.3.4.
iii. After the preset time has elapsed, the wire will
stop feeding, the arc will be broken, and the
shielding gas will stop flowing.
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.
26
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)
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 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.
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
MED.
Avoid gas leaks in a confined space, as the leaked gas
can dangerously reduce oxygen concentration in the
breathing air.
DO NOT bring gas cylinders into confined spaces.
LOW
LOAD LINE
VOLTS = 14+ (.05 x AMPS)
AMPERES
50
100
150
200
250
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.
27
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.
c. Before welding on aluminum, be sure to clean
surface thoroughly using a stainless steel brush.
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.
4.3.3
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.
b. Fine Arc Voltage Setting, 1 thru 8 (the higher the
number, the hotter the weld).
H. Wear dark substantial clothing to protect exposed
skin from arcburn, sparks and flying hot metal.
c. Wire Speed setting, 0 thru 10 (the higher the
number, the faster the speed).
I. Turn off welding power before adjusting or replacing
electrodes.
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-OnGun 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.
4.3.2
SET-UP PROCEDURE
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.
PRE-WELD REQUIREMENTS
Before welding commences, with all power OFF, check
the following:
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.
A. All safety requirements have been read and understood.
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.
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.
For “straight polarity”, do just the opposite; torch
fitting to NEG (-) output terminal and “Work” cable
to POS (+) output terminal.
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.
4.3.4
A. Turn Power switch (on unit) to ON position -- be
careful not to operate the torch switch.
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.
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.
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.
WELDING OPERATION
28
SECTION 4
OPERATION
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.
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.
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).
E. The torch angle relative to the length of the weld should
be approximately 100 from the vertical (Fig. 4.3.4.2).
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.
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.
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.
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.
TABLE 4.3, Continuous/Stitch Weld Conditions
Fig. 4.3.4.1 - Angle of Welding Wire with Joint
29
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.
30
SECTION 5
V.
SERVICE
5.1
MAINTENANCE
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.
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.
Shut OFF shielding gas supply at source.
To aid in checking and servicing, use Schematic, Figure
5.1.
5.2
INSPECTION AND SERVICE
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.
SERVICE
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.
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.
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.
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.
5.2.1
POWER SOURCE
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.
31
SECTION 5
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.
NOTE:
5.2.1.2
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
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.
Thermal conductive compound (Wakefield Engineering #120 Thermal Compound or equivalent) must be reapplied to heat sink-diode mating surface whenever a diode is replaced.
5.3
FAN MOTOR
TROUBLESHOOTING
If welding equipment doesn’t work right despite compliance with checklist inspect as follows:
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.
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.
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.
5.2.1.4
WIRE FEEDER
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).
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 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.
IF MOTOR DOES NOT RUN:
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 potentiometer 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
32
SECTION 5
SERVICE
5.3.3
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).
When replacing the gas solenoid valve, the inlet (with the
word IN) must face the rear of the Unit.
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.
5.3.2
SOLENOID VALVE REPLACEMENT
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.
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.
General Replacement
Do not make any repairs to equipment unless you
are fully qualified, as described in the maintenance
section.
The exploded views in the Parts Section indicate generally, in numbered parts sequence, the disassembly of the
wire drive and feeder parts.
Reassemble in reverse order.
TABLE II. TROUBLESHOOTING GUIDE
WELD CONDITION
POSSIBLE CAUSE
REMEDY
1. No weld or control power.
a. Primary input power not available.
b. Faulty connection, primary input
cable, or power switch (S3)
c. Blown line fuse.
a. Check for Voltage at primary input.
b. Repair or replace cable or switch
(TGS1) as necessary.
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 representative.
b. Check diodes and replace if req’d.
c. Check all wiring.
b. Shorted diode in main rectifier.
c. Open in wiring
3. Fan does not run.
a. See Weld Condition 1.
b. Malfunctioning fan motor (M1)
4. Erratic welding current.
a. Poor workpiece connection.
b. Loose welding connections.
c. Wrong polarity.
5. Welding output Voltage
and/or current too low.
a. Low line Voltage.
b. Welding cables too long or too
small.
