ESAB MigMaster 250 Welding Package Manuel utilisateur
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- Système de soudage
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- Manuel utilisateur
F15-087-J 04 / 2003
MigMaster 250
Welding Package
Instruction Manual
2
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.
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
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.
3
SECTION NO. PAGE NO.
SECTION 1 - SAFETY PRECAUTIONS FOR WELDING
AND CUTTING ........................................................................................................... 3
SECTION II - INTRODUCTION ............................................................................................ 11
2.1 GENERAL ................................................................................................................................ 11
2.2 RECEIVING-HANDLING.......................................................................................................... 11
2.3 DESCRIPTION, Available Packages/Contents....................................................................... 11
2.4 OPTIONAL ACCESSORIES..................................................................................................... 12
2.5 SAFETY .................................................................................................................................... 14
SECTION III - INSTALLATION............................................................................................ 15
3.1 LOCATION ............................................................................................................................... 15
3.2 ELECTRICAL INPUT CONNECTIONS.................................................................................... 15
3.3 SECONDARY OUTPUT CONNECTIONS ............................................................................... 18
3.4 TORCH CONNECTIONS......................................................................................................... 18
3.5 WIRE FEEDER MECHANISM .................................................................................................. 18
3.6 CONNECTION OF THE SHIELD GAS..................................................................................... 19
3.7 WELDING CABLE CONNECTIONS ........................................................................................ 20
3.8 ASSEMBLE REAR WHEELS ................................................................................................... 20
3.9 INSTALLING OPTIONAL SPOT/STITCH/ANTI-STICK MODULE............................................. 20
3.10 INSTALLING OPTIONAL DIGITAL METER .............................................................................. 21
SECTION IV - OPERATION ................................................................................................ 23
4.1 CONTROLS ............................................................................................................................. 23
4.2 PROCESS SETUP .................................................................................................................. 24
4.3 OPERATING PROCEDURES.................................................................................................. 27
SECTION V - SERVICE ...................................................................................................... 31
5.1 MAINTENANCE........................................................................................................................ 31
5.2 INSPECTION AND SERVICE .................................................................................................. 31
5.3 TROUBLESHOOTING ............................................................................................................. 32
SECTION VI - PARTS ......................................................................................................... 41
6.1 SPARE PARTS ........................................................................................................................ 41
6.2 REPLACEMENT PARTS.......................................................................................................... 41
6.3 ORDERING.............................................................................................................................. 41
TABLE OF CONTENTS
4
TABLE OF CONTENTS
5
WARNING:
These Safety Precautions are for
your protection. They summarize precaution-
ary 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 pro-
cesses are noisy and require ear pro-
tection. The arc, like the sun, emits ul-
traviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip-
ment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a weld-
ing 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 ex-
plosions. 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 pro-
duce 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.
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 neces-
sary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-
cesses", available from the National Fire Protection As-
sociation, 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 move-
ment 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 dam-
aged 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 mis-
take the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow-
ing through any conductor causes lo-
calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre-
ates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physi-
cian before welding. EMF may interfere with some pace-
makers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to mini-
mize 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.
SECTION 1 SAFETY PRECAUTIONS
6
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield-
ing 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 posi-
tive mechanical ventilation is provided. Do not breathe
fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. 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 cylin-
der, 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 regu-
lator 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 installa-
tion, 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 Goug-
ing", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi-
ami, 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 Tung-
sten 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, seri-
ous 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.
SECTION 1 SAFETY PRECAUTIONS
7
ADVERTENCIA:
Estas Precauciones de Seguridad
son para su protección. Ellas hacen resumen de
información proveniente de las referencias listadas
en la sección "Información Adicional Sobre La Seguridad". Antes
de hacer cualquier instalación o procedimiento de operación ,
asegúrese de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja de datos de
seguridad del material, calcomanias, etc. El no observar las
Precauciones de Seguridad puede resultar en daño a la persona
o muerte
.
