INSTRUCTIONS for
MIGMASTER 250
WELDING PACKAGES
F-15-087-E
August, 1997
F-15-087-E
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles
of operation and safe practices for electric welding 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 on page 2 before installing or operating this equipment.
NOTE: This manual is also suitable for use with L-TEC Migmaster 250 package.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
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. Defective 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 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.
2
TABLE OF CONTENTS
SECTION NO. PAGE NO.
SECTION 1 - GENERAL SAFETY RULES FOR WELDING
AND CUTTING ........................................................................................................... 4
GENERAL PRECAUTIONS ..................................................................................................4
PRECAUTION SYMBOL DEFINITIONS ........................................................................ 5
SECTION II - INTRODUCTION .............................................................................................6
2.1 GENERAL .................................................................................................................. 6
2.2 RECEIVING-HANDLING ............................................................................................6
2.3 DESCRIPTION, Available Packages/Contents ...........................................................6
2.4 OPTIONAL ACCESSORIES.......................................................................................7
2.5 SAFETY ..................................................................................................................... 9
SECTION III - INSTALLATION ............................................................................................. 9
3.1 LOCATION .................................................................................................................9
3.2 ELECTRICAL INPUT CONNECTIONS ...................................................................... 9
3.3 SECONDARY OUTPUT CONNECTIONS................................................................ 12
3.4 TORCH CONNECTIONS ......................................................................................... 12
3.5 WIRE FEEDER MECHANISM..................................................................................12
3.6 CONNECTION OF THE SHIELD GAS ..................................................................... 13
3.7 WELDING CABLE CONNECTIONS......................................................................... 14
3.8 ASSEMBLE REAR WHEELS ...................................................................................14
3.9 INSTALLING OPTIONAL SPOT/STITCH/ANTI-STICK MODULE ............................ 14
3.10 INSTALLING OPTIONAL DIGITAL METER ............................................................. 14
SECTION IV - OPERATION................................................................................................ 15
4.1 CONTROLS.............................................................................................................. 15
4.2 PROCESS SETUP ................................................................................................... 16
4.3 OPERATING PROCEDURES ..................................................................................19
SECTION V - SERVICE ...................................................................................................... 22
5.1 MAINTENANCE ....................................................................................................... 22
5.2 INSPECTION AND SERVICE .................................................................................. 22
5.3 TROUBLESHOOTING.............................................................................................. 23
SECTION VI - PARTS......................................................................................................... 26
6.1 SPARE PARTS ........................................................................................................ 26
6.2 REPLACEMENT PARTS.......................................................................................... 26
6.3 ORDERING ..............................................................................................................26
3
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary
information from the references listed in Addi-
tional Safety Information section. Before performing any installation or operating procedures, be sure to
read and follow the safety precautions listed below as well
as all other manuals, material safety data sheets, labels, etc.
Failure to observe Safety Precautions can result in injury or
death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and not
to expose themselves to the rays of the electric-arc or hot
metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding
helmet or cap for hair protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may
also be desirable as protection against radiated heat and
sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks with
a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices
in floors or wall openings and cause a hidden smoldering
fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there are
no substances on the workpiece which might produce
flammable or toxic vapors. Do not do hot work on closed
containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
--
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to make
certain there are no hot sparks or hot metal which could
cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes",
available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is
confined, or if there is danger of falling.
1. Be sure the power source frame (chassis) is connected to
the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work
and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS — May
be dangerous. Electric current flowing
through any conductor causes localized
Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around
welding cables and welding machines.
Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away from
your body as possible.
4
11/95
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying operations.
The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and
other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for
specific ventilation recommendations.
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from the
compressed gas cylinder. Do not use adaptors. Maintain
hoses and fittings in good condition. Follow manufacturer's
operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain or
strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve
protection cap in place if regulator is not connected.
Secure and move cylinders by using suitable hand trucks.
Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause
injury or death. Therefore:
1. Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not perform
any electrical work unless you are qualified to perform
such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces, wet
conditions such as water puddles, oil or grease, corrosive
atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and
in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and
cutting equipment, ask your supplier for a
copy of "Precautions and Safe Practices for
Arc Welding, Cutting and Gouging", Form
52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous
Substances."
This symbol appearing throughout this manual means Atten-
tion! Be Alert! Your safety is involved.
The following definitions apply to DANGER,
WARNING, CAUTION found throughout this
manual:
Used to call attention to immediate hazards which, if not avoided, will result in
immediate, serious personal injury or loss
of life.
Used to call attention to potential hazards which could result in personal injury
or loss of life.
Used to call attention to hazards which
could result in minor personal injury.
5
II. INTRODUCTION
2.1 GENERAL
This manual has been prepared especially for use in
familiarizing personnel with the design, installation, operation, maintenance, and troubleshooting of this equipment. All information presented here in should be given
careful consideration to assure optimum performance of
this equipment.
2.2 RECEIVING-HANDLING
l 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), an 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
Prior to installing this equipment, clean all packing material from around the unit and carefully inspect for any
damage that may have occurred during shipment. Any
claims for loss or damage that may have occurred in
transit must be filed by the purchaser with the carrier. A
copy of the bill of lading and freight bill will be furnished
by the carrier on request if occasion to file claim arises.
When requesting information concerning this equipment,
it is essential that Part, Serial and Model Numbers of the
equipment be supplied.
2.3 DESCRIPTION
The Migmaster 250 is a portable Welding System designed for fine wire, (0.023, 0.030, 0.035 and 0.045 in.)
welding using the short arc method, as well as for spray
arc aluminum, short arc and spray arc stainless steel and
spray arc cored wires. It incorporates a running gear with
provisions for one gas cylinder, and a ST-23A spool-ongun control.
2.3.1 AVAILABLE PACKAGES AND CONTENTS
The following Migmaster 250 “Consisting of” Packages
are available:
MM-250 for 208/230-V. Input w/12-ft. Kit . P/N 604560
MM-250 for 208/230-V. Input w/15-ft. Kit . P/N 604561
MM-250 for 208/230/380/400/460/575-V. Input w/12-ft. Kit
.............................................................. P/N 604563
MM-250 for 208/230/380/400/460/575-V. Input w/15-ft. Kit
.............................................................. P/N 604570
Depending on the “primary input voltage” of the MM-250,
and the “torch length”, each package includes the following:
l One (1), Migmaster 250 Kit as follows:
-- 12-ft. Kit .................................................P/N 32993
Includes:
MT-200cc, 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
-- 15-ft. Kit .................................................P/N 32994
Includes same accessories as 12-ft. Kit except for torch,
which is:
MT-200cc, 15-ft. lg. for .035/.045 wire, .......P/N 21117
2.3.2 POWER SUPPLY
The power supply consists of a tapped single phase
transformer, tap selection switches, secondary contactor,
single phase full wave rectifier, stabilizing reactor, slope
resistor, filtering capacitors and internal output connections for polarity reversal.
2.3.3 WIRE FEEDER
The wire feeder pushes 0.023, 0.030, 0.035 and 0.045 in.
wire at speeds up to 650 IPM. Dynamic braking prevents
excessive wire overrun. A double grooved drive roll
(0.035 and 0.045 in.) 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.
6
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 & Cored 0.023 inch (.6mm) 0.035 inch (.899mm)
0.030 inch (.762mm)0.045 inch (1.143mm)
Feed Rate 20-650 IPM
MT-200cc TORCH
Cooling Air
Gooseneck Angle 45 degrees
Rated 60% Duty Cycle
(DCRP) Amps: 200 w/Argon Mixtures, 300 w/CO
Conduit Length see section 2.3.1
2
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.
2.3.4 MT-200cc WELDING TORCH (F-15-085),
The lightweight air cooled welding gun included in selected systems is supplied complete and ready to weld
0.035 in. steel wire. It is built with a one piece service
conduit and includes a 45 degree gooseneck. Changing
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.
the contact tip to 0.045 in. allows the use of the larger
wire.
2.3.5 CONTROLS
2.4 OPTIONAL ACCESSORIES
2.4.1 SPOT/STITCH/ANTI-STICK MODULE, P/N
32858.
The Migmaster 250 System can be used to weld hard and
aluminum wire with an optional ST-23A spool-gun torch.
An optional spot/stitch control allows a welder to spot or
stitch weld within a range of 0.4 to 3.5 seconds. The builtin spool-on-gun adaptors and control, when used in
conjunction with the optional ST-23A torch, permits aluminum wire welding with the machine.
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.
7
If a Spotwelding operation is to be used, it is recommended that you also order a #12S Spotweld Nozzle,
P/N 999625.
2.4.2 DIGITAL VOLT/AMMETER MODULE, P/N 32857.
This easy-to-install, plug-in module mounts in place of
the top blank cover plate of the upper-right front panel
location in the 250 unit. This unique meter module
alternately displays welding voltage and current (of the
dial-set welding condition) every 4-seconds. Two L.E.D.’s
labeled Amps and Volts provided below the meter windows, alternately illuminate to indicate which condition is
being displayed. The voltage indication is displayed in 1/
10-volt increments (e.g.: 20.5), while the current indication is usually displayed in three-whole digits (e.g.: 225).
After the torch trigger is released, the meter will continue
to flash for 45-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).
thirty (30) foot service lines; one is a control cable with
amphenol plug, and the other is a gas and power cable
with a screw-on connector. For installation and operation, see Section 4.1.7 and for detailed instruction booklet refer to F-14-353.
2.4.4 TORCH NOZZLES
A No. 8 Nozzle (1/2" I.D.), P/N 998893 to fit the MT200CC Torch, is included in the Migmaster 250 package.
This slip-on type nozzle includes a permanently mounted
insulator/spatter shield. The following standard duty slipon nozzles, also equipped with the insulator/spatter
shield, are available:
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
Additionally, the following heavy-duty slip-on nozzles,
also equipped with the insulator/spatter shield, are available:
The Migmaster 250 unit is equipped with a built-in control
for the ST-23A Spool-On-Gun welding torch. The ST23A is a high performance, 250 ampere continuous duty
spool-on-gun torch designed for the mig welding pro-
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
cess. It is completely portable (up to 30-ft.), air-cooled
and hand operated, and weighs less than three (3)
pounds which allows for great maneuverability and
2.4.5 TORCH/WIRE FEED ACCESSORIES -- See
Tables 2.4.5.1 and 2.4.5.2.
operator convenience. The gun is equipped with two-
TABLE 2.4.5.1 Recommended MT-200cc 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
.045" (1.2mm) 999578 996999 996998 2075237 17718 2075238 .
.052" (1.4mm) 948340 2075349 - 2075239 17719 2075240
1/16" (1.6mm) 948341 996997 - 2075239 17719 2075240
Soft Wires (aluminum)
.035" (.9mm) - 996995 996996 948862 - 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 visability and proper wire stick in dip transfer
Mig welding.
* Requires support liner for .023" wire. Order P/N 999797.
Table 2.4.5.2 Guide Tubes/Feed Rolls
Wire Guide Feed
Size & Type Tube Roll
Hard Wires - "V" Groove
.023" (.6mm) 21163 21155
.030" (.8mm) 21164 21155
.035" (.9mm) 21165 21156
.045" (1.2mm) 21165 21156
Cored Wires - Serrated
.030" (.8mm) 21164 21160
.035" (.9mm) 21165 21160
.045" (1.2mm) 21165 21161
.052" (1.4mm) 21166 21161
1/16" (1.6mm) 21166 21161
Soft Wires (aluminum) - "U" Groove
.035" (.9mm) 21167* 21158
3/64" (1.2mm) 21168* 21158
* Requires support tube. Order P/N 21169
8
2.5 SAFETY
Before the equipment is put into operation, the safety
section at the front of this manual should be read
completely. This will help avoid possible injury due to
misuse or improper welding applications.
The symbol which precedes safety notes appearing throughout this manual means “Attention! Be Alert!
Your safety is involved.” The definitions relating to the
DANGER, WARNING and CAUTION safety notations
are described at the end of the Safety Section in the front
of this manual -- read them and their specific text
references carefully.
‡
32 ¼" 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 movement into and out of the welding machine, and also least
subjects the unit to dust, dirt, moisture, and corrosive
vapors. A minimum of 18 inches (46 cm) unrestricted
space must be maintained between the welding machine side and rear panels and the nearest obstruction.
The installation site should also permit easy removal of
the welding machine outer enclosure for maintenance
functions.
CAUTION: Do not place any filtering device over the
intake air passages of the welding machine as this would restrict the volume of
intake air and thereby subject the welding
machine internal components to an overheating condition and subsequent failure.
Warranty is void if any type of filtering
device is used.
If a forklift vehicle is used for lifting the unit, be sure that
the lift forks are long enough to extend completely under
the base.
Do not operate the machine without the running
gear installed.
ˆ
ˆ
‡
1/2"
19
ˆ
Figure 3.1 Dimensional Drawing
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
welding 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.
40"
‡
9
A. Input Electrical Requirements
TABLE 3.1 Input Conductor and Fuse Size
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.
B. 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 electrical input requirements internally-connected for the highest voltage rating available in each model (e.g.: 230-volt
for the 208/230-volt units; and 575-volt for the "multivoltage" units).
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
Only qualified personnel should make these
changes. Make certain the primary power has been
discoonnected and all safety procedures have been
followed before proceeding with these instructions.
Fig. 3.3A shows the 230v and 208v connections for the
208/230 dual voltage model. Change over is made by
removing the right side panel below the wire feed compartment and switching the primary transformer tap at
the top of the power switch with the unused alternate
voltage tap located next to the main transformer (see
Fig. 3.3B). Both voltage taps (the one currently connected to the switch and the unused alternate voltage)
are marked with the input voltage requirement. All units
are supplied from the factory connected for the highest
voltage (230 vac). Before switching the voltage taps,
verify the actual voltage requirement as well as the
current voltage connection to be certain re-connection is
necessary. If voltage tap re-connection is necessary, the
following paragraphs cover the procedure to switch the
voltage tap for either 208vac or 230vac input.
SINGLE-PHASE
GRD
Figure 3.2 A
208/230 MODEL ONLY (With Plug-Cap)
Fused
Line
Disconnect
Switch,
or
Circuit Breaker
Wall Receptacle
MIGMASTER
SYSTEM
CONNECTS HERE
THREE-PHASE
GRD
Figure 3.2 B
Figure 3.2 - Primary Connection
10
GRD
GREEN
208/230/380/400/460/575-V. MODELS
SINGLE-PHASE
CONDUCTOR
(GROUND)
THREE-PHASE
GRD
GREEN
Figure 3.2 DFigure 3.2 C
Figure 3.3A - Primary Reconnections at Switch
For 208/230 Volt Models
When changing the input voltage connections, the
unused lead must be insulated and positioned to
prevent contact with any other internal components
of the machine or the machine side panel. The clearance between the unused lead and other components must be at least one inch (see Fig. 3.3B for
illustration of the proper position). FAILURE TO
INSULATE AND POSITION THIS LEAD PROPERLY
WILL CAUSE A SERIOUS SHOCK HAZARD.
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.
C CONNECTING FOR 208 VAC INPUT
After the panel is removed, locate the 208 Vac lead (Fig.
3.3B) and cut the tie-wrap to remove the insulation
sleeving (on early models this lead may have been
wrapped with black electrical tape). Open the insulating
cover around the power switch (Fig. 3.3C.) to expose the
terminals and disconnect the 230 Vac lead from the top
of the switch as shown in Fig. 3.3A. Insulate the 230 Vac
lead that was removed from the power switch with
sleeving or approved electrical tape and re-position to a
safe area beside the transformer (see Fig. 3.3B), leaving
a minimum of one inch clearance from other components and the side panel.
D CONNECTING FOR 230 VAC INPUT
Fig. 3.3B - Position of Alternate Voltage Tap
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
Fig. 3.3C - Power Switch Connection
11
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