MultiMaster 160

Mig / Tig / Stick Welding Package

Instruction Manual

F15-678-D 07 / 2005

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 1.0 - SAFETY PRECAUTIONS ......................................................................................................................................... 3

SECTION 2.0 - INTRODUCTION ....................................................................................................................................................... 9

SECTION 3.0 - INSTALLATION ...................................................................................................................................................... 13

3.1

LOCATION .......................................................................................................................................................... 13

3.2

ELECTRICAL INPUT CONNECTIONS ............................................................................................................. 13

3.2.1

INPUT ELECTRICAL REQUIREMENTS ........................................................................................................... 13

3.2.2

INPUT PLUG ...................................................................................................................................................... 13

3.3

3.4

SECONDARY OUTPUT CONNECTIONS ......................................................................................................... 13

WIRE FEEDER MECHANISM ........................................................................................................................... 13

3.4.1

DRIVE ROLLS .................................................................................................................................................... 13

3.4.2

WELD WIRE SPOOL INSTALLATION .............................................................................................................. 13

3.4.3

THREADING THE WELDING WIRE ................................................................................................................. 14

3.4.4

SPOOL BRAKE DRAG ADJUSTMENT ............................................................................................................. 14

3.5

CONNECTION OF SHIELDING GAS SUPPLY ................................................................................................ 14

3.5.1

R-33-FM-580 REGULATOR (OPTIONAL) ........................................................................................................ 14

3.5.2

TO REGULATE FLOW ....................................................................................................................................... 15

SECTION 4.0 - OPERATION ............................................................................................................................................................ 16

4.1

STANDARD CONTROLS ................................................................................................................................... 16

4.1.1

POWER ON/OFF SWITCH ................................................................................................................................ 16

4.2.2

TEMP LAMP ....................................................................................................................................................... 16

4.1.3

PROCESS SELECTOR SWITCH ...................................................................................................................... 16

4.1.4

SECONDARY WELDING CONNECTIONS ....................................................................................................... 16

4.1.5

WIRE FEED SPEED CONTROL ....................................................................................................................... 16

4.1.5

VOLTAGE CONTROL ........................................................................................................................................ 16

4.1.7

CURRENT CONTROL ....................................................................................................................................... 16

4.1.8

HOT START ....................................................................................................................................................... 16

4.2

OPERATING PROCEDURES ............................................................................................................................ 18

4.2.1

MIG WELDING SET-UP ..................................................................................................................................... 18

4.2.2

TIG WELDING SET-UP ..................................................................................................................................... 19

4.2.3

STICK WELDING SET-UP ................................................................................................................................. 20

SECTION 5.0 - MAINTENANCE ...................................................................................................................................................... 21

5.1

5.2

MAINTENANCE AND SERVICE ....................................................................................................................... 21

INSPECTION AND SERVICE ............................................................................................................................ 21

5.2.1

POWER SOURCE .............................................................................................................................................. 21

5.2.1.1 RECTIFIERS AND TRANSISTORS .................................................................................................................. 21

5.2.1.2 FAN MOTOR ...................................................................................................................................................... 21

5.2.1.3 TRANSFORMER ................................................................................................................................................ 21

5.2.1.4 OVER-TEMPERATURE PROTECTION ............................................................................................................ 21

5.2.2

WIRE FEEDER ................................................................................................................................................... 21

SECTION 6.0 - REPLACEMENT PARTS ........................................................................................................................................ 23

6.1

REPLACEMENT PARTS ................................................................................................................................... 23

6.2

6.3

GENERAL ........................................................................................................................................................... 23

ORDERING ......................................................................................................................................................... 23

3

Table of Contents

4

SAFETY PRECAUTIONS

WARNING:

T hese 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:

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.

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. 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.

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 nonflammable 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. 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.

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:

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

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 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.)

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.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. 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.

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."

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

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. 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 convient-il d’observer les précautions suivantes: a. 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.

b. 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.

c. 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.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité

à l’aide d’un écran ininflammable adéquat.

e. 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.

f. 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.

2. 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 observer les précautions suivantes:

PRÉCAUTIONS DE SÉCURITÉ

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 assurer 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

7

levage, des câbles de grue ou divers chemins

électriques.

g. 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.