PROTEJASE USTED Y A LOS DEMAS--
Algunos procesos de soldadura, corte y
ranurado son ruidosos y requiren protección
para los oídos. El arco, como el sol , emite
rayos ultravioleta (UV) y otras radiaciones que pueden dañar
la piel y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y sus procesos
es esencial para prevenir accidentes. Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados siempre
que esté en el área de trabajo, aún cuando esté usando careta
de soldar, protector para su cara u otro tipo de protección.
2. Use una careta que tenga el filtro correcto y lente para proteger
sus ojos, cara, cuello, y oídos de las chispas y rayos del arco
cuando se esté operando y observando las operaciones. Alerte
a todas las personas cercanas de no mirar el arco y no
exponerse a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa pesada de
mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y
careta de soldar con capucha para el pelo, para proteger el
cuerpo de los rayos y chispas calientes provenientes del metal
fundido. En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las chispas.
4. Chispas y partículas de metal caliente puede alojarse en las
mangas enrolladas de la camisa , el ruedo del pantalón o los
bolsillos. Mangas y cuellos deberán mantenerse abotonados,
bolsillos al frente de la camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas
calientes con una cortina adecuada no-flamable como división.
6. Use careta protectora además de sus gafas de seguridad
cuando esté removiendo escoria o puliendo. La escoria puede
estar caliente y desprenderse con velocidad. Personas cercanas
deberán usar gafas de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de las
flamas y el arco pueden ocacionar fuegos.
Escoria caliente y las chispas pueden
causar fuegos y explosiones. Por lo tanto:
1.
Remueva todo material combustible lejos del
área de trabajo o cubra los materiales con una cobija a prueba
de fuego. Materiales combustibles incluyen madera, ropa,
líquidos y gases flamables, solventes, pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en las grietas
y agujeros de pisos y paredes causando fuegos escondidos en
otros niveles o espacios. Asegúrese de que toda grieta y
agujero esté cubierto para proteger lugares adyacentes contra
fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado hasta
que la pieza de trabajo esté totalmente limpia y libre de substancias
que puedan producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques cerrados.
Estos pueden explotar si contienen vapores inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso
instantáneo, como por ejemplo una manguera con agua, cubeta
con agua, cubeta con arena, o extintor portátil. Asegúrese que
usted esta entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por ejemplo,
el calor causado por cable sobrecarga en los cables de soldar
pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área
de trabajo para cerciorarse de que las chispas o metal caliente
ocasionen un fuego más tarde. Tenga personal asignado para
vigilar si es necesario.
7. Para información adicional , haga referencia a la publicación
NFPA Standard 51B, "Fire Prevention in Use of Cutting and
Welding Processes", disponible a través de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
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.
Asegúrese de que el chasis de la
fuente de poder esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de tierra física.
3. Conecte el cable de retorno a la pieza de trabajo. Cables y
conductores expuestos o con malas conexiones pueden
exponer al operador u otras personas a un choque eléctrico
fatal.
4. Use el equipo solamente si está en buenas condiciones.
Reemplaze cables rotos, dañados o con conductores
expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los
cables, antorchas, pinza del electrodo, y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están insuladas
de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja
en lugares estrechos o áreas húmedas; trabaje sobre un
pedazo de madera seco o una plataforma insulada y use
zapatos con suela de goma.
8. Use guantes secos y sin agujeros antes de energizar el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC Standard Z49.1
(listado en la próxima página) para recomendaciones específicas
de como conectar el equipo a tierra. No confunda el cable de
soldar a la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETICOS -
Son peligrosos. La corriente eléctrica fluye
através de cualquier conductor causando a
nivel local Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y
soldadura, crean EMF alrrededor de los
cables de soldar y las maquinas. Por lo tanto:
1. S
oldadores 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.
SECTION 1 PRECAUCION DE SEGURIDAD
8
HUMO Y GASES -- El humo y los gases,
pueden causar malestar o daño,
particularmente en espacios sin
ventilación. No inhale el humo o gases. El
gas de protección puede causar falta de
oxígeno.
