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ESAB Migmaster 275, Instruction Manual

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ESAB Migmaster 275 Instruction Manual Download Page 47

47

12 / 2008 - Initial release

04 / 2009 - Added "Burn Back" phrase in several locations and deleted redundant or unneeded information per 

Bob Bitzky / George Magee redlines.

06 / 2009 - Updates made per J. Magee.

07 / 2009  -  Added stainless and aluminum setup charts per Bob Bitzky.

reVIsIon hIstorY

Summary of Contents for Migmaster 275

Page 1: ...Instruction Manual 0558008552 07 2009 Welding Package Migmaster 275 OPTIONAL DIGITAL METER MODULE OPTIONAL BURN BACK MODULE ...

Page 2: ... from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a ser vice facility designated by the manufacturer Be sure this information reaches the operator You can get extra copies through your supplier These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operation and safe practices for arc w...

Page 3: ... INPUT CONNECTIONS 21 3 3 SECONDARY OUTPUT CONNECTIONS 24 3 4 TORCH CONNECTIONS 25 3 5 WIRE FEEDER MECHANISM 25 3 6 CONNECTION OF THE SHIELD GAS 26 3 7 WELDING CABLE CONNECTIONS 26 3 8 INSTALLING OPTIONAL BURN BACK MODULE 27 3 9 INSTALLING OPTIONAL DIGITAL METER 27 SECTION 4 OPERATION 29 4 1 CONTROLS 29 4 2 PROCESS SETUP 31 4 3 OPERATING SAFETY PROCEDURES 32 SECTION 5 SERVICE 37 5 1 MAINTENANCE 37...

Page 4: ...4 TABLE OF CONTENT ...

Page 5: ...thing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Usegogglesoversafetyglasseswhenchippingslag orgrinding Chippedslagmaybehotandcanflyfar Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs can start fires Hot slagorsparkscanalsocausefiresand explosions Therefore 1 Remove all combusti...

Page 6: ... 2 ExposuretoEMFmayhaveotherhealtheffectswhich 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 Connecttheworkcabletothewo...

Page 7: ...s 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 Alwayshavequalifiedpersonnelperformtheinstal lation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance ...

Page 8: ...d Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances Meaning of symbols As used throughout this manual Means Atten tion Be Alert Your safety is involved Meansimmediatehazardswhich if not avoided will result in im mediate serious personal injury or loss of life Means potential hazards which could result in personal injury or loss of life Meanshazardswhichcouldr...

Page 9: ...os del arco y chis pascalientesconunacortina adecuadano flamable como división 6 Usecaretaprotectoraademásdesusgafasdesegu ridad 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 lasflamasyelarco puedenocacionar fuegos Escoria caliente y las chi...

Page 10: ... 2 Exponerseacamposelectromagnéticos EMF puede causar otros efectos de salud aún desconocidos 3 Los soldadores deberán usar los siguientes proced imientos 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 sol...

Page 11: ...IMIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede causar daño o muerte Por lo tanto 1 Siempre tenga personal cualificado para efec tuar 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 suminis...

Page 12: ...ón Esté Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediatamente en serio daño personal o la muerte Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte Significa el posible riesgo que puede resultar en menores daños a la persona ...

Page 13: ...rotection Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires Avant de procéder à l installation ou d utiliser l unité assurez vous de lire et de suivre les précautions de sécurité ci dessous danslesmanuels lesfichesd informationsurla sécuritédumatérieletsurlesétiquettes etc Toutdéfaut d observer ces précautions de s...

Page 14: ...e 4 Consultez ANSI ASC Standard Z49 1 à la page suivante pour des recommandations spécifiques concernant la ventilation 1 Assurez vous que le châssis de la source d alimentation est branché au système de mise à la terre de l alimentation d entrée 2 Branchez la pièce à traiter à une bonne mise de terre électrique 3 Branchez le câble de masse à la pièce à traiter et assurezunebonneconnexionafind évi...

Page 15: ... ou des gaz contenant des chimiques consid éres par l état de la Californie comme étant une cause des malformations congénitales et dans certains cas du cancer California Health Safety Code 25249 5 et seq MANIPULATION DES CYLINDRES La manipulation d un cylindre sans observerlesprécautionsnécessaires peut produire des fissures et un échappement dangereux des gaz Unebrisuresoudaineducylindre delasou...