4. 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: a. 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.

b. 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.

c. 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.

d. 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.

e. 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.

f. Consultez les recommandations particulières en matière de ventilation indiquées à l’alinéa 6 de la norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise 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.

8

SECTION 2 INTRODUCTION

Input

Output

Table 1 Multimaster 160 Specifications

Primary Input Voltage ....................................................................... 208 Vac, 1-Phase

......................................................................................................... 230 Vac, 1-Phase

Primary Input Current ....................................................................... 30 Amp @ 208 Vac

......................................................................................................... 27 Amp @ 230 Vac

Frequency ........................................................................................ 50/60Hz

Power Factor .................................................................................... 0.81

Nominal Power - MIG ....................................................................... 5.4KVA

Nominal Power - electrode ............................................................... 6.3KVA

Nominal Power - TIG ........................................................................ 3.9KVA

Protective Fuses ............................................................................... 20A time-lag

Degree of Protection ........................................................................ IP 21

Insulation Class ................................................................................ F

Operating Temperature .................................................................... From 14°F to 104°F (-10°C to +40°C)

Duty Cycle - MIG .............................................................................. 160A - 60%

Duty Cycle - electrode ...................................................................... 160A - 60%

Duty Cycle - TIG DC ......................................................................... 160A - 70%

OCV .................................................................................................. 75V

Arc Voltage - MIG ............................................................................. 13.0 - 23.0

Arc Voltage - electrode ..................................................................... 20.2 - 26.4

Arc Voltage - TIG .............................................................................. 10.2 - 16.4

Regulation range - MIG .................................................................... 20 - 160

Regulation range - electrode ............................................................ 5 - 160A

Regulation range - TIG ..................................................................... 10 - 160A

Hot Start ........................................................................................... Adjustable

Arc Force .......................................................................................... Automatic (built-in)

Antisticking ....................................................................................... Automatic (built-in)

Ignition - electrode ............................................................................ Scratch

Ignition - TIG ..................................................................................... Lift-arc

Wire Spool ........................................................................................ 5/15/20kg (12/33/44 lb)

Wire .................................................................................................. Metal, fluxed core (no gas)

Dimensions

Length .............................................................................................. 22.4” (560mm)

Width ................................................................................................ 9.2” (230mm)

Height ............................................................................................... 15.4” (385mm)

Weight .............................................................................................. 33lbs(15Kg )(net)

Ordering Information

MultiMaster

®

160 cvcc Multi-Process Packages

Multimaster packages listed below include power source with builtin wire feeder with .030/.035 drive roll, primary input cable, welding gun, work cable with clamp, FREE #10 spool of .030 Coreshield

®

15 wire, and #1 sample 6013LV 1/8” stick electrodes.

Multimaster

®

160 w/13-ft. MXL 200 ........................................... 0558002772

Multimaster ® 160 w/13-ft. MXL 200 & Stinger ........................... 0558002773

Multimaster

®

160 w/13-ft. MXL 200 & Stinger/HW-17/Reg ............ 0558002774

9

SECTION 2

Optional Equipment

MultiMaster ® 160 Options & Accessories

Replacement Work Cable - 10 ft. ........................................................ 0369857881

Electrode Holder and Work Cable Kit - 25mm 10 ft. ............................ 0349501078

Replacement AF-1 Electrode Holder only ................................................... 882F25

HW-17V 25 ft. w/25mm Connector ...................................................... 0558002690

Kit, Accessory HW-17 ................................................................................. 999126

R-33 FM-580 Reg/Flowmeter ........................................................................ 21557

Primary Extension Cord (25 ft.) 50 amp ........................................................ 37833

Feedroll .023”/.030” V for Hard Wire .............................................................. 21155

Feedroll .030”/.030” Serrated for Core Wire .................................................. 21160

MXL 200cc 10 ft. (3m) x .023”-.030” ................................................... 0700200002

MXL 200cc 13 ft. (4m) x .023”-.030” ................................................... 0700200003

Gas Nozzle - Standard 7/16” (12mm) ................................................. 0700200054

Gas Nozzle - Straight 5/8” (16mm) ..................................................... 0700200057