Por lo tanto:
1. Siempre provea ventilación adecuada en el área de
trabajo por medio natural o mecánico. No solde, corte, o
ranure materiales con hierro galvanizado, acero inoxidable,
cobre, zinc, plomo, berílio, o cadmio a menos que provea
ventilación mecánica positiva . No respire los gases
producidos por estos materiales.
2. No opere cerca de lugares donde se aplique substancias
químicas en aerosol. El calor de los rayos del arco pueden
reaccionar con los vapores de hidrocarburo clorinado
para formar un fosfógeno, o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de ojos,
nariz o garganta mientras est á operando, es indicación
de que la ventilación no es apropiada. Pare de trabajar
y tome las medidas necesarias para mejorar la
ventilación en el área de trabajo. No continúe operando
si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones
específicas en la ventilación.
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.)
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
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 Weld-
ing and Cutting of Containers That Have Held Hazardous
Substances."
Significa riesgo inmediato que, de no ser
evadido, puede resultar inmediatamente
en serio daño personal o la muerte.
Significa el riesgo de un peligro potencial
que puede resultar en serio daño per-
sonal o la muerte.
Significa el posible riesgo que puede
resultar en menores daños a la persona.
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.
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.
SIGNIFICADO DE LOS SIMBOLOS --
Según usted avanza en la lectura de
este folleto: Los Símbolos Significan
¡Atención! ¡Esté Alerta! Se trata de su
seguridad.
SECTION 1 PRECAUCION DE SEGURIDAD
9
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 combus-
tibles 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
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 incandes-
cent 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 com-
bustibles solides, liquides ou gazeux. Aussi faut-il
SECTION 1 PRÉCAUTIONS DE SÉCURITÉ
10
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 mal-
aises 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 ventila-
tion 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. Arrêtez-
vous de travailler afin de prendre les mesures néces-
saires 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’élimi-
ner 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 qua-
lifié 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 Weld-
ing, 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.
SECTION 1 PRÉCAUTIONS DE SÉCURITÉ
11
Depending on the primary input voltage of the MM-250,
and the torch length, each package includes the follow-
ing:
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
CO
2
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 connec-
tions 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.
II. INTRODUCTION
2.1 GENERAL
This manual has been prepared especially for use in
familiarizing personnel with the design, installation, op-
eration, maintenance, and troubleshooting of this equip-
ment. 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 mate-
rial 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 de-
signed for fine wire, (0.023, 0.030, 0.035 and 0.045 in.)
welding using the short arc method, as well as for spray
arc aluminum, short arc and spray arc stainless steel and
spray arc cored wires. It incorporates a running gear with
provisions for one gas cylinder, and a ST-23A spool-on-
gun control.
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 CO
2
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
SECTION 2 INTRODUCTION
12
2.3.6 RUNNING GEAR
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.
2.4 OPTIONAL ACCESSORIES
2.4.1 SPOT/STITCH/ANTI-STICK MODULE, P/N
32858.
This easy-to-install, plug-in module mounts in place of
the lower blank cover plate of the upper-right front panel
location in the 250 unit. It enables the operator to use the
250 for Spot or Stitch or Continuous welding operations.
It also includes an adjustable Anti-Stick feature that
allows you to select various wire burnback times to
prevent wire from sticking in the puddle after a weld. For
installation, see Section 3.9 and for operating instruc-
tions see Section 4.2.
2.3.4 GUNMASTER 250 WELDING TORCH (F-15-085),
The lightweight air cooled welding gun included in se-
lected 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 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 built-
in spool-on-gun adaptors and control, when used in
conjunction with the optional ST-23A torch, permits alu-
minum wire welding with the machine.
TABLE 1. SPECIFICATIONS
POWER SOURCE MIGMASTER 250
Rated Output 250 Amps @ 27 Volts d.c.
Duty Cycle, 208/230V Unit 50% @ 60 Hz.; 40% @ 50 Hz.