33
a. Repair or replace cable or switch
as necessary.
b. Replace fan motor (M1).
a. Check workpiece grounding
connection.
b. Check all connections.
c. Check for correct polarity.
a. Use correct Voltage.
b. Use correct cable size.
SECTION 5
WELD CONDITION
SERVICE
POSSIBLE CAUSE
c. Loose connection.
d. Malfunctioning capacitor bank.
6. Stringy irregular bead,
poor penetration.
REMEDY
c. Check all welding cable
connections.
d. Check capacitors for low
leakage resistance.
a. Torch moved too fast.
b. Controls are not set properly for
metal gauge thickness.
c. Wrong polarity.
a. Move Torch slower along seams.
b. Reset control properly.
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
spatter, weld porous.
a. Incorrectly set controls.
a. Reset controls.
b. Shield gas flow is too low or
stopped.
c. Torch nozzle is too far from work.
b. See Condition 10.
d. Faulty regulator or adapter.
e. Faulty gas solenoid valve (SOL).
f. Wrong polarity.
10.Shield gas flow low or
stopped
a. Cylinder valve closed.
b. Cylinder empty.
c. Faulty regulator or adaptor.
d. Faulty gas solenoid valve.
c. Check for correct polarity.
c. Maintain 1/4" (.6 mm) wire
protrusion; hold closer to work.
d. Check flow at outlet;
replace faulty item.
e. Replace solenoid valve.
f. Check polarity.
a. Turn off regulator, slowly open
valve, until regulator reaches
35 c.f.h. pressure.
b. Replace if gauge so indicates.
c. Check flow at outlet; replace
faulty item.
d. Replace solenoid valve.
11.Wire stubs on work
while welding.
a. Controls not set properly for
metal gauge, thickness.
a. Reset controls properly.
12.Wire burns back into
contact tip.
a. Contact tip loose.
b. Tip too close to work.
a. Firmly tighten with pliers.
b. Maintain 1/4" (.6 mm) wire
protrusion; hold Torch further
from work.
c. Increase pressure on pressure
roll by adjusting pressure knob.
d. Trim back tip 1/16" (1.6 mm) max.
Replace if still faulty.
e. Adjust setting.
f. Clean rolls or replace.
c. Wire feed slipping.
d. Contact tip damaged.
e. Voltage setting too high.
f. Drive or pressure roll dirty or worn.
34
SECTION 5
WELD CONDITION
13.Wire does not feed; motor
running (drive roll turns).
SERVICE
POSSIBLE CAUSE
REMEDY
a. Kink, etc. in wire, or wire bound
on reel.
b. Wire freezing to contact tip
(burnback).
c. Clogged liner.
14.Wire does not feed;
motor NOT running
(drive roll does not turn).
a. Motor
b.Power switch S3 and fuses.
c. Speed Potentiometer (POT).
d. Malfunctioning speed control board.
15.Wire feed does not stop.
a. Torch trigger switch.
b. Malfunctioning relay (K3).
16.Gas continues to flow
after trigger release.
a. Gas solenoid valve stuck open.
35
a. Straighten; or feed wire until
clear and cut off.
b. Free freeze, or remove contact
tip feed wire until clear cut end free,
and replace tip.
c. Replace liner.
a. With wire speed dial on 10,
press trigger. If voltage
appears across motor leads
but motor does not run, check
motor gears and commutator
areas.
b. With S3 ON, if voltage
across terminal 1 and 3 is 24 VAC,
switch and fuses are good.
c. Check for 1K ohms across
POT outside terminals.
d. Check board voltages
(Para 5.3.1 b. and c.)
a. Check continuity of Torch trigger
circuit; check to see if trigger lever
is stuck in “ON” position.
b. Check for proper action.
a. Tap solenoid or click on and off
to clear valve.
