ESAB MIGMASTER 250 Instruction Manual Download Page 1

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F15-087-J

04 / 2003

MigMaster 250

Welding Package

Instruction Manual

Summary of Contents for MIGMASTER 250

Page 1: ...F15 087 J 04 2003 MigMaster 250 Welding Package Instruction Manual...

Page 2: ...ten request to ESAB WELDING CUTTING PRODUCTS ATTN LITERATUREDEPT 411 S EBENEZER ROAD FLORENCE SC 29501 USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contai...

Page 3: ...NNECTIONS 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 INSTALLINGOPTIONALSPOT STITCH AN...

Page 4: ...4 TABLE OF CONTENTS...

Page 5: ...stances 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 gar...

Page 6: ...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 12...

Page 7: ...extintor de fuego para uso instant neo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor port til Aseg rese que usted esta entrenado para su uso 5 No use el equipo fue...

Page 8: ...de protecci n sobre la v lvula si el regulador no est conectado Asegure y mueva los cilindros utilizando un carro o transporte adecuado Evite el manejo brusco de los Las siguientes publicaciones dispo...

Page 9: ...asse l ossature du b timent ou en un point loign de la zone de travail augmente en effet le risque de passage d un courant de sortie par des cha nes de AVERTISSEMENT Ces r gles de s curit ont pour obj...

Page 10: ...rticuli res en mati re de ventilation indiqu es l alin a 6 de la norme Z49 1 de l AWS 5 ENTRETIEN DE L QUIPEMENT Un quipement entretenu de fa on d fectueuse ou inad quate risque non seulement de r ali...

Page 11: ...lding 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 e...

Page 12: ...5 CONTROLS TheMigmaster250Systemcanbeusedtoweldhardand aluminum wire with an optional ST 23A spool gun torch An optional spot stitch control allows a welder to spot or stitchweldwithinarangeof0 4to3...

Page 13: ...2S Spotweld Nozzle P N 999625 2 4 2DIGITALVOLT AMMETERMODULE P N32857 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 25...

Page 14: ...to misuse orimproperweldingapplications Thesymbol which precedes safety notes appear ingthroughoutthismanualmeans Attention BeAlert Your safety is involved The definitions relating to the DANGER WARNI...

Page 15: ...completely under the base Do not operate the machine without the running gearinstalled 3 2ELECTRICALINPUTCONNECTIONS It is recommended that a line disconnect switch be installed in the input circuit...

Page 16: ...phscover the procedure to switch the voltage tap for either 208vac or230vacinput 3 2 2InputConductorConnections The input power cord on 208 230 Volts primary input model is provided with an attachment...

Page 17: ...will resultinanelectricallyhotweldingmachinechassis 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 sleevi...

Page 18: ...cted to the welding polarity D C Reverse or D C Straight via the secondaryoutputterminalslocatedinsidethewirefeed ing compartment see Fig 4 1 The machine comes set up for D C R P welding as described...

Page 19: ...er 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...

Page 20: ...ectric 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 th...

Page 21: ...untingscrews b Locate the harness connected 10 pin plastic plug PL1 inside the mounting cavity This plug does not have a jumper plug connected to it c Connect the 10 pin plug into the matching recep t...

Page 22: ...22 SECTION 3 INSTALLATION...

Page 23: ...n 18 and 56 volts DC when the secondary contactor is energized 4 1 2 VOLTAGE CONTROL Coarse Range Selector and Fine Adjustment Range Selector Voltage control is by means of two high current tap switch...

Page 24: ...he charged capacitor bank in the secondary circuit the output voltage will take a few seconds before falling to zero volts The gas valve shuts off when the contactor opens The Migmaster 250 is equippe...

Page 25: ...s weld mode center position for mig seam welding B Setthe Anti StickTime asrequired see4 2 3 1 IMPORTANT Always make sure that the plasticplug is screwed back into the adaptor when the ST 23A gas powe...

Page 26: ...e arc will be ON for each sequence by adjusting the Spot Stitch Weld Time control on the power supply s front panel This timerhasanapproximaterangeoffrom0 4seconds at the minimum setting to 3 5 second...

Page 27: ...ene and perchlorethylene to form phosgene evenwhenthesevaporsarepresentinlowconcen trations DONOTweldwherechlorinatedsolvents are present in atmospheres in or around the arc C DONOTtouchtheelectrode n...

Page 28: ...ove loose surface rust scale or paint with wire brush or sander b Attempting to weld over grease or oil can cause welddefects c Before welding on aluminum be sure to clean surfacethoroughlyusingastain...

Page 29: ...g either up or down it is very important to keep the arc on the leading edge of the puddle to ensure complete pen etration G Some welders who are accustomed to welding with stick electrodes may tend t...

Page 30: ...nt is provided with a thermostat OL in the transformer T1 windingswhichwillopenandpreventthe contactor CON fromclosingifthetransformerwindings areoverheated Ifthethermostatopens allowtheequip ment to...

Page 31: ...dwareincludingelectrical connection Loose power connections overheat during welding Immediately replace all worn or damaged power cables andconnectors Checkforfrayedandcrackedinsulation particularly i...

Page 32: ...e necessary to replace this or any other fuse in the welding machine ensure that the proper size fuse is used as a replacement 5 2 1 5OVER TEMPERATUREPROTECTION The machine is equipment with a thermos...