208/230/380/400/460/575V Unit 35% for 208 through 400V; 50% for 460 & 575V
Primary Input Single Phase 208/230; 208/230/380/400/460/575 Volts 50 60 Hz
Primary Input Amperes 208-71, 230-62, 380-37,400-36, 460-31, 575-25
Output Current Range 30 to 280 Amps.
Maximum Open Circuit Volts 55 v.d.c.
FEEDER
Feed Type Push
Wire Sizes: Hard 0.023" (0.6mm) through 0.045" (1.2mm)
Cored 0.030" (0.8mm) through 1/16" (1.6mm)
Soft 0.035" (0.9mm) and 3/64" (1.2mm)
Feed Rate 20-650 IPM
GUNMASTER 250 TORCH
Cooling Air
Gooseneck Angle 45 degrees
Rated 60% Duty Cycle
(DCRP) Amps: 200 w/Argon Mixtures, 300 w/CO
2
Conduit Length see section 2.3.1
PHYSICAL
Net Weight *210 lbs (95 Kg.)
Height *32.25 inches (819 mm)
Width *19.5 inches (495 mm)
Depth *40.0 inches (1016 mm)
*Includes running gear & bottle tray.
SECTION 2 INTRODUCTION
13
TABLE 2.4.5.1 Recommended GUNMASTER 250 Torch Accessories
Wire Contact Tips Liners
Size & Type Short (S) Medium (M) Long (L) 10' 12' 15'
Hard Wires & Cored Wires
.023" (.6mm) - 20543 999742 999743* - -
.030" (.8mm) - 20544 996994 948850 17717 -
.035" (.9mm) - 996995 996996 2075237 17718 2075238
.040" (1.0mm) - 37287 37288
.045" (1.2mm) 999578 37290 996998 2075237 17718 2075238
.052" (1.4mm) 948340 2075349 - 2075239 17719 2075240
1/16" (1.6mm) 948341 37289 - 2075239 17719 2075240
Soft Wires (aluminum)
.035" (.9mm) - 996995 996996 948862 - -
.040" (1.0mm) - 37287 37288
3/64" (1.2mm) 999578 996999 996998 948863 - -
(S) Short contact tips are recommended for proper wire stick out for flux cored wire welding.
(M) Medium contact tips are recommended for proper wire stick out in spray transfer Mig
welding.
(L) Long contact tips are recommended for good visibility and proper wire stick in dip transfer
Mig welding.
* Requires support liner for .023" wire. Order P/N 999797.
New ID for improved arc performance on steel/flux cored wire.
2.4.4 TORCH NOZZLES
A No. 8 Nozzle (1/2" I.D.), P/N 998893 for the
GUNMASTER 250 Torch, is included in the Migmaster
250 package. This slip-on type nozzle incorporates a
permanent insulator/spatter shield. Other standard duty
slip-on nozzles with insulator/spatter shield, are available
separately:
No. 6 Nozzle, Tapered (3/8" I.D.)............ P/N 998895
No. 10 Nozzle (5/8" I.D.)......................... P/N 998894
No. 12S Spotweld Nozzle (3/4" I.D.)......... P/N 17316
The following heavy-duty slip-on nozzles with insulator/
spatter shield, are available separately:
No. 8 Nozzle (1/2" I.D.)........................... P/N 999471
No. 10 Nozzle (5/8" I.D.)......................... P/N 999472
No. 12 Nozzle (3/4" I.D.)......................... P/N 999473
No. 12 Spot Nozzle (3/4" I.D.) ................ P/N 999625
New Long Life MT Nozzles. These nozzles have a
patented coating to reduce weld spatter and extend the
life of the nozzle.
No. 6 XL Nozzle, (MT Std.).................P/N 998895XL
No. 8 XL Nozzle, (MT Std.).................P/N 998893XL
No. 10 XL Nozzle, (MT Std.)...............P/N 998894XL
No. 8 XL Nozzle, (MT HD)..................P/N 999471XL
No. 10 XL Nozzle, (MT HS) ................P/N 999472XL
2.4.5 TORCH/WIRE FEED ACCESSORIES -- See
Tables 2.4.5.1 and 2.4.5.2.