Gas Nozzle - Conical 3/8” (9.5mm) .................................................... 0700200060

Contact Tip, .023” (0.6mm) .................................................................. 0700200063

Contact Tip, .030” (0.8mm) .................................................................. 0700200064

Contact Tip, .035” (0.9mm) .................................................................. 0700200065

Contact Tip, .040” (1.0mm) .................................................................. 0700200066

MXL 200 Tip Adapter - Short ............................................................... 0700200072

MXL 200 Tip Adapter - Long ................................................................ 0700200067

MXL 200 Nozzle Spring ....................................................................... 0700200078

Steel Liner .023”-.030” (0.6-0.8mm) x 13ft. (4m) ................................. 0700200086

Steel Liner .035”-.045” (0.9-1.2mm) x 13ft. (4m) ................................. 0700200088

Teflon Liner .023”-.030” (0.6-0.8mm) x 13ft. (4m) ............................... 0700200090

Teflon Liner .035”-.045” (0.9-1.2mm) x 13ft. (4m) ............................... 0700200092

Gas Meter ...................................................................................................... 19043

25mm Connectors - quick-acting twist lock connectors for attaching output power cables or torches to power source:

Gas / Power Adapter for Heliarc HW-9 and 17 Torches ............................... 37158

Male Quick Connector ................................................................................... 37159

INTRODUCTION

10

SECTION 2 INTRODUCTION

2.1 GENERAL

This manual has been prepared for experienced welders. 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.

This manual is intended for use in familiarizing personnel with the design and operation of this equipment. All information presented here should be read carefully before installing and using this equipment.

and tubular cored wires. This unit is suitable for carbon steel and stainless steel. It provides a power source with built in wire feeder.

2.4.2 PACKAGE CONTENTS (Standard Accessories)

Each Multimaster 160 package includes:

• Power source with built-in wire feeder.

• Gun Master 250 Mig Gun with .035" accessories.

• Dual groove feed rolls for .030/.035” core wire

• 10' work cable and clamp.

• 8' primary cable with plug.

• Mig Welding Handbook and set-up guide.

• Tig Welding Handbook

• Coreshield 15—.035 x 10# Spool

• LV 6013 Stick Electrodes 1#

2.2 RECEIVING-HANDLING

Upon receipt of this equipment, clean all packing material from around the unit and immediately inspect for any damage that may have occurred during shipment. Any claims for loss or damage occurring in transit must be filed with the carrier. The carrier will furnish a copy of the bill of lading and the freight bill on request, if the need to file a damage claim arises.

When requesting information regarding this equipment, make sure that you include product name, part number, and serial number.

2.4.4 POWER SOURCE

The power source is a DC output designed for single phase primary connections. An output controlled fan provides proper cooling during normal welding operations If the duty cycle is exceeded, the unit will automatically shut down and the Over Temperature light will illuminate. Once the unit reaches a safe operating temperature, the unit will automatically reset and welding can resume..

2.3 SAFETY

The safety section at the front of this manual should be read completely before attempting to install and operate this equipment. Both equipment and personnel hazards are reduced if proper safety precautions are taken. If you are unsure of yourself in any situation, ask your supervisor or other experienced personnel for help.

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.

2.4.5 WIRE FEEDER

The wire feeder is built into the power source cabinet.

Cooling air is not drawn through the wire feeder compartment or electronic controls reducing exposure to dirt and dust which improves product performance and reliability.

The wire feeder pushes wire at speeds from 65 to 650 ipm (inches per minute).

2.4.6 CONTROLS

The Multimaster 160 can be used to weld solid and flux cored wires. The operator selects the process desired on a three position switch located on the front panel. A detailed description of the power source controls is included in Section 4 (Operation) of this manual.

2.4 DESCRIPTION

The Multimaster 160 is a DC welding system designed for Mig (GMAW), Tig (GTAW) or Stick (SMAW) welding.

In the Mig mode this unit is capable of operating with short arc or spray arc transfer and handles both solid wires

2.4.8 MXL 200 MIG GUN

This air-cooled welding gun is supplied complete and ready to weld .030 in. flux cored wire. Other wire sizes and types can be used. Refer to Section 2, for other wire size and alloy accessories.