Page 16: ...n Soyez vigilant Votre sécurité est en jeu Signifie un danger immédiat La situation peut entraîner des blessures graves ou mortelles Signifieundangerpotentielquipeutentraînerdes blessures graves ou mortelles Signifieundangerquipeutentraînerdesblessures corporelles mineures DANGER AVERTISSEMENT ATTENTION ...

Page 17: ...3 1 AVAILABLE PACKAGES AND CONTENTS Migmaster 275 Packages Each of the following packages includes power source with built in wire feeder factory installed undercarriage with cylinder tray GunMaster NAS Mig gun with 035 in and 045 in accessories dual groove 035 in 045 in feed roll R 33 flowmeter regulator 6 ft gas hose 15 ft work cable and clamp 8 ft primary input cable with plug 10 lb sample of 0...

Page 18: ...turn the cooling fan on and off as required This serves to reduce overall shop noise and the amount of air bourne debris that is drawn into the unit 2 4 2 BURN BACK MODULE P N 0558008623 This easy to install plug in module enables the use of an adjustable Anti Stick feature that allows adjustment of burnback time to prevent wire sticking at the end of a weld See Sec 3 8 Installation and Sec 4 2 Op...

Page 19: ...34330 TABLE 2 2 MIGMASTER 275 GUNMASTER 250 WEAR PARTS TABLE 2 3 GUNMASTER 250 NOZZLES TIP ADAPTER WEAR PARTS GUNMASTER 250 WIRE FEEDER Wire Size Contact Tip Std Duty Contact Tip Heavy Duty Liner DRIVE ROLL Groove Type OUTLET GUIDE INLET GUIDE 023 0 6MM Hard 20543 0558001675 0558008700 V Solid 0558008651 23612461 030 0 8mm Hard 20544 0558002367 37031 0558008700 V Solid 0558008651 23612461 035 0 9m...

Page 20: ...20 section 2 INTRODUCTION ...

Page 21: ...rdconductorforgroundingmustalsobe connected between the disconnect and the receptacle 3 1 LOCATION Figure 3 1 Proper installation permits free air movement into and out of the unit and minimizes exposure to dust dirt moisture and corrosive vapors A minimum of 18 inches 46 cm unrestricted space must be maintained between the rear panel and the nearest obstruction 32 25 19 50 40 00 CAUTION Do not pl...

Page 22: ...ese instructions section 3 INSTALLATION 3 2 4a CONNECTING FOR 208 VAC INPUT Fig 3 3A shows the 230v and 208v connections for the 208 230dualvoltagemodel Changeoverismadebyremov ing the right side panel below the wire feed compartment and switching the primary transformer tap at the top of the powerswitchwiththeunusedalternatevoltagetaplocated next to the main transformer see Fig 3 3B Both voltage ...

Page 23: ...nal board in the center of the lower compartment This board containscopperlinkswhichmustbereconnectedtomatch the silk screened voltage designations for the input you plan to use it comes factory connected for a 575 volt input see Figure 3 4 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 co...

Page 24: ...Plus FLAT tap or the Minus Tap depending on the polarity and slope desired Table 3 2 Primary Reconnections at Voltage Change over Terminal Board for 208 230 380 400 460 575Volt Models Figure 3 5 Short Arc Solid Wire DC Electrode Positive Steep Slope for a soft smooth arc with low spatter Figure 3 6 Short Arc Spray Arc Solid Wire and Fluxcore DC Electrode Positive Steep Slope for a crisp driving ar...

Page 25: ...o rotate clockwise as wire is unwound hub pin must engage hole in spool C Replace nut 3 5 3 THREADING WELDING WIRE When the power switch is on and gun trigger is de pressed the electrode becomes electrically hot and the feed rolls are activated Keep fingers clear of the drive mechanism A Turn power switch to OFF B Release pressure drive roll assembly Check that proper wire diameter groove is in th...

Page 26: ...tions at the regulator and at the Migmaster 275 for leakage Correct any leaks before starting work i If work is to be stopped for a half hour or more or theregulatoristoberemovedfromthecylinder shut down the regulator as follows a Close the cylinder valve b Releasegasfromtheregulatorbyclosingthetorch trigger lever c Whenpressuregaugedropstozero theregulator is de pressurized and shutdown j Each re...

Page 27: ... 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 3 9 INSTALLING OPTIONAL DIGITAL METER a Remove the top blank cover plate from the upper right front panel of the power supply Save the four mounting screws b Locate the harness connected 10 pin plastic plug PL1 inside the mounting cavity This p...

Page 28: ...28 section 3 INSTALLATION ...

Page 29: ...ANGESelectorisathree position switch 1 LOW 2 MED 3 HIGH whichselectsthe range ofvoltage orheat thatdeterminesthearclength tobeap plied to the weld It is a coarse selection control and is used in conjunction with the Fine Voltage Adjustment selector following It must not be switched under load 4 1 4 2 4 2 Optional Digital Meter Kit not shown 4 1 3 Positive Output Receptacle Steep Slope 4 1 1 4 1 2 ...

Page 30: ...t the WORK cable to the Positive output and the TORCH fitting cable to the Negative output terminal Because of the charged capacitor bank in the second ary circuit the output voltage will take a few seconds before falling to zero volts 4 1 4 WIRE FEED SPEED CONTROL Wirefeedspeediscontrolledbythewirespeedpotentiom eter knob on the front panel The solid state control allows for infinitely variable s...

Page 31: ...er 275 is equipped with a built in control for the SpoolGunwhichoperatesviatheamphenolcontrolreceptacle andpoweradaptor p n37301 thatprovidesGasandPower The ST 23ATorch see Section 2 4 3 has a amphenol plug control cable connection and a gas power cable see Figure 4 2 2 To operate the unit with the ST 23A Torch connected do the following refer to Fig 4 2 2 A Place the Standard Spool Gun selector t...

Page 32: ...rves B Theradiantenergyofthearccandecomposechlorinated solventvapors suchastrichloroethylene and perchlor ethylene to form phosgene even when these vapors are present in low concentrations DO NOT weld where chlorinated solvents are present in atmospheres in or around the arc C DO NOT touch the electrode nozzle or metal parts in contactwiththemwhenpowerinON allareelectrically energized HOT and can ...

Page 33: ...ations to set the following a Coarse Voltage Range b Fine Arc Voltage Setting c Wire Speed setting B Set the two position switch in the wire feeder compart ment to STANDARD for seam welding with the GUN MASTER 250 torch For ST 23A Spool On Gun welding see Section 4 2 2 C If optional Burn Back module is installed refer to Sec tion 4 2 3 for operation settings and welding condition table D Makesuret...

Page 34: ...heCoarse Voltage Range and Fine Voltage setting must not be switched while welding H To stop the weld release the trigger and pull the torch from the work When leaving equipment unattended alwaysshutOFFanddisconnectallinputpowerandshut off shielding gas at source Figure 4 7 Angle Of Weld To Joint section 4 OPERATION Connect cables for DCEP torch polarity cable to the POS output Steep Slope recepta...

Page 35: ...5 5 2 5 4 6 3 7 0 8 5 8 5 3 4 5 6 8 2 4 7 5 6 5 1 5 7 1 1 1 1 1 2 3 3 2 2 2 3 3 3 1 6 1 8 2 1 2 3 2 8 4 3 4 5 4 0 4 5 5 0 5 4 5 6 5 7 4 5 6 7 2 8 4 8 1 2 5 6 6 1 1 1 1 2 2 3 2 3 3 3 3 3 Wire Size 1 8 3 16 1 4 3 8 1 2 5 8 3 16 1 4 3 8 1 2 5 8 3 3 3 5 5 2 5 5 5 5 6 0 4 5 4 8 5 5 5 0 5 7 045 2 3 8 2 2 3 8 1 3 2 4 2 2 2 3 3 3 2 3 3 3 3 CS Carbon Steel Material Type CS Dual Shield 710X Flux Core 100 CO...

Page 36: ...36 section 4 OPERATION TABLE 4 3 Weld Condition Setup Guide Aluminum TABLE 4 4 Weld Condition Setup Guide Stainless Steel ...

Page 37: ...a bared cable or part touching a grounded surface may damage unprotected eyes or start a fire Bodycontactwithabaredcable connector oruncovered conductor can shock possible fatally Keeppowercablesdry freeofoilandgrease andprotected at all times from damage by hot metal and sparks Cleandirtandmetalparticlesfromdriverollgrooveweekly replace roll if badly worn 5 2 1 POWER SOURCE 5 2 1a RECTIFIER It is...

Page 38: ... just as the accumulation being removed may do 5 3 TROUBLESHOOTING Ifweldingequipmentdoesn tworkrightdespitecompliance with checklist inspect as follows A With all power controls ON and other operating controls at required settings visually check all power cables and connections for evidence of overheating or sparking To avoid shock do NOT touch electrode wire or parts in contact with it or uninsu...

Page 39: ...nput b Faulty connection primary input b Repair or replace cable or switch cable or power switch S3 TGS1 as necessary c Blown line fuse c Replace fuse If it blows again contact ESAB representative 2 No welding power a Thermostat has opened a Wait 15 minutes with fan running If still no power contact ESAB repre sentative b Shorted diode in main rectifier b Check diodes and replace if req d c Open i...

Page 40: ...heck flow at outlet replace faulty item e Faulty gas solenoid valve SOL e Replace solenoid valve f Wrong polarity f Check polarity 10 Shield gas flow low or a Cylinder valve closed a Turn off regulator slowly open stopped valve until regulator reaches 35 c f h pressure b Cylinder empty b Replace if gauge so indicates c Faulty regulator or adaptor c Check flow at outlet replace faulty item d Faulty...

Page 41: ...ner c Replace liner 15 Wire does not feed a Motor a With wire speed dial on 10 motor NOT running press trigger If voltage drive roll does not turn appears across motor leads but motor does not run check motor gears and commutator areas b Power switch S3 and fuses b With S3 ON if voltage across terminal 1 and 3 is 24 VAC switch and fuses are good c Speed Potentiometer POT c Check for 1K ohms across...

Page 42: ...42 section 5 SERVICE ...

Page 43: ... section 6 REPLACEMENT PARTS 6 1 General Always provide the serial number of the unit on which the parts will be used The serial number is stamped on the unit nameplate To ensure proper operation it is recommended that only genuine ESAB parts and products be used with this equipment The use of non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB Distributor Be sure...

Page 44: ...B KIT DESIG 1 1 0558002993 D Shaft Wirefeeder 5 75L 2 AR 61341133 Screw HC 375 16 x 1 00 3 AR 64302037 Washer Lock 375 4 1 0558002992 Bracket Spool Support 5 1 33191M Shelf Silkscreened 6 AR 63300916 Nut Hex 10 24 7 AR 64302920 Washer Lock 8 8 2 948255 Pad Braking 9 1 2360 0982 Spring 10 1 634347 Pin Hitch Clip 11 1 8948258 Hub Reel 12 1 92044046 Screw 10001 Stl ZPC 375 16 x 1 00 13 1 64304125 Was...

Page 45: ...8008595 Axle Pressure Roll 5 0558008596 Washer Spacer 6 0558008597 Spacer Axle 7 0558008599 Spring Pressure Arm 8 0558008598 Axle Pressure Arm 9 0558008600 Pressure Arm Housing RH with nut 10 0558008601 Pressure Arm Complete RH includes Items 2 4 5 6 7 8 and 9 2 3 4 5 6 7 9 or 10 5 8 1 See Table 2 2 Subsection 2 5 See Table 2 2 Subsection 2 5 See Table 2 2 Subsection 2 5 2 Roll WIRE DRIVE SYSTEM ...

Page 46: ...46 section 6 REPLACEMENT PARTS ...

Page 47: ...ded Burn Back phrase in several locations and deleted redundant or unneeded information per Bob Bitzky George Magee redlines 06 2009 Updates made per J Magee 07 2009 Added stainless and aluminum setup charts per Bob Bitzky revision history ...

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Page 58: ...ax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Registrations G WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW...

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