2.4.6 SPOOL SPACER
For 8" dia. spools..................................... P/N 17511
For 10" dia. spools ....................................P/N 34330
If a Spotwelding operation is to be used, it is recom-
mended 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 win-
dows, 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 indi-
cation 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 pro-
cess. 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.
Table2.4.5.2 Drive Roll & Guide Tube Selection
Upper
Wire Type / Lower Pressure Guide
Diameter Drive Roll Roll Tube
Hard Wires (“V” groove)
.023 in. (0.6mm) 21155 23612397 21163
.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) 21158 23612397 21167**
3/64 in. (1.2mm) 21159 23612397 21168**
Cored Wires (Serrated “V” groove - lower)
.030 in. (0.8mm) 21160 23612369 21164
.035 in. (0.9mm) 21160 23612369 21165
.040 in. (1.0mm) 21161 23612369 21165
.045 in. (1.2mm) 21161 23612369 21165
.052 in. (1.4mm) 21161 23612369 21166
1/16 in. (1.6mm) 21161 23612369 21166
Cored Wires (Serrated “V” groove - upper and lower)†
.045 in. (1.2mm) 37319 37319 21165
.052 in. (1.4mm) 37319 37319 21166
1/16 in. (1.6mm) 37320 37320 21166
* Supplied with Migmaster 250.
** Requires Support Tube 21169.
† Recommended for use with soft cored wires that are easy to
flatten.
SECTION 2 INTRODUCTION
14
2.5 SAFETY
Before the equipment is put into operation, the safety
section at the front of this manual should be read com-
pletely. This will help avoid possible injury due to misuse
or improper welding applications.
The symbol which precedes safety notes appear-
ing 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.
SECTION 2 INTRODUCTION
15
40.00"
19.50"
32.25" Overall
III. 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 move-
ment 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 ma-
chine side and rear panels and the nearest obstruction.
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 ma-
chine as this would restrict the volume of
intake air and thereby subject the welding
machine internal components to an over-
heating 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
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 weld-
ing machine whenever it is necessary to perform any
internal function on the unit. (See Figure 3.2A.)
Before making electrical input connections to the
welding machine, “Machinery Lockout Procedures”
should be employed. If the connections are to be
made from a line disconnect switch, the switch should
be padlocked in the off position. If the connection is
made from a fusebox, remove the fuses from the box
and padlock the cover in the closed position. If
locking facilities are not available, attach a red tag to
the line disconnect switch (or fuse box) to warn others
that the circuit is being worked on. If the plug-cap is
used, (see 3.2B) remove plug from receptacle.
3.2.1 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.
Figure 3.1 Dimensional Drawing
SECTION 3 INSTALLATION
16
Figure 3.2 - Primary Connection
208/230 MODEL ONLY (With Plug-Cap)
208/230/380/400/460/575-V. MODELS
SINGLE-PHASE
THREE-PHASE
SINGLE-PHASE
THREE-PHASE
GRD
GRD
GREEN
CONDUCTOR
(GROUND)
GREEN
Fused
Line
Disconnect
Switch,
or
Circuit Breaker
Wall Receptacle
MIGMASTER
SYSTEM
CONNECTS HERE
Figure 3.2 A
Figure 3.2 B
Figure 3.2 DFigure 3.2 C
TABLE 3.1 Input Conductor and Fuse Size
Recommended
Full Primary
Primary Load Input Ground
Input Line Fuse Conductor Conductor
Volts Amperes Size Size Size
208 71 90 8 8
230 62 90 8 8
380 37 50 10 10
400 36 50 10 10
460 31 40 12 12
575 25 30 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 compart-
ment and switching the primary transformer tap at the top
of the power switch with the unused alternate voltage tap
located next to the main transformer (see Fig. 3.3B). Both
voltage taps (the one currently connected to the switch
and the unused alternate voltage) are marked with the
input voltage requirement. All units are supplied from the
factory connected for the highest voltage (230 vac). Before
switching the voltage taps, verify the actual voltage
requirement as well as the current voltage connection to
be certain re-connection is necessary. If voltage tap re-
connection is necessary, the following paragraphs cover
the procedure to switch the voltage tap for either 208vac
or 230vac input.