11

SECTION 2

Inlet Guide

Drive Motor

INTRODUCTION

MIG Gun

Connector

2 Roll

Drive Stand

Handle Strap

MIG Polarity Changeover

Connectors

Wire Spindle

Assembly

Primary Input

Cable

Hinged Wire

Compartment Door with Setup Chart

Figure 1 - Components

12

SECTION 3

3.0 INSTALLATION

3.1 LOCATION

Several factors should be considered when locating the unit for use. Adequate ventilation is necessary to provide cooling, and the amount of dirt and dust to which the machine is exposed should be minimized. There should be at least 18 inches of unrestricted space between the machine’s side and rear panels and the nearest obstruction to provide freedom of air movement through the power source.

Installing or placing any type of filtering device will restrict the volume of intake air, thus subjecting the internal components to overheating. Warranty is void if any type of filtering device is used.

INSTALLATION

3.2.2 INPUT PLUG

The input power cord is provided with an attachment plug.

The plug will mate with a 250 volt, 50 Amp receptacle conforming to NEMA 6-50R configuration. The receptacle must be wired to a separately fused disconnect or circuit breaker by a qualified electrician.

3.3 SECONDARY OUTPUT CONNECTIONS

The Multimaster 160 Welding System has an internal Polarity changeover for the MIG Process located under the

Hinge Cover. Front panel output receptacles make for easy polarity changeover for TIG and STICK. See Sections

4.2.1, 4.2.2 and 4.2.3 for specific details on Connect Leads and Cables for your application. Also the MIG torch connections are external allowing easy changes.

9.2”

230 mm

15.4”

385 mm

3.4 WIRE FEEDER MECHANISM

3.4.1 DRIVE ROLLS (Figure 5 and 7)

When viewing the drive roll, the stamped designation fac ing you is the groove in use. The drive roll has two grooves: the small groove feeds .030 in. diameter wire, the large groove feeds .035 in. wire. The groove nearest the gear motor feeds the wire. If the required groove is not correctly positioned, perform the following:

A. Release the pressure drive roll lever.

B. Remove the screw holding the drive roll.

C. Reverse the drive roll on the drive roll shaft.

D. Replace the screw and tighten.

E. Secure the pressure drive roll assembly.

22.4”

560 mm

Figure 2 - Dimensions

3.2 ELECTRICAL INPUT CONNECTIONS

A cord with plug attached is provided. Connect the plug to a properly grounded and protected (fuse or circuit breaker)

230 Vac receptacle.

3.4.2 TORCH INSTALLATION

A Mig torch with a euro-type adapter is supplied as standard equipment with the Multimaster 160 System. This torch connects directly to the 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 Figure #3).

Before making any connections to the power supply output terminals, make sure that all primary input power to the machine is deenergized (off) and that input power cable is unplugged.

3.2.1 INPUT ELECTRICAL REQUIREMENTS

The primary input voltage requirements are shown on the power source nameplate. The power source is designed to be operated from 208/230 vac single phase 50/60 Hz.

Figure 3 - Torch Connection

13

SECTION 3 INSTALLATION

3.4.3 WELDING WIRE SPOOL INSTALLATION

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 resilience of the wire which can quickly unravel, or a cut wire end which may shoot across the room.

To ensure 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.

D. Lower pressure roll assembly and secure. Turn the power “on” and feed wire through to gun tip using the gun trigger to start wire feeding.

Install a spool of welding wire on the spindle as follows:

C. Feed the wire from the spool through the inlet guide, across the drive roll grooves into the outlet guide and cc connection tube.

A. Unscrew red plastic nut.

B. Place wire spool on the spindle to rotate counterclockwise (wire feeds off of the top) as wire is unwound; spindle brake pin must engage hole in spool.

C. Spool spacer is used when running a 10# Spool of

Wire. Place wire on first, followed by spacer, and then plastic nut.

D. Replace the locking nut.

3.4.4 THREADING WELDING WIRE

A. Turn off power switch.

B. Release pressure drive roll assembly. Check that proper wire diameter grooves are in the inner position.

When the power switch is on, and gun trigger is depressed, the electrode wire becomes electrically hot, and the wire drive rolls will rotate.

3.4.5 SPOOL BRAKE DRAG ADJUSTMENT

Spool brake disc friction should provide enough drag to keep the wire spool from spinning freely after wire feed stops. If adjustment is required, turn the adjusting screw inside the spindle housing clockwise to increase drag or counterclockwise to decrease it. Drag should be just enough to limit wire overrun.

Pressure Release Lever

Before threading welding wire, make sure chisel point and burrs have been removed from wire end to pre-

vent wire from jamming in gun or liner.

Inlet Guide

Feed Roll Release Screw

Figure 4 - Wire Feeder Mechanism

14

Threading the wire through the inlet guide

Figure 5 - Threading the Wire

3.5 CONNECTION OF SHIELDING GAS SUPPLY

3.5.1 R-33-FM-580 Regulator (OPTIONAL)

The R-33-FM-580 regulator is an adjustable regulator designed for use with Argon, Helium, and C-25 (75% Argon/25% CO

2

) gas service. Table 2 table provides the recommended flow ranges for the R-33-FM-580 regulator.

SECTION 3

Argon

Helium

C-25

10-50 cfh

150-230 cfh

10-50 cfh

Table 2 - Typical Flow Rates

Cylinders must be secured in a safe fashion. For additional information, refer to CGA Standard P-1, “Precautions for

Safe Handling of Compressed Gases in Cylinders”.

Wire

Spool

INSTALLATION

E. Attach the regulator to the cylinder valve. Align the regulator so that the flowmeter is vertical and then tighten the connection nut with a 1-1/8 in. open end or adjustable wrench. To prevent damaging the Oring seals and plastic tube, do not use the flowmeter tube as a 'handle' when attaching the regulator.

Cylinder Valve

Cylinder

Pressure

Gauge

Outlet

Connection

Figure 7

F. Close the flow control valve on the flowmeter.

G. Attach the gas hose from the rear of the Multimaster

160 to the regulator outlet connection.

Locking Nut

Never stand directly in front of or behind the regulator when opening the cylinder valve. Always stand to one side.

Figure 6 - Wire Spool Assembly

Unscrew the cylinder cap.

Do not clamp regulator cap in a vise or grip it with a pair of pliers. Distortion of cap can jam the internal parts and cause excessively high delivery pressure as well as weaken the threaded joint to the regulator body. This may cause the cap to fly off and possibly injure personnel in area.

H. Open the cylinder valve SLOWLY a fraction of a turn.

This will prevent damage to the gauge and critical components in the regulator. When the gauge needle stops moving, then open the cylinder valve fully.

I.

Using a leak test solution, such as P/N 998771 (8 oz.

ctr) or soapy water, test for leakage around the cylinder valve stem, the regulator inlet connection, and the hose connections at the regulator. Correct any leaks before starting work.

D. Open the cylinder valve slightly, for an instant, to blow out any dust or dirt that may have collected in the valve outlet. BE SURE to keep your face away from the valve outlet to protect your eyes.

3.5.2 TO REGULATE FLOW

Flow is controlled by adjusting the flowmeter valve until desired flow is indicated by the ball float in the flowmeter tube. Always take the reading across the TOP of the ball.

15

SECTION 3 INSTALLATION

4.0 OPERATION

4.1 STANDARD CONTROLS

4.1.4 SECONDARY WELDING CONNECTIONS

The secondary output welding terminals, POS (+) and

NEG (-) are located in the lower front panel. Refer to Polarity Setup.

4.1.1 POWER ON/OFF SWITCH & LAMP

The main power switch is located on the front panel in the lower right-hand corner. This switch energizes the main transformer, control circuitry and illuminates the switch face.

4.1.2 TEMP LAMP (Figure 8)

The TEMP lamp illuminates if an over temperature condition occurs within the Multimaster 160. This condition may be caused by excessive duty cycle or over-current conditions. When an over temperature condition occurs, the welding output is turned off and the unit must be allowed to cool. The machine will automatically reset when the temperature falls to a safe level.

4.1.3 PROCESS SELECTOR SWITCH (Figure 8)

The three position process selector switch is located in the upper left-hand corner of the control panel. The process selector switch provides the visual indication of which process (STICK, TIG, MIG) has been selected.

4.1.5 WIRE FEED SPEED CONTROL (Figure 8)

The wire feed speed control potentiometer located in the upper left-hand side, allows wire feed speed adjustments between 65 and 650 inches per minute (IPM).

4.1.6 VOLTAGE CONTROL (Figure 9)

The arc voltage is controlled with this knob when the Process selector switch is in the MIG position. Refer to Weld

Chart and set the recommended setting.

4.1.7 CURRENT CONTROL (Figure 8)

The welding current is controlled with this knob when the

Process selector switch is in the STICK OR TIG position.

Refer to Weld Chart and set the recommended setting.

4.1.8 HOT START (Figure 8)

The Hot Start feature is used to control the amount of starting current in the Stick welding mode. This helps ensure positive arc strikes for difficult to start electrodes and also allows for softer starts on thin material.

16

SECTION 4

Wire Feed Speed

Weld Process

Switch

Voltage Set

Current Set

OPERATION

Temperature

Lamp

Figure 8 - Control Panel

Hot Start

Wire Feed

Speed Trim

IPM

Positive Output

Connection

Main

Power

Switch

Negative Output

Connection

Figure 9 - Front Panel

17

SECTION 4

4.2 OPERATING PROCEDURES

Comply with all ventilation, fire and other safety requirements for arc welding as established in the

SAFETY Section at the front of this manual.

4.2.1 MIG WELDING SET-UP

When the PROCESS switch is placed in the MIG position the Multimaster 160 is set to turn ”ON” when the Mig Gun trigger is depressed.

Step 1. Choose the weld parameters based of the wire alloy, diameter, material thickness and shielding gas from Table 3 - MIG PARAMETERS CHART.

Set the polarity as shown in Filgure 10 for the process being used.

Step 2. Place the WELD PROCESS (1) switch in the MIG

(FAR RIGHT) position.

Step 3. Turn the Wire Speed Knob (2) to the desired speed.

Step 4. Turn the VOLTAGE (3) knob to the desired arc voltage.

Step 5. Pull the gun trigger and start welding. Trim the wire speed and volts as needed for the desired arc characteristics.

Option: If using one, set the shielding gas flow rate to 35 cfh by pulling the gun trigger and turning the adjustment knob on the R33-FM 580 Flowmeter.

Table 3 - MIG PARAMETERS CHART

MIG - DCEP (Electrode Positive)

Connector

OPERATION

MIG Gun

Work Cable and Clamp

Polarity

Changeover

Connector

Figure 10 - MIG Polarity Connection

2

1

3

Figure 11 - Front Control Panel -

MIG (GMAW) Process Setup

18

SECTION 4 OPERATION

4.2.2 TIG WELDING SETUP

When the PROCESS switch is placed in the TIG position, the Multimaster 160 turns “ON” the weld contactor so that power is immediately available to the output connection. The

Touch TIG starting system is then enabled.

Step 2. Be sure to set the polarity to DCEN (Electrode

Negative) by placing the Heliarc Torch in the

Negative connection terminal on the front of the power source as shown in Figure 12.

Step 3. Place the WELD PROCESS (1) switch in the

TIG (center) position.

When the WELD PROCESS switch is moved to the TIG or STICK position, electrode becomes electrically

“HOT”. Do not allow the electrode to contact ground potential until you are ready to make a weld.

Step 1. Determine the weld parameters based on the metal thickness in Table 4 or use the ESAB TIG Welding

Handbook for suggested welding parameters.

Step 4. Turn the CURRENT (4) knob to the desired weld current.

Step 5. Set the shielding gas flow rate to 20 cfh by opening the manual gas valve on the Heliarc torch and adjusting the control knob on the R-

33-FM-580 flowmeter.

NOTE: The Wirespeed (2) and Volume (3) knobs have no effect in the

TIG mode.

Step 6. Touch the tungsten electrode to the workpiece momentarily to establish the welding arc. Trim the current as desired by turning theCURRENT

(4) knob.

TIG - DCEN (Electrode Negative)

2

1

Work Cable and Clamp

Figure 12 - TIG Polarity Connection

Table 4 - TIG PARAMETERS CHART

3

4

Figure 13-Front Control Panel -

TIG (GTAW) Process Setup

19

SECTION 4 OPERATION

4.2.3 STICK WELDING SET-UP

When the PROCESS switch is placed in the STICK position, the Multimaster 160 turns “ON” the weld contactor so that power is immediately available to the output connection. This means that the STICK electrode holder is “HOT”, and an arc will strike when the electrode comes in contact with the workpiece or any other object at ground potential.

Step 2. Be sure to set the polarity to DCEP (Electrode

Positive) by placing the Electrode Holder cable in the Positive connection terminal on the front of the power source.

In general, choose a polarity based on electrode being used. Some can be run with straight polarity - electrode negative. Some can be run with reversed polarity - electrode positive.

When the WELD PROCESS switch is moved to the

TIG or STICK position, electrode becomes electrically

“HOT”. Do not allow the electrode to contact ground potential until you are ready to make a weld.

Reversed polarity is used when more penetration is re-

Step 1. Choose the weld parameters based on the Stick

Electrode and diameter being used from Table 5

- STICK PARAMETERS CHART.

quired; typically for thicker material. Straight polarity is used when you want less penetration; typically for thinner material.

Step 3. Place the WELD PROCESS (1) switch in the

STICK (FAR LEFT) position.

Step 4. Adjust the CURRENT (4) knob to the desired weld current in the top digital display window.

STICK - DCEP (Electrode Positive)

Hot Start gives you a burst of current to ensure easy arc start. The higher the setting, the bigger the burst.

Step 5. Strike the electrode and start welding. Trim the welding current as needed for the desired puddle control.

Work Cable and Clamp

NOTE: The Wirespeed STICK (2) and Voltage (3) knobs have no

effect in the STICK mode.

2

Figure 14 - STICK Polarity Connection

1

Table 5 - STICK PARAMETERS CHART

3

4

Figure 15 - Front Control Panel -

STICK (SMAW) Process Setup

20

SECTION 5 MAINTENANCE

5.0 MAINTENANCE

5.1 MAINTENANCE AND SERVICE

Be sure that the branch circuit or main disconnect switch and Multimaster power switch are off or electrical input fuses are removed before attempting any inspection or work inside the power source. Placing the power switch on the power source in the off position does not remove all power from inside the equipment.

5.2.1 POWER SOURCE

5.2.1.1 RECTIFIERS AND TRANSISTORS

It is recommended that the internal components be cleaned occasionally by blowing them out with low pressure 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.

The hermetically sealed diodes and transistors are specially designed for welding machine use and will not age or deteriorate with use. The rectifiers are mounted on heat sinks. A periodic cleaning of dust and dirt from these is necessary to insure cooling of the rectifiers. Should any rectifier need replacement, it can be quickly removed from the heat sink.

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.

5.2.1.2 FAN MOTOR

All models are equipped with an exhaust fan and rely on forced draft for adequate cooling for high duty cycles and overloads.

5.2 INSPECTION AND SERVICE

Keep equipment in clean and safe operating condition free of oil, grease, and (in electrical part) liquid and metallic particles which can cause short circuits.

Do not use filters on this unit as they would restrict the volume of intake air. Output ratings on this unit are based on an unobstructed supply of cooling air drawn over its internal components. Warranty is void if any type of filtering device is used.

Regularly check cylinder valves, regulators, hoses, and gas connections for leaks with soap solution or leak test solution (P/N 998771).

Check for and tighten loose hardware including electrical connections. Loose power connections overheat during welding.

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.

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 Power

Source case cover should be removed and a clean, dry low pressure air stream should be used for this cleaning operation.

Immediately replace all worn or damaged power cables and connectors. Check for frayed and cracked insulation, particularly in areas where conductors enter equipment.

5.2.1.4 OVER-TEMPERATURE PROTECTION

The Power Source is protected from high internal temperatures by thermal switches. When the Power Source is operated under high current applications for long periods, the thermal switches may reach a high temperature causing it to de-energize the contactor. These thermal switches will reset automatically after the heat sink or transformer windings have cooled to a safe level. While de-energized, the contactor can not be operated. But, if the gun trigger is depressed, the unit will still feed wire and the solenoid will operate.

If uninsulated cable and parts are not replaced, an arc caused by a bare cable or part touching a grounded surface may damage unprotected eyes or start a fire. Body contact with a bare cable, connector, or uncovered conductor can cause a fatal shock.

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.

5.2.2 WIRE FEEDER

As 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.

21

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.

SECTION 5 MAINTENANCE

22

SECTION 6 REPLACEMENT PARTS

6.1 General

6.2 Ordering

Replacement Parts are illustrated on the following figures.

When ordering replacement parts, order by part number and part name, as illustrated on the figure.

Replacement parts may be ordered from your ESAB distributor or from:

Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

ESAB Welding & Cutting Products

Attn: Customer Service Dept.

PO Box 100545, Ebenezer Road

Florence, SC, 29501-0545

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide on back cover of this manual for a list of customer service phone numbers.

23

SECTION 6 REPLACEMENT PARTS

24

SECTION 6

17

18

19

20

21

22

23

13

14

15

16

9

10

11

12

Item No.

Part No.

7

8

5

6

3

4

1

2

0558002626

0558002704

0558002735

0558002736

0558002707

0558002708

0558002709

0558002710

0558002795

0558002711

0558002738

0558002739

34574

0558002746

0558002716

0558002717

0558002747

0558002719

58V58

136Z08

35N22

0558002711

21161

21156

Spare Parts List

MultiMaster 160

Description

Multimaster 160

Lid with Handle/Strap (Not Shown)

Knob Ø 25mm

Knob Ø 22mm

Connector Dinse 25

Bottom Plate

MIG EURO Connector

Wire Feeder Assembly

Includes:

Feed Motor

Reel Hub

Fan

Fan Grid

Mains Power Cable w/Plug 10Ft.

EMI Filter

Inverter AC PCB

Control PCB

ON/OFF Switch

Solenoid Valve Assembly

Bulkhead Adaptor for Gas Fittings

Gas Inlet Nut

Gas Inlet Nipple

Spacer for Reel Hub

Serrated Feed Roll 0.9 - 1.0mm

Solid Wire Feed Roll 1.0 - 1.2mm

REPLACEMENT PARTS

Cct. Ref.

+, -

VR1 & 2

S1

25

SECTION 6

61 62

REPLACEMENT PARTS

63

68

64

67

66

Multimaster 160 - Bottom Plate

26

65

SECTION 6

Item No.

Part No.

65

66

67

68

61

62

63

64

0558002726

0558002727

0558002728

0558002729

0558002730

0558002731

0558002732

0558002733

Spare Parts List (Con’t)

MultiMaster 160

Description

Plate

Sink Heat w/Diodes

Output Diodes

Choke

Rectifier Bridge

Varistor

Auxiliary Transformer

Transformer

REPLACEMENT PARTS

Cct. Ref.

27

Notes

28

Notes

29

Notes

30

Revision History

Revision “A” edition of this manual updates the Specification Table on page 7 and revises the MIG, TIG and STICK

Process Charts in Section 4 - Operation.

Revision “B” - graphics were updated to show current black painted surfaces. Minor part number updates done in spare parts list.

Revision “C” - added block diagram on Page 22.

Revision “D” - changed “Ordering Information” and “Optional Equipment” text on pages 9 and 10.

31

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548

Order Entry Product Availability Pricing

Hours: 8:00 AM to 7:00 PM EST

Order Information Returns

B. ENGINEERING SERVICE:

Telephone: (843) 664-4416 / Fax : (800) 446-5693

Warranty Returns

Hours: 7:30 AM to 5:00 PM EST

Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:

Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Specifications

Hours: 8:00 AM to 5:00 PM EST

Equipment Recommendations

D. LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557

Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864

Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123

Hours: 7:30 AM to 4:00 PM EST

Hours: 7:30 AM to 3:30 PM EST

Hours: 7:30 AM to 4:00 PM EST

Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4452

Hours: 7:30 AM to 5:00 PM EST or visit us on the web at http://www.esabna.com

The ESAB web site offers

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F15-678-D 07 / 2005