Page 33: ...an appropriate instrument Do not make any repairs to equipment unless you are fully qualified as described in the maintenance section TABLEII TROUBLESHOOTINGGUIDE WELDCONDITION POSSIBLECAUSE REMEDY 1...

Page 34: ...er d Check flow at outlet replace faulty item e Faulty gas solenoid valve SOL e Replace solenoid valve f Wrong polarity f Check polarity 10 Shield gas flow low or a Cylinder valve closed a Turn off re...

Page 35: ...leads but motor does not run check motor gears and commutator areas b Power switch S3 and fuses b With S3 ON if voltage across terminal 1 and 3 is 24 VAC switch and fuses are good c Speed Potentiomet...

Page 36: ...sition mumbers refer to numbers on back of switch NOTE Recent modifications to the power source may not be reflected in this schematic For up to date information on your model refer to the schematic o...

Page 37: ...r source may not be reflected in this schematic For up to date information on your model refer to the schematic on the inside cover of the power source or contact the factory D 33310 C PRIMARY VOLTAGE...

Page 38: ...38 Figure 5 3 Wiring Migmaster 250 for 208 230 V Model D 32861 F...

Page 39: ...39 Figure 5 4 Wiring Migmaster 250 for 208 230 380 400 460 575 V Model D 33311 D...

Page 40: ...40 SECTION 5 SERVICE...

Page 41: ...idualparts These parts are listed indented one space below the assem bly When any of the parts can be broken down as a sub assembly its individual parts as listed below it indented two spaces Attachin...

Page 42: ...KNOB 13 1 32818 SWITCH FINE VOLTS ADJ 8 POS S1 14 2 2062171 KNOB 15 1 647233 RECEPTACLE 8 PIN J3 16 2 2062171 KNOB w SET SCREW 17 1 32902 SWITCH COARSE VOLTS ADJ 3 POS S2 18 1 951069 PLUG PLASTIC C S...

Page 43: ...43 FIGURE 6 2 MiGMASTER 250 Main Assembly Left Side 19 20 15 16 22 23 5 25 FAN ASSEMBLY See Figure 6 4 7 17 18 14 12 8 6 4 26 1 21 24 SECTION 6 REPLACEMENT PARTS...

Page 44: ...HING 14 1 31484 P C BOARD SPEED CONTROL PCB1 15 1 2360 8111 TERMINAL BLOCK 8 PT TB1 16 1 1373 5940 MARKER TERMINAL 17 2 950760 RELAY from 1 1 94 K2 K3 2361 0322 RELAY 4 PDT 24 VAC 10A 18 1 1373 0469 B...

Page 45: ...45 1 2 3 5 6 7 11 19 14 18 16 9 10 20 FIGURE 6 3 MiGMASTER 250 Main Assembly Right Side SECTION 6 REPLACEMENT PARTS...

Page 46: ...1 634709 HOLDER FUSE 9 1 2361 2348 GEAR MOTOR 50 675 IPM 10 1 2361 2479 KEY MOTORSHAFT 11 1 33199M COVER P C BOARD 14 1 952939 DRIVE STAND ASSEM See Fig 6 6 15 1 82F31 WORKCLAMP 16 1 1373 2232 FILTER...

Page 47: ...0 1 1373 2226 MOTOR FAN M1 3 2 1 7 6 5 4 8 9 FIGURE 6 5a MIGMASTER 250 LEXAN HUB KIT ITEM QTY PART CKT NO REQ NO DESCRIPTION HUBKIT DESIG 2360 5780 REEL HUB KIT INCLUDES 1 8 1 1 2360 0255 BRAKE DISC 2...

Page 48: ...375 4 1 0558002992 Bracket Spool Support 5 1 33191M Shelf Silkscreened 6 AR 63300916 Nut Hex 10 24 7 AR 64302920 Washer Lock 8 8 2 948255 Pad Braking 9 1 2360 0982 Spring 10 1 634347 Pin Hitch Clip 1...

Page 49: ...ESSURE DEVICE ASSY 10 1 23612473 LOCATINGPIN 11 1 23612461 INLETGUIDE 12 1 21156 DRIVE ROLL see Table 2 1 13 1 952944 ADAPTORDRIVEROLL 14 1 952925 FEED ROLL THUMB SCREW 15 1 23612478 FEED PLATE 16 1 3...

Page 50: ...23612478 Feed Plate 106 1 23612461 Inlet Guide 035 045 Also see Table 1 3 107 5 23612462 MTG Screw Drive Stand 108 1 952944 Feed Roll Adaptor See Table 1 3 for Drive Rolls 109 2 23612384 Locating Scre...

Page 51: ...REROLL 9 1 23612460 PRESSURE DEVICE ASSY 10 1 23612473 LOCATINGPIN 11 1 23612461 INLETGUIDE 12 1 21156 DRIVE ROLL see Table 2 1 13 1 23612383 GEAREDADAPTORDRIVEROLL 14 1 23612398 FEEDROLLRETAININGSCRE...

Page 52: ...52 SECTION 6 REPLACEMENT PARTS...

Page 53: ...53 NOTES...

Page 54: ...NOTES...

Page 55: ...t parts list of Figure 6 2 5 Changed the drive stand from 23612627 to 952939 6 Added parts call out Figure 6 7 for drive stand with driven upper pressure roll 23612627 The H edition 12 00 of this manu...

Page 56: ...rranty Returns Authorized Repair Stations WeldingEquipmentTroubleshooting C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications S...

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