3.2.2 Input Conductor Connections
The input power cord on 208/230 Volts primary input
model is provided with an attachment plugcap. The
plugcap will mate with a 250 Volts, 50 Ampere receptacle
conforming to NEMA 6-50 R configuration.
The receptacle should be wired to a separately fused
disconnect or circuit breaker of the size listed in Table 3.1.
This disconnect or breaker can be wired to a single phase
system or to two conductors of a three phase system. A
third conductor for grounding should also be connected
between the disconnect and the receptacle.
Figure 3.2A illustrates wiring to a single phase system
and Figure 3.2B illustrates wiring to a three phase
system.
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 electri-
cal input requirements internally-connected for the high-
est voltage rating available in each model (e.g.: 230-volt
for the 208/230-volt units; and 575-volt for the "multi-
voltage" units).
Only qualified personnel should make these changes.
Make certain the primary power has been discon-
nected and all safety procedures have been followed
before proceeding with these instructions.
GRD
GRD
SECTION 3 INSTALLATION
17
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 clear-
ance between the unused lead and other compo-
nents 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.
Fig. 3.3C - Power Switch Connection
Fig. 3.3B - Position of Alternate Voltage Tap
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.
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 compo-
nents 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
SECTION 3 INSTALLATION
18
terminals and disconnect the 208 Vac lead from the top of
the switch as shown in Fig. 3.3A. Insulate the 208 Vac
lead that was removed from the power switch with sleeving
or approved electrical tape and re-position to a safe area
beside the transformer (see Fig. 3.3B), leaving a minimum
of one inch clearance from other components and the side
panel.
Connect the proper voltage (208 Vac or 230 Vac) tap to the
power switch and tighten securely. Check all other leads
connected to the power switch for tightness and clearance
from internal components before securing the insulating
cover around the power switch. Replace the side panel.
3.2.5 Reconnecting from 575 VAC Input
Figure 3.3.1 shows you how to reconnect the "multi-
voltage" model from a 575-volt input to any of the remain-
ing 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.
3.3 SECONDARY OUTPUT CONNECTIONS
The Migmaster 250 Welding System is completely self-
contained 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 feed-
ing 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.
3.5 WIRE FEEDER MECHANISM
3.5.1 DRIVE ROLLS
The drive roll has two grooves: the small groove feeds
0.035 in. diameter wire, the large groove feeds 0.045 in.
wire. The groove nearest the gear motor feeds the wire.
If the required groove is not in that position:
A. Release the pressure drive roll lever and lift the
assembly upward.
B. Remove the two (2) screws holding the drive roll to
the gear.
C.Reverse the drive roll on the drive roll shaft.
D.Replace the screws and tighten.
E. Secure the pressure drive roll assembly.
Figure 3.3.1-Primary Reconnections at Voltage
Changeover Terminal Board for 208/230/380/400/460/
575Volt Models
PRIMARY VOLTAGE CONNECTION CHART
VOLTAGE CONNECTION NO. OF STRIPS
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 2 - 6 2
7 - 8 FLEX
460 2 - 6 2
4 - 8 FLEX
575 2 - 3 2
4 - 8 FLEX
SECTION 3 INSTALLATION
19
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.
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 THREADING WELDING WIRE
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 cas-
ing, make sure chisel point and burrs have
been removed from wire end to prevent wire
from jamming in gun casing or liner.
C. Feed the wire from the spool through the inlet
guide, across the drive roll groove and into gun
outlet guide.
Make sure that the proper “outlet guide tube” is inserted
into the front-panel gun fitting for the size and type of wire
being used, see Table 2.4.5.2 for wire feed accessories
(Section 2.4.5).
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.
D. Lower pressure roll assembly and secure. Check
that the gears mesh. Feed wire through to gun tip
with gun trigger (power ON).
OUTLET
CONNECTION
CYLINDER
PRESSURE
GAUGE
f. Attach the gas hose from the rear of the Migmaster
250 to the regulator outlet connection (see Fig. 3.6).
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)
CYLINDER
VALVE
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 de-
crease 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:
Do Not adapt R-33-FM-580 for use with CO
2
. Relief
device may rupture if CO
2
is used with the R-33-FM-
580. For CO
2
service, order R-33-FM-320, P/N 21558.
a. With the cylinder cap in place CAREFULLY slide
the cylinder of gas onto the Migmaster 250 cylinder
rack.
b. Secure the cylinder to the unit, using the chain
provided.
c. Unscrew the cylinder cap.
d. Open the cylinder valve slightly, just for an instant,
to blow away any dirt or dust which may have ac-
cumulated in the cylinder valve outlet. Be sure to
keep your face away from the valve outlet
to protect your eyes.
e. Attach the regulator to the cylinder valve, tighten
the union nut securely with a 1-1/8in. open end or
an adjustable wrench.
SECTION 3 INSTALLATION
20
Never stand directly in front of or behind the regula-
tor 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 regu-
lator and at the Migmaster 250 for leakage. Correct
any leaks before starting work.
i. If work is to be stopped for a half-hour or more, or
the regulator is to be removed from the cylinder,
shut down the regulator as follows:
a. Close the cylinder valve.
b. Release gas from the regulator by closing the
torch trigger lever.
c. When pressure gauge drops to zero, the regu-
lator is de-pressurized and shutdown.
j. Each regulator is equipped with a porous metal
inlet filter, P/N 71Z33, pressed into the regulator
inlet nipple. No. regulator should be connected to
a cylinder or station valve unless it contains this
filter. You can replace the filter if you have reason
to do so. To remove a filter refer to the regulator
instruction literature for details.
k. Regulators in need of repair should be returned to
your Welding Equipment distributor or to an autho-
rized Remanufacturing Center.
If welding is performed in a confined area, shielding
gas leaks could result in a buildup of shielding gas
concentration, displacing oxygen, thereby endan-
gering personnel enter the area.
3.7 WELDING CABLE CONNECTIONS
Connect the work clamp solidly to the workpiece or work
table. Clamp onto a bare metal area.
A good electrical connection to the work is essential
to proper welding operation and to prevent electric
shock.
Welding cables should be kept as short as possible and
be of adequate current carrying capacity. Resistance of
the welding cables and connections causes a voltage
drop which is added to the voltage drop of the arc.
Excessive cable resistance may result in a reduction of
the maximum usable current output of the equipment.
The proper operation of this equipment is to a large extent
dependent on the use of welding cables and connections
which are in good condition and of adequate size.
3.8 ASSEMBLE REAR WHEELS
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. Insert the axle through the holes provided at the
rear of the gear.
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 as-
sembly by inserting a pin in each end of the axle.
c. Remove the existing shipping supports by un-
screwing from chassis.
3.9 INSTALLING OPTIONAL SPOT/STITCH/ANTI-
STICK MODULE
a. Remove lower blank-cover plate from upper-right
front panel of power supply -- save the four mount-
ing 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 con-
nected to it -- remove (and save) the jumper plug.
(The jumper plug must be reinstalled if the module
is ever removed.
c. Connect the 15-pin plug into the matching recep-
tacle on the rear of the optional control module. The
plug will only fit one way.
d. Install the control module in place of the blank
panel removed in Step a., using the same four
screws that you saved.
SECTION 3 INSTALLATION
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ESAB MigMaster 250 Welding Package Manuel utilisateur
- Catégorie
- Système de soudage
- Taper
- Manuel utilisateur
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