D-32860-D
36
NOTE:
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 5.1 - Schematic Migmaster 250 for 208/230 V. Model
D-33310-C
PRIMARY VOLTAGE
CONNECTION CHART
NO. OF
STRIPS
VOLTAGE
CONNECTION
1-2
1
208
6-7
1
7-8
FLEX
1-2
1
230
6-7
1
5-8
FLEX
380
3-7
2
4-8
FLEX
400
460
575
2-6
2
7-8
FLEX
2-6
2
4-8
FLEX
2-3
2
4-8
FLEX
37
NOTE:
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
D-32861-F
38
Figure 5.3 - Wiring Migmaster 250 for 208/230 V. Model
D-33311-D
39
Figure 5.4 - Wiring Migmaster 250 for 208/230/380/400/460/575 V. Model
SECTION 5
SERVICE
40
SECTION 6
VI.
PARTS
6.1
SPARE PARTS
To assure minimum downtime, it is recommended that
the spare parts noted by the symbol (*) in the Stock No.
column of the parts list be kept on hand.
6.2
REPLACEMENT PARTS
The following illustrations of the equipment identify each
replacement part by item number as tabulated in the
related parts lists. The list identifies each part by part,
number, description, and quantity used (in parentheses,
if more than 1). Some assemblies can be ordered as
complete units or broken down as individual parts. These
parts are listed - indented one space - below the assembly. When any of the parts can be broken down as a subassembly, its individual parts as listed below it - indented
two spaces.
REPLACEMENT PARTS
Attaching hardware items are listed, deeply indented,
below the part they attach. They may not be shown.
Order them separately.
6.3
ORDERING
To assure proper operation, it is recommended that only
genuine ESAB parts and products be used with this
equipment. To order replacement parts:
a. Give the part number, description and quantity of
each part required.
b. Give part number and description of equipment on
which the parts are to be used.
c. Indicate any special shipping instructions.
41
SECTION 6
REPLACEMENT PARTS
11, 12
27
6
7
21, 22, 23
8
13,14
5
15
18, 19
10
2
25
16, 17
26
20
3
24
28
FIGURE 6.1 MIGMASTER 250 SYSTEMS
ITEM QTY
NO. REQ.
2
3
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
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
2
1
1
1
PART
NO.
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
952929
33190
82F31
13730912
950396
951672
950695
0558001651
0558001652
DESCRIPTION (Figure 6.1)
PANEL, SIDE, RIGHT
STRAIN, RELIEF
LATCH, DOOR
PLATE, BLANK COVER*
COVER, HINGED
PANEL, CONTROL, SILKSCREENED
PANEL, SIDE, LEFT
POTENTIOMETER, 1K, WIRE SPEED CTRL.
KNOB
SWITCH, FINE VOLTS ADJ., 8 POS.
KNOB
RECEPTACLE, 8 PIN
KNOB w/ SET SCREW
SWITCH, COARSE VOLTS ADJ., 3 POS.
PLUG, PLASTIC "C" SIZE
ADAPTOR, POWER & GAS (SPOOL GUN)
SWITCH, TOGGLE, (ON/OFF)
GUIDE TUBE
TORCH ADAPTOR ASSY. includes:
POWER LUG
ADAPTOR BLOCK ASS'Y.
HOUSING, GUN ADAPTOR (STRAIGHT)
CONNECTION TUBE, 4" LG BRASS
BUSBAR, COPPER
WORK CLAMP
WHEEL
CASTER, SWIVELS 5"
HANDLE (From (1/1/94)
HANDLE (Before 1/94)
GUNMASTER 250cc 12'
GUNMASTER 250cc 15'
CKT.
DESIG.
R1
S1
J3
S2
S3
* 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.
42
SECTION 6
REPLACEMENT PARTS
19,20
7
18
17
14
15,16
24
21
12
FAN ASSEMBLY
See Figure 6.4
26
1
4
5,25
6
22,23
8
FIGURE 6.2 MiGMASTER 250 Main Assembly (Left Side)
43
SECTION 6
REPLACEMENT PARTS
ITEM QTY.
NO. REQ.
1
4
5
6
1
1
1
1
1
7
1
8
12
14
15
16
17
7
3
1
1
1
2
18
19
20
21
22
23
24
25
26
1
1
2
1
1
3
1
1
1
PART
NO.
33184M
672225
1373 6750
33176
951634
1373 0628
951633
2360 6726
1373 2230
1373 0222
31484
2360 8111
1373 5940
950760
2361 0322
1373 0469
952173
0558001290
9951 2178
2360 9967
674216
1371 5289
1373 1989
951649
DESCRIPTION (Figure 6.2)
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 (before 1/94)
CONNECTOR, "Y" from 1/1/94)
HOSE CONNECTION (before 1/94)
CAPACITOR 10,000 MT, 50V
BUSHING
P.C. BOARD, SPEED CONTROL
TERMINAL BLOCK, 8 PT
MARKER, TERMINAL
RELAY (from 1/1/94)
RELAY, 4 PDT, 24 VAC, 10A
BRIDGE, RECTIFIER
CONTACTOR
BUSBAR “E” STAMPING
RESISTOR, 50 OHM, 50W
TERMINAL, 3 POS
CAPICATOR .02uf 1KV
RESISTOR 1 OHM 25W
THERMOSTAT 145°
POWERCORD
CKT.
DESIG.
T1
T1
SOL1
C 1-7
PCB1
TB1
K2, K3
BR1
K1
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.
44
SECTION 6
REPLACEMENT PARTS
6,7
5
3
11
2
1
19
18
14
9,10
20
16
FIGURE 6.3 MiGMASTER 250 Main Assembly (Right Side)
45
SECTION 6
REPLACEMENT PARTS
ITEM QTY
NO. REQ.
1
2
3
5
6
7
9
10
11
14
15
16
17
18
19
20z
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
PART
NO.
+
+
+
33186M
2360 5057GY
2360 6237
634519
- 1373 5464
634709
2361 2348
- 2361 2479
33199M
952939
82F31
- 1373 2232
951649
1373 0583
676701
97W63
DESCRIPTION (Figure 6.3)
REAR, PANEL
SUPPORT, REEL
HUB, REEL (See Figure 6.5)
SWITCH, TOGGLE, 4 PDT
FUSE, 10A
HOLDER, FUSE
GEAR MOTOR, 50-675 IPM
KEY, MOTOR SHAFT
COVER P.C. BOARD
DRIVE STAND ASSEM. (See Fig. 6.6)
WORK CLAMP
FILTER, CHOKE
POWERCORD
BUSHING, TERMINAL
TERMINAL ASS'Y., OUTPUT
STRAIN RELIEF
+ - DENOTES RECOMMENDED ON HAND SPARE PART
- Added "D" Edition, 3/96
z
46
CKT.
DESIG.
S4
F1
L1
TP
SECTION 6
REPLACEMENT PARTS
6
4, 3
5
2
10, 9
2
6
FIGURE 6.4 MIGMASTER 250 FAN & CAPACITOR BANK
ITEM
NO.
QTY.
REQ.
PART
NO.
2
3
4
5
6
9
10
2
4
4
2
2
1
1
99511916
1373 0680
1373 0681
1373 1597
1373 0378
951939
1373 2226
DESCRIPTION (Detail "B" FAN)
DIODE, SILICON, STRAIGHT POLARITY
INSULATOR, COLLAR
INSULATOR, SHOULDER
WELDMENT, RESISTOR
DIODE, SILICON, REVERSE POLARITY
BLADE, FAN
MOTOR, FAN
9
CKT.
DESIG.
D1, D2
D3, D4
M1
8
7
REF.
1
6 5
4
3
2
FIGURE 6.5a MIGMASTER 250 LEXAN HUB KIT
ITEM
NO.
QTY.
REQ.
1
2
3
4
5
6
7
8
9
2
1
1
1
1
1
1
1
1
PART
NO.
2360 5780
2360 0255
2360 6237
2360 0982
2360 0010
9204 0101
9205 6007
2360 0952
2360 5057GY
DESCRIPTION (HUB KIT)
REEL HUB KIT (INCLUDES 1-8)
BRAKE, DISC
HUB, REEL
SPRING
NUT, PLASTIC
SCREW, R.H.M., 3/8-16 x .75
WASHER, PLAIN
WASHER, "D"
SUPPORT, REEL
SHELF (REF.)
47
CKT.
DESIG.
SECTION 6
REPLACEMENT PARTS
5
6, 7
4
9
10
8
11
2, 3
1
12
14
13
FIGURE 6.5b MIGMASTER 250 LEXAN HUB KIT
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
QTY.
REQ.
1
AR
AR
1
1
AR
AR
2
1
1
1
1
1
1
PART
NO.
0558002993
61341133
64302037
0558002992
33191M
63300916
64302920
948255
2360 0982
634347
8948258
92044046
64304125
0558003320
DESCRIPTION (HUB KIT)
D-Shaft, Wirefeeder, 5.75L
Screw, HC, .375-16 x 1.00
Washer, Lock, .375
Bracket, Spool Support
Shelf, Silkscreened
Nut, Hex, 10-24
Washer, Lock, #8
Pad, Braking
Spring
Pin, Hitch Clip
Hub, Reel
Screw, 10001 Stl ZPC, .375-16 x 1.00
Washer, 53001, Stl ZPC, .375
Washer, D-Type
48
CKT.
DESIG.
SECTION 6
21
REPLACEMENT PARTS
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
*
11
18
Items shown in exploded view for clarity.
*12
*14
17
*13
13
14
12
*17
15
19
2-Roll (Undriven Upper) Drive Stand
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
QTY.
REQ.
PART
NO.
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
3
1
1
952939
952704
23612477
23612475
23612474
23612470
23612472
23612368
23612476
23612460
23612473
23612461
21156
952944
952925
23612478
34608
952945
952926
23612462
23612662
23612663
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)
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
49
SECTION 6
REPLACEMENT PARTS
*103
101
102
*104
106
111
*108
*110
105
*109
107
108
*112
112
109
110
*
Items shown in exploded view for clarity.
2-Roll (Undriven Upper) Drive Stand Assembly, 952583 - Migmaster 251
No.
Qty.
Req.
101
102
103
104
105
106
107
108
109
110
111
112
1
1
1
1
1
1
5
1
2
1
2
1
Item
No.
23612470
23612460
952592
952593
23612478
23612461
23612462
952944
23612384
23612398
952926
------------
Description
Pivot Pin
Pressure Device Complete
Pressure Arm Complete
Locating Pin
Feed Plate
Inlet Guide, .035/.045 (Also see Table 1-3)
MTG Screw Drive Stand
Feed Roll Adaptor (See Table 1-3 for Drive Rolls)
Locating Screw Feed Roll
Retaining Screw Feed Roll
Thumb Screw m6 x 16
Drive Roll (See Table )
50
Circuit
Symbol
SECTION 6
REPLACEMENT PARTS
*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.
2-Roll (Driven Upper) Drive Stand
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
QTY.
REQ.
PART
NO.
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
3
1
1
23612627
23612626
23612387
23612475
23612385
23612470
23612472
23612397
23612386
23612460
23612473
23612461
21156
23612383
23612398
23612478
23612479
23612480
23612384
23612462
23612662
23612663
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)
GEARED ADAPTOR, PRESSURE ROLL
PRESSURE DEVICE ASSY.
LOCATING PIN
INLET GUIDE
DRIVE ROLL, (see Table 2.1)
GEARED ADAPTOR DRIVE ROLL
FEED ROLL RETAINING SCREW
FEED PLATE
FEED ROLL KEY
MOTOR SHAFT SNAP RING (Not Shown)
LOCATING SCREW
SCREW, MOTOR MOUNTING
SPACER TUBE (Pressure Arm)
SPRING PRESSURE ARM
51
SECTION 6
REPLACEMENT PARTS
52
NOTES
53
NOTES
54
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:
1.
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:
1.
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:
1.
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:
1.
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 F15-612-D.
The "M" edition (12/03) of this manual covers the following:
1.
Updated part number 26 on Page 42 from 959396 to 950396.
55
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
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Product Availability
Pricing
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Telephone: (843) 664-4416 / Fax : (800) 446-5693
Warranty Returns
Authorized Repair Stations
Hours: 7:30 AM to 5:00 PM EST
Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
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Part Numbers
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Specifications
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 8:00 AM to 7:00 PM EST
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Hours: 8:00 AM to 5:00 PM EST
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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
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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:
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H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
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IF YOU DO NOT KNOW WHOM TO CALL
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Hours: 7:30 AM to 5:00 PM EST
or
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F15-087-M
12 / 2003
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