ESAB Migmaster 275 Welding Package Instruction manual

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Migmaster 275

Welding Package

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL BURN BACK

MODULE

Instruction Manual

0558008552 07 / 2009

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENT

SECTION NO. .......................................................................................................................................................PAGE NO.

SECTION 1 - SAFETY PRECAUTIONS ...............................................................................................................................5

SECTION 2 - INTRODUCTION ..........................................................................................................................................17

2.1 GENERAL ........................................................................................................................................................................................................17

2.2 RECEIVING-HANDLING ..............................................................................................................................................................................17

2.3 DESCRIPTION, Available Packages/Contents ....................................................................................................................................17

2.4 OPTIONAL ACCESSORIES .........................................................................................................................................................................18

2.5 MIGMASTER 275 / GUNMASTER 250 WEAR PARTS .........................................................................................................................19

SECTION 3 - INSTALLATION ............................................................................................................................................21

3.1 LOCATION ......................................................................................................................................................................................................21

3.2 ELECTRICAL 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

5.2 INSPECTION AND SERVICE.......................................................................................................................................................................37

5.3 TROUBLESHOOTING ..................................................................................................................................................................................38

SECTION 6 - REPLACEMENT PARTS ................................................................................................................................43

6.1 GENERAL ........................................................................................................................................................................................................43

6.2 ORDERING .....................................................................................................................................................................................................43

TABLE OF CONTENT

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize precautionary information from the references

listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

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 tted with the correct lter 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 ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess 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 ameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, 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-ammable partition or curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far. Bystanders should also wear goggles over safety glasses.

1.1 Safety - English

FIRES AND EXPLOSIONS -- Heat from ames and arcs can start res. Hot slag or sparks can also cause res and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-ammable 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 oors or wall openings and cause a hidden smoldering re or res on the oor 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 ammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable re 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 re 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 re. Use re 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 conned, or if there is danger of falling.

SECTION 1 SAFETY PRECAUTIONS

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.

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.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in conned spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specic grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current owing 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 eects which

are unknown.

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 specic ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ttings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualied 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.

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 xtures 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 ames. 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 Jeerson Davis Highway, Arlington, VA 22202.

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

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"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

SECCION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad 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 ltro 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 chis-

pas calientes con una cortina adecuada no-amable como división.

6. Use careta protectora además de sus gafas de segu-

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 las amas 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 amables, 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 inamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inamables.

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 corri-

ente alterna (AC) en áreas húmedas, de movimiento connado en lugares estrechos o si hay posibilidad de caer al suelo.

SECCION 1 SEGURIDAD

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 especícas 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 uye 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. Soldadores 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.

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 sub-

stancias 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 especícas en la ventilación.

SECCION 1 SEGURIDAD

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

1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualicado 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 modique 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.

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"

MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECCION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.

Signica riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

Signica el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

Signica el posible riesgo que puede resultar en menores daños a la persona.

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. 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, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les ches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord et des chaussures montantes an de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininammable an de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La chaleur provenant des ammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ssures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

SECTION 1 SÉCURITÉ

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 assurez une bonne connexion an d'éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez eectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spéciques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conduc-

teur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée de votre corps.

LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages

corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique. N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation ecaces. Ne respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spéciques concernant la ventilation.

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres 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 observer les précautions nécessaires, peut produire des fissures et un

échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne xez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualié. N'eectuez aucune réparation électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des aques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

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"

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures corporelles mineures.

SECTION 2 INTRODUCTION

2.1 GENERAL

This manual has been prepared for use in familiarizing personnel with the safe installation, operation, maintenance, and troubleshooting of this equipment. All information presented here in must be given careful consideration to assure safe operation and use of this equipment.

2.2 RECEIVING-HANDLING

Upon receipt, carefully inspect for damage that may have occurred during shipment. Claims for loss or damage that may have occurred in transit must be led by the purchaser with the carrier. A copy of the bill of lading and freight bill will be furnished by the carrier on request.

When requesting information concerning this equipment, Part number, Serial number and Model name will be required. Please take a few moments now to record the information in the box below for future reference.

Date / / Model Name Stock Number Serial Number

2.3 DESCRIPTION

2.3.1 AVAILABLE PACKAGES AND CONTENTS

Migmaster

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 owmeter-regulator, 6 ft. gas hose, 15 ft. work cable and clamp, 8 ft. primary input cable with plug, 10 lb. sample of .035 ESAB Spoolarc 87HP welding wire, and an ESAB Mig Welding Handbook.

Migmaster® 275 Package w/12 ft. GM-250 NAS Torch/Argon

208/230 vac, 1 phase, 60 Hz .................................................. 0558008708

208-575 vac multi-voltage*, 1 phase, 50/60 Hz .............0558008709

Migmaster® 275 Package w/15 ft. GM-250 NAS Torch/Argon

208/230 vac, 1 phase, 60 Hz ...................................................0558008707

208-575 vac multi-voltage*, 1 phase, 50/60 Hz ..............0558008710

Migmaster® 275 Package w/15 ft. GM-400 NAS Torch/Argon

208/230 vac, 1 phase, 60 Hz ................................................... 0558008711

Migmaster® 275 Package w/o Torch/Argon

208/230 vac, 1 phase, 60 Hz ...................................................0558008714

275 Packages

Migmaster® 275 Packages with Spool-On-Gun

Spool-On-Gun Packages also include the indicated spool gun and all components necessary to install it on the Migmaster® 250. The spool gun is set up to run 3/64 in. wire.

Migmaster® 275 Package w/15 ft. GM-250 NAS Torch and MT-250SG / Argon

208/230 vac, 1 phase, 60 Hz ...................................................0558008712

Migmaster® 275 Package w/15 ft. GM-250 NAS Torch and ST-23A / Argon

208/230 vac, 1 phase, 60 Hz ...................................................0558008713

*Multi-Voltage model: 208/230/380/400/460/575 (60Hz) vac and 380/400 (50Hz) vac.

The Migmaster 275 self contained welding system is designed to deliver superior performance using short arc, spray arc, as well as ux and metal cored wires ranging from .023 (.6mm), to 1/16" (1.6mm) diameter.

The unit consists of a tapped single phase power section with a built in wire feeder and is supplied as a ready to weld package. It utilizes a dual groove feed roll and is capable of 40 to 750 Inches Per Minute wire speed.

An Esab GunMaster 250, lightweight air cooled welding gun included in select systems is supplied complete and ready to weld 0.035 / 0.045 in. steel wire.

Quick connect output receptacles provide for easy polarity reversal as well connection point for an optional Spool Gun.

The built in Spool Gun Control can be used to weld hard and aluminum wire with an optional MT-250SG or ST-23A spool-guns.

The built in running gear assures convienent shop mobility and features a cylinder tray and support.

Special Order

Migmaster® 275 for use with MIG-41A Push-Pull Gun

Push-Pull Ready console is set up to accept the ESAB MIG-41A Push-Pull gun (order gun, gun ttings and package accessories separately)

Migmaster® 275 console with Push-Pull Module Installed

208/230 vac, 1 phase, 60 Hz ...................................................0558008621

208-575 vac multi-voltage*, 1 phase, 50/60 Hz ............. 0558008622

*Multi-Voltage model: 208/230/380/400/460/575 (60Hz) vac and 380/400 (50Hz) vac.

Complete Product, Ordering, and Accessory information can be found in

the Sales Data Page ARC-23244 or on the World Wide Web at

www.esabna.com.

SECTION 2 INTRODUCTION

POWER SOURCE MIGMASTER-275

FEEDER Feed Type/Speed Range Push Type - 40 to 750 IPM (1 - 16.3 m/min.)

Welding Gun Cooling Air GunMaster-250 Gooseneck Angle 45 degrees

Physical Net Weight *210 lbs (95 Kg.)

*Includes running gear Height *32.25 inches (819 mm) & cylinder tray. Width *19.5 inches (495 mm)

Primary Input -Single Phase 208/230/380/400/460/575 Vac Rated Output 275 Amps @ 28V Output Current / Voltage Range 30 A/12V - 300A/30V Maximum Open Circuit Volts 55 Vdc Duty Cycle:

208/230V Unit 40% 275 Amps @ 28 Vdc

Duty Cycle: 208/230/460/575 Unit 380/400 Unit

Primary 60 HZ Input (Amps): 208/230 Unit 208/230/460/575 Unit

Primary 50 HZ Input (Amps): 380/400 37/36 Amps

Wire Sizes: Hard 0.023" (0.6mm) through 0.045" (1.2mm) Cored 0.035" (0.9mm) through 1/16" (1.6mm) Soft 3/64" (1.2mm) and 1/16" (1.6mm)

Rated 60% Duty Cycle (DCEP) 200 Amps Argon Mixtures, 300 Amps CO2 Conduit Length Available in 10, 12, and 15 ft. - See Section 2.3.2

Depth *40.0 inches (1016 mm)

60% 250 Amps @ 26 Vdc 100% 200 Amps @ 24 Vdc

35% 275 Amps @ 28 Vdc 60% 225 Amps @ 25 Vdc 100% 180 Amps @ 23 Vdc

66/61 Amps 66/61/30/25 Amps

TABLE 2.1 SPECIFICATIONS

2.4 OPTIONAL ACCESSORIES

2.4.1 AUTO-FAN KIT, P/N 16781

The Auto-Fan kit controls the operation of the cooling fan. It will automatically turn the cooling fan on and o 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 Operation Process Setup.

For Spot Welding, Spotweld Nozzle, P/N 0885001602 is recommended.

2.4.3 DIGITAL VOLT/AMMETER MODULE, P/N 0558008585.

This easy-to-install digital meter kit alternately displays the actual welding voltage and welding current every 4-seconds. L.E.D.’s below the meter indicate which condition is being displayed. After the torch trigger is released, the meter will continue to ash for 20-seconds the last condition used during welding. At the end of this time, the meter will reset to zero. See Section 3.9 Installation.

2.4.4 MT-250SG and ST-23A SPOOL GUN

The Migmaster 275 unit is equipped with a built-in control that accepts the MT-250SG or ST-23A spool gun. These air cooled spool guns are designed for mig welding with soft wires. They are completely portable up to 25-ft. and weigh less than three (3) pounds. See 4.2.2 Installation/ Operation.

MT-250SG Spool Gun ................................................P/N 36779

Instruction Literature ........................................................F15-380

ST-23A Spool Gun .......................................................P/N 19164

Requires Adaptor ................................................................... 37301

Instruction Literature ........................................................F14-353

SECTION 2 INTRODUCTION

2.4.5 SPOOL SPACER

For 8" dia. spools .........................................................P/N 17511

For 10" dia. spools ......................................................P/N 34330

2.5 MIGMASTER 275 / GUNMASTER 250 WEAR PARTS

WEAR PARTS GUNMASTER 250 WIRE FEEDER

Wire Size

.023" (0.6MM) Hard .030"(0.8mm) Hard .035" (0.9mm) Hard

Contact Tip

Std Duty

20543 0558001675 0558008700 V- Solid 0558008651 23612461 20544 0558002367 37031 0558008700 V- Solid 0558008651 23612461

996995 0558002368 37032 0558008536 V- Solid 0558008650 34615

.040" (1.0mm) Hard .045" (1.2mm) Hard .035" (0.9mm) Cored .045" (1.2mm) Cored .052" (1.4mm) Cored .062" (1.6mm) Cored 3/64" (1.2mm) AL

37290 37286 37032 0558008536 V- Solid 0558008650 34615

996995 0558002368 37032 0558008540 K- Cored 0558008650 34615

37290 37286 37032 0558008540 K- Cored 0558008650 34615

2075349 17778 37033 0558008541 K- Cored 0558008649 0558001758

996997 37291 37033 0558008541 K- Cored 0558008649 0558001758 996999 17765 37034** 0558008538 U - Soft 0558008654 23612461

1/16" (1.6mm) AL

* All Liners supplied 15 ft. and must be trimmed to t the gun per instructions. ** Requires Jumper Liner Sleeve 0558003050 Bold indicates "as supplied from factory".

Contact Tip Heavy Duty

0558002369 37032 0558008536 V- Solid 0558008650 34615

948835 37040** 0558008538 U - Soft 0558008654 23612461

2.4.6 Primary Extension Cord

25 ft. (9.5m) / 50 Amp ..................................................P/N 37833

2.4.7 Gas Meter

Measures shield gas ow at the nozzle .................P/N 19043

Liner *

DRIVE ROLL Groove

Type

OUTLET

GUIDE

INLET

GUIDE

TABLE 2.2 MIGMASTER 275 / GUNMASTER 250 WEAR PARTS

GUNMASTER-250 STANDARD DUTY NOZZLES & TIP ADAPTER w/ Std Contact Tips w/ HD Contact Tips

3/8" Nozzle 0558001609 COPPER Flush with nozzle Recessed 1/8" into nozzle

1/2" Nozzle 0558001612 COPPER Recessed 1/8" into nozzle Flush with nozzle

1/2" Nozzle 0558001611 COPPER Flush with nozzle Extends1/8" out of nozzle

1/2" Nozzle 0558001613 COPPER Extends1/8" out of nozzle Extends1/4" out of nozzle

5/8" Nozzle 0558001614 COPPER Flush with nozzle Extends1/8" out of nozzle

5/8" Nozzle 0558001615 COPPER Extends1/8" out of nozzle Extends1/4" out of nozzle

SPOT Nozzle 0558001602 BRASS Recessed 3/8" into nozzle Recessed 3/8" into nozzle

Tip/Nozzle Adapter 0558001608 BRASS

GUNMASTER-250 HEAVY DUTY NOZZLES & TIP ADAPTER w/ Std Contact Tips w/ HD Contact Tips

5/8" Nozzle 0558001599 COPPER Recessed 1/8" into nozzle Flush with nozzle

5/8" Nozzle 0558001600 COPPER Recessed 1/4" into nozzle Recessed 1/8" into nozzle

5/8" Nozzle 0558001598 COPPER Flush with nozzle Extends1/8" out of nozzle SPOT Nozzle 0558001602 BRASS Recessed 3/8" into nozzle Recessed 1/4" into nozzle Tip/Nozzle Adapter 0558001888 BRASS

TABLE 2.3 GUNMASTER 250 NOZZLES & TIP ADAPTER

SECTION 2 INTRODUCTION

SECTION 3 INSTALLATION

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.

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL BURN BACK

MODULE

32.25"

40.00"

19.50"

Before making electrical input connections to the welding machine, “Machinery Lockout Procedures” must be employed. If the connections are to be made from a line disconnect switch, the switch must be padlocked in the o 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.

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 standard 250 Volts, 50 Ampere receptacle conforming to NEMA 6-50 R conguration.

Figure 3.1 Dimensions

CAUTION: Do not place any ltering device over the

air intake passages of the unit. This would restrict air intake and cause an overheating condition and possible failure. Warranty is void if any type of ltering 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

A line disconnect switch must be installed in the input circuit to the welding machine. This is to provide a safe means to completely remove all electrical power from the welding machine whenever it is necessary to perform service on the unit. (See Figure 3.2A.)

The 208-575 volt primary input model must 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 must also be connected between the disconnect and the receptacle.

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 66 90 6 8 230 61 80 8 8 380 37 50 10 10 380 (50Hz) 38 50 10 10 400 36 50 10 10 400 (50Hz) 36 50 10 10 460 30 40 12 12 575 25 35 12 12

SECTION 3 INSTALLATION

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 must be connected to a reliable ground and the two remaining wires must be connected to the separately fused lines of the disconnect or breaker as shown in Figures 3.2C and 3.2D.

3.2.4a CONNECTING FOR 208 VAC INPUT

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).

3.2.3 PRIMARY VOLTAGE INPUT CONNECTION

All units leave the factory with the primary electrical input connected for their highest voltage connection (e.g.: 230volt for the 208/230-volt units; and 575-volt for the "multivoltage" units).

Only qualied personnel may make these changes. Make certain the primary power has been disconnected and all safety procedures have been followed before proceeding with these instructions.

Figure 3.3A - Primary Reconnections at

Switch For 208/230 Volt Models

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 reconnection is necessary, the following paragraphs cover the procedure to switch the voltage tap for either 208vac or 230vac input.

Fig. 3.3B - Position of Alternate Voltage Tap

SECTION 3 INSTALLATION

switch (Fig. 3.3C.) to expose the terminals and disconnect the 208 Vac lead from the top of the switch as shown in Fig.

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.

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.

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.

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.

Fig. 3.3C - Power Switch Connection

3.2.4b CONNECTING FOR 230 VAC INPUT

3.2.5 RECONNECTING FROM 575 VAC INPUT

Figure 3.4 & Table 3.2 shows how to reconnect the "multivoltage" model from a 575-volt input to each of the available voltage inputs. These connections are made by removing the right side panel below the wire feeding compartment, and locating the primary voltage changeover terminal board 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 3.4.

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

Figure 3.3.1-Primary Reconnections at Voltage Change-

over Terminal Board for

208/230/380/400/460/575Volt Models

SECTION 3 INSTALLATION

PRIMARY VOLTAGE CONNECTION CHART

VOLTAGE CONNECTION NO. OF STRIPS

208

230

380

400

460

575

Table 3.2 Primary Reconnections at Voltage Change-

over Terminal Board for

208/230/380/400/460/575Volt Models

1 - 2 1 6 - 7 1 7 - 8 FLEX 1 - 2 1 6 - 7 1 5 - 8 FLEX 3 - 7 2 4 - 8 FLEX 2 - 6 2 7 - 8 FLEX 2 - 6 2 4 - 8 FLEX 2 - 3 2 4 - 8 FLEX

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL

BURN BACK

MODULE

3.3 SECONDARY OUTPUT CONNECTIONS

The Migmaster 275 Welding System is completely selfcontained so that the front panel welding gun ttings are internally connected to the electrode polarity cable on the front panel. The electrode polarity cable is inserted into either the Plus (+) SLOPE tap, Plus (+) FLAT tap, or the Minus (-) Tap depending on the polarity and slope desired.

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL

BURN BACK

MODULE

Figure 3.6 Short Arc, Spray Arc Solid Wire and Fluxcore

- DC Electrode Positive Steep Slope for a crisp driving arc with higher output power.

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL

BURN BACK

MODULE

Figure 3.5 Short Arc - Solid Wire - DC Electrode Positive

Steep Slope for a soft smooth arc with low spatter.

Figure 3.7 Gassless Fluxcore - DC Electrode Negative

Steep Slope for a crisp driving arc with

higher output power.

SECTION 3 INSTALLATION

3.4 TORCH CONNECTIONS

The GunMaster 250 supplied standard with the Migmaster 275 System, is provided with a NAS-type connector which connects directly to the gun receptacle on the front panel. Line up the NAS pin to the hole, rmly push on and tighten the locking thumb screw. Connect the trigger lead to the gun receptacle and to the trigger receptacle on the machine.

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 screw holding the drive roll to the motor shaft. C. Reverse the drive roll on the drive roll shaft. D. Replace the screw and tighten. E. Secure the pressure drive roll assembly.

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

When the power switch is on, and gun trigger is depressed, the electrode becomes electrically hot, and the feed rolls are activated. Keep ngers 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 the inner posi tion.

CAUTION: Before threading welding wire through casing,

make sure chisel point and burrs have been removed from wire end to prevent wire from jamming in gun casing or liner.

Fig. 3.8 WIRE DRIVE ASSEMBLY

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 o at the spool or at the end of the torch. Hold onto the wire coming o 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.

C. Feed the wire from the spool through the inlet guide, across the drive roll groove and into the outlet guide.

Make sure that the proper “outlet guide” is inserted into the front-panel gun adapter for the size and type of wire being used, see Table 2.2 for wire feed accessories (Section 2.5).

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. Turn the power switch to "ON". Feed wire through to gun tip with gun trigger.

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 decrease it. Drag should be just low enough to limit wire overrun.

SECTION 3 INSTALLATION

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.

Do Not adapt R-33-FM-580 for use with CO2. Relief device may rupture if CO2 is used with the R-33-FM-580. For CO2 service, order R-33-FM-320, P/N 21558.

a. With the cylinder cap in place CAREFULLY slide the cylinder onto the cylinder tray. b. Using the chain, secure the cylinder to the unit. c. Unscrew the cylinder cap.

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

d. Crack the cylinder valve for an instant to blow away dirt or dust which may have accumulated in the 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. wrench.

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 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

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 regulator

is de-pressurized and shutdown.

j. Each regulator is equipped with a porous metal

inlet lter, P/N 71Z33, pressed into the regulator inlet nipple. No. regulator should be connected to a cylinder or station valve unless it contains this lter. You can replace the lter if you have reason to do so. To remove a lter 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 authorized Remanufacturing Center.

f. Attach the gas hose from the rear of the Migmaster

275 to the regulator outlet connection (see Fig. 3.9).

g. Slowly open the cylinder valve a fraction of a turn.

When the regulator pressure gauge pointer stops moving, open the cylinder valve fully.

CYLINDER VALVE

CYLINDER PRESSURE GAUGE

OUTLET CONNECTION

Fig. 3.9 R-33-FM-580 Regulator (Illustrated)

If welding is performed in a conned area, shielding gas leaks could result in a buildup of shielding gas concentration, displacing oxygen, thereby endangering 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.

SECTION 3 INSTALLATION

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.

OPTIONAL

3.8 INSTALLING OPTIONAL BURN BACK MODULE

a. Remove lower blank-cover plate from upper-right front

panel of power supply. Save the mounting hardware.

b. Locate the harness-connected 15-pin plastic plug, P3,

inside the feeder compartment. Note that this plug will have a jumper plug with jumper wires connected 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 receptacle

on the rear of the optional control module. The plug will only t 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

Blank Panel for Optional Burn Back Module

Fig. 3.10 INSTALLING OPTIONAL DIGITAL METER

DIGITAL METER

MODULE

OPTIONAL

BURN BACK

MODULE

Blank Panel for Optional Digital Meter Kit

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 plug does not have a jumper plug connected to it.

c. Connect the 10-pin plug into the matching receptacle on

the rear of the optional meter module.

d. Install the meter module in place of the blank panel

removed in Step a., using the same four screws that you saved.

SECTION 3 INSTALLATION

SECTION 4 OPERATION

4.1 CONTROLS (See Figure 4.1)

4.1.1 POWER SWITCH

The front panel Power Switch energizes the primary of the main transformer, the control circuits, the wire feed circuit, gun trigger circuit and the cooling fan.

When switched to the "ON" position the machine is in the ready to weld mode.

When switched to the "OFF" position, primary input voltage to the main transformer is interrupted and the unit will be inoperable. However, primary voltage will still be present inside the cabinet up to the switch.

Torch Wrap and Spare Parts Kit

4.1.4

4.1.2

Temperature Fault Indicator

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL BURN BACK

MODULE

2.4.2 Optional Digital Meter Kit (not shown)

4.1.2 VOLTAGE CONTROL (Coarse Range Selector and Fine Adjustment Range Selector)

Voltage control is by means of two high current tap switches which connect the rectier bridge to eight secondary taps.

The COARSE VOLTAGE RANGE Selector is a three-position switch, (1) LOW / (2) MED / (3)HIGH, which selects the range of voltage (or heat, that determines the arc length) to be applied 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.

Burn Back

Connector

4.2.3 Optional Burn Back Module (not shown)

4.2.2

Torch Trigger Receptacle

4.1.1

Output Polarity Plug

Digital Meter Connector

10 Amp Fuse

4.1.5

Stock Serial # Plate

(-) Output Receptacle

Work Cable Assembly

Torch Cable

4.1.3 Positive Output Receptacle Flat Slope

Secondary Output Terminals for welding polarity change-over

4.1.3 Positive Output Receptacle Steep Slope

Figure 4.1 CONTROLS

Drive Roll

SECTION 4 OPERATION

The FINE VOLTAGE ADJUSTMENT Selector is an eight-

Dial Setting Wire Speed IPM

position switch for selecting the exact amount of arc volt-

position switch for selecting the exact amount of arc voltage (or heat) to be applied to the weld arc. This allows for

age (or heat) to be applied to the weld arc. This allows for

age (or heat) to be applied to the weld arc. This allows for ne tuning of the voltage required to stabilze the arc. The

ne tuning of the voltage required to stabilze the arc. The

ne tuning of the voltage required to stabilze the arc. The Fine Voltage Selector switch also has an "open" detent at

Fine Voltage Selector switch also has an "open" detent at

Fine Voltage Selector switch also has an "open" detent at the six o'clock position. Placing the switch in this position

the six o'clock position. Placing the switch in this position

the six o'clock position. Placing the switch in this position allows operation of the torch trigger to feed electrode wire

allows operation of the torch trigger to feed electrode wire

allows operation of the torch trigger to feed electrode wire without the wire being electrically "hot". This switch must

without the wire being electrically "hot". This switch must

not be switched under load.

These tap switches carry several hundred amperes

These tap switches carry several hundred amperes while welding, and must not be switched under load,

while welding, and must not be switched under load,

while welding, and must not be switched under load, as this will cause the contacts of the switches to arc.

as this will cause the contacts of the switches to arc.

4.1.3 SECONDARY WELDING CONNECTIONS

A solid state secondary contactor is used to energize the

A solid state secondary contactor is used to energize the welding curcuit. This contactor is activated with the torch

welding curcuit. This contactor is activated with the torch

welding curcuit. This contactor is activated with the torch trigger and is energized when the trigger is pulled. The gas

trigger and is energized when the trigger is pulled. The gas

trigger and is energized when the trigger is pulled. The gas solenoid is energized at the same time. When the trigger

solenoid is energized at the same time. When the trigger

solenoid is energized at the same time. When the trigger switch is released, the contactor opens and disconnects the

switch is released, the contactor opens and disconnects the

switch is released, the contactor opens and disconnects the load. The gas valve shuts o when the contactor opens.

load. The gas valve shuts o when the contactor opens.

The secondary output welding terminals, POS.(+) and NEG(-

The secondary output welding terminals, POS.(+) and NEG(), are located on the front panel and are used to set the

), are located on the front panel and are used to set the

), are located on the front panel and are used to set the welding polarity (D.C.R.P. or D.C.S.P.) (see Fig. 4.1). TORCH

welding polarity (D.C.R.P. or D.C.S.P.) (see Fig. 4.1). TORCH

welding polarity (D.C.R.P. or D.C.S.P.) (see Fig. 4.1). TORCH tting is connected to Positive, and WORK cable/clamp

tting is connected to Positive, and WORK cable/clamp

tting is connected to Positive, and WORK cable/clamp is connected to Negative output). To weld using D.C.S.P.,

is connected to Negative output). To weld using D.C.S.P.,

is connected to Negative output). To weld using D.C.S.P., simply mount the WORK cable to the Positive output and

simply mount the WORK cable to the Positive output and

simply mount the WORK cable to the Positive output and the TORCH tting cable to the Negative output terminal.

the TORCH tting cable to the Negative output terminal.

4.1.5 STANDARD/SPOOL GUN SELECTOR

This two-position toggle switch is used to select standard

This two-position toggle switch is used to select standard metal inert gas welding (MIG) with the GUNMASTER 250, or

metal inert gas welding (MIG) with the GUNMASTER 250, or welding with the MT-250SG/ST-23A spool guns.

welding with the MT-250SG/ST-23A spool guns.

Dial Setting Wire Speed IPM

0 0

0 0 1 30

1 30 2 115

2 115 3 200

3 200 4 300

4 300 5 380

5 380 6 455

6 455 7 525

7 525 8 615

8 615 9 703

9 703

10 760

Table 4.1 Relationship of

wire speed vs. potentiometer setting

Standard / Spool Gun Select Switch

Because of the charged capacitor bank in the second-

Because of the charged capacitor bank in the secondary circuit, the output voltage will take a few seconds

ary circuit, the output voltage will take a few seconds

ary circuit, the output voltage will take a few seconds before falling to zero volts.

before falling to zero volts.

4.1.4 WIRE FEED SPEED CONTROL

Wire feed speed is controlled by the wire speed potentiom-

Wire feed speed is controlled by the wire speed potentiometer knob on the front panel. The solid state control allows

eter knob on the front panel. The solid state control allows

eter knob on the front panel. The solid state control allows for innitely variable speeds up to 750 IPM.

for innitely variable speeds up to 750 IPM.

This wire speed pot is used to set the speed at which the

This wire speed pot is used to set the speed at which the welding wire is fed out from the torch and hence the welding

welding wire is fed out from the torch and hence the welding

welding wire is fed out from the torch and hence the welding amperage. The panel-face numbers on the dial (0-10) are

amperage. The panel-face numbers on the dial (0-10) are

amperage. The panel-face numbers on the dial (0-10) are used for reference and do not directly indicate wire feed

used for reference and do not directly indicate wire feed

used for reference and do not directly indicate wire feed speed; the higher the number, the faster the speed. Table

speed; the higher the number, the faster the speed. Table

4.1 show the relationship of wire speed vs. potentiometer

4.1 show the relationship of wire speed vs. potentiometer setting.

setting.

Figure 4.2 Standard/SPOOL GUN SELECTOR

SECTION 4 OPERATION

F. Connect the gas hose to the R-33-FM-580 Flowmeter

Regulator and adjust to 25 - 35 CFH.

G Set Migmaster 275 voltage tap switches to RANGE and

FINE ADJUSTMENT VOLTAGE settings desired.

H. Turn on the Migmaster 275’s power switch and begin

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL BURN BACK

MODULE

seam Mig welding.

If the optional Burn Back module is installed, the MT-250SG and the ST-23A gun may be operated using these optional features, see Section 4.2.3.

4.2.3 OPTIONAL BURN BACK MODULE

This optional control module provides an adjustable Anti-Stick feature to select various burnback times to prevent wire from sticking in the puddle after a weld.

This delay time, controlled by the “anti-stick” potentiometer, is variable from approximately 0.05 seconds to 0.5 seconds. The required delay time generally depends on the WIRE SPEED Adjustment setting on the front panel - the higher the setting, the faster wire will feed into the weld, and the more delay time will be required.

Figure 4.3 Electrode Posistive Flat Slope

4.2 PROCESS SETUP

4.2.1 STANDARD MIG SEAM WELDING W/ GUNMASTER 250

Refer to Sections 4.3.1, 4.3.2, 4.3.3, 4.3.4, and Table 4.3.3.

4.2.2 ST-23A SPOOL-ON-GUN CONTROL CONNECTION/OPERATION

The Migmaster 275 is equipped with a built-in control for the Spool Gun which operates via the amphenol control receptacle and power adaptor, p/n 37301, that provides Gas and Power. The ST-23A Torch (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 toggle switch

(4.1.6) in the 275 to its Spool Gun position.

B. Connect the ST-23A control cable amphenol to the

receptacle labeled CONTROL on the 275’s front panel.

C. Connect the ST-23A gas/power cable to the power

adaptor P/N 37301 using a counter-clockwise rotation. (see Section 4.1.3).

D. Connect the power adapter to the 275’s Positive Flat

Electrode receptacle

If, when using the Anti-Stick feature, the welding wire tends to stick in the puddle at the end of a weld, the Anti-Stick time should be increased; if, on the other hand, the wire burns back into the torch tip, the anti-stick time should be decreased. Setting the anti-stick time to “Min” eectively cancels the anti-stick feature.

4.2.4 DUTY CYCLE (Figure 4.5)

The duty cycle of the equipment is the percentage of a 10 minute period which it can operate safely at a given output current. The Migmaster system is rated at 50% duty cycle. This means that the equipment can be safely operated at 250 amperes for ve minutes out of every 10. This cycle can be repeated indenitely (See Figure 4.5).

Duty Amps

325

300

275

250

225

200

175

WELDING AMPERES

150

125

100

20 305

30 285

(35) 275

40 265

50 245

60 225

70 214

80 203

90 191

100 180

20 30 (35) 40 50 60 70 80 90 100

(RATED OUTPUT)

295

255

235

219

208

197

186

% DUTY CYCLE

E. Connect the work cable assembly to the negative output

receptacle and attach to the welding work piece.

Fig. 4.5 Duty Cycle Curves

SECTION 4 OPERATION

4.2.5 VOLT/AMPERE CURVES (Figure 4.6)

The Volt/Ampere curves show the output Voltage available at any given output current for the various Voltage Selector positions in each range low, medium, and high.

The actual operating point of load Voltage and Current is determined by type of process, electrode, shield gas, wire feed speed, and operating technique.

Fig. 4.6 Volt/Amp Curves

4.3 OPERATING PROCEDURES

4.3.1 OPERATING SAFETY PRECAUTIONS

Comply with all ventilation, re and other safety requirements for arc welding as established in the SAFETY Section at the front of this manual.

Also remember the following:

A. Because of the radiant energy of the welding arc

and the possibility of drawing an arc before the helmet is lowered over the face, the operator should wear ash goggles with lter lenses under his helmet. The helmet lter plated should be shade number 11 (nonferrous) or 12 (ferrous). All those viewing the arc should use helmets with lter plates, as well as ash goggles. Nearby personnel should wear ash goggles.

B. The radiant energy of the arc can decompose chlorinated

solvent vapors, such as trichloroethylene and perchlorethylene, 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

contact with them when power in ON: all are electrically energized (HOT) and can cause a possibly fatal shock. DO NOT allow electrode to touch grounded metal: it will create an arc ash that can injure eyes. It may also start a re or cause other damage.

D. When working in a conned space, be sure it is safe to

enter. The conned space should be tested for adequate oxygen (at least 19%) with an approved oxygen measuring instrument. The conned space should not contain toxic concentrations of fumes or gases. If this cannot be determined, the operator should wear an approved air supplied breathing apparatus.

SECTION 4 OPERATION

Avoid gas leaks in a conned space, as the leaked gas can dangerously reduce oxygen concentration in the breathing air.

DO NOT bring gas cylinders into conned spaces.

When leaving a conned space, shut OFF gas supply at the source to prevent gas from leaking into the space if the switch is accidently kept depressed. Check the breathing atmosphere in the conned space to be sure it is safe to reenter.

E. Never operate the equipment at currents greater than

the rated ampere capacity; overheating will occur.

F. Never operate equipment in a damp or wet area

without suitable insulation for protection against shock. Keep hands, feet and clothing dry at all times.

G. Whenever the equipment is left unattended, turn

all control and power supply switches and gas supplies OFF and open the main line switch.

D. Correct size wire accessories have been installed

on the wire feeder, drive gears are meshed, wire pressure set, and guide tube is installed for type and size wire you plan to use, refer to Tables

3.1 and Figure 4.7.

E. Spool of correct size wire is locked in place, brake

tension is set, and wire is properly threaded through the inlet guide to the gun tip.

F. The wire feeding compartment cover is closed and

secure.

G. Make sure that the metal to be welded is properly

prepared:

a. Remove loose surface rust, scale or paint with wire brush or sander.

b. Attempting to weld over grease or oil will cause weld defects.

c. Before welding on aluminum, be sure to clean surface thoroughly using a stainless steel brush.

4.3.3 SET-UP PROCEDURE

H. Wear dark substantial clothing to protect exposed

skin from arcburn, sparks and ying hot metal.

I. Turn o welding power before adjusting or replacing

electrodes.

Never operate the welding machine with any portion of the outer enclosure removed. In addition to a hazard, improper cooling may result in damage to the welding transformer and the welding machine components. Warranty is void if the machine is operated with any portion of the outer enclosure removed.

4.3.2 PRE-WELD REQUIREMENTS

Before welding commences, with all power OFF, check the following:

A. All safety requirements have been read and under-

stood.

B. All hoses and cables are in good condition, safely

insulated and securely connected.

C. Turn on gas supply by slowly opening cylinder

valve to full ON.

A. Determine the material type, thickness and joint conguration to be welded from Table 4.2 and use the recommendations 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 GUNMASTER 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. Make sure the GUNMASTER 250 gun tting and the “Work”

cable are connected to the proper output terminals for the polarity desired.

Only qualied personnel should make these changes. Make certain the primary power has been disconnected and all safety procedures have been followed before proceeding with these instructions.

SECTION 4 OPERATION

Connect cables for “DCEP”; torch polarity cable to

the POS (+) output Steep Slope receptacle and the “Work” cable to the NEG (-) output terminal. See Figure 3.5.

For “DCEN", torch polarity cable to the NEG (-) output

receptacle and the “Work” cable to the POS (+) Flat Slope output receptacle . See Figure 3.7.

4.3.4 WELDING OPERATION

A. Turn Power switch to ON - be careful not to operate

the torch switch.

B. Before starting the weld, clip o the end of the wire

with insulated cutters so the welding wire extends about 1/2-inch beyond the end of the nozzle.

Power supply contactor becomes energized the moment the torch trigger is depressed. Arcing can occur if the wire is brought to a ground. Keep the torch away from ground until welding is to begin.

C. To start the weld, hold the torch so the welding wire is

approximately 1/4-in. from the work, then press the torch trigger.

D. The welding wire should be pointed into the joint at

angles of approximately 45 mately 900 for butt welds, (Fig 4.7).

E. The torch angle relative to the length of the weld should

be approximately 100 from the vertical (Fig. 4.8).

F. When welding in the vertical position, traveling either up

or down, it is very important to keep the arc on the leading edge of the puddle to ensure complete penetration.

G. Some welders who are accustomed to welding with stick

electrodes may tend to push the torch into the weld. This is neither necessary nor desirable, since the wire electrode is being mechanically fed into the weld.

Please note that the Wire Speed control can be adjusted

for the gauge of metal to be welded. However, the Coarse

Voltage Range and Fine Voltage setting must not be switched while welding.

for llet welds, and approxi-

H. To stop the weld, release the trigger and pull the torch

from the work. When leaving equipment unattended, always shut OFF and disconnect all input power and shut o shielding gas at source.

Figure 4.7 Angle Of Weld To Joint

SECTION 4 OPERATION

Figure 4.8 Angle of Welding Wire with Joint

SETUP LEGEND

Wire Speed

Tap Setting

Range Setting

Material

Top #

Middle #

Bottom

Wire Size

Type

24 ga. 20 ga. 18 ga. 16 ga. 3/32" 1/8" 3/16" 1/4"

.023"

.030"

.035"

CARBON STEEL

.045"

All Short Arc settings above use Steep Slope Tap

All Flux Core & Metal Core settings use Flat Slope Tap

CS - Carbon Steel

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL BURN BACK

MODULE

MIGMASTER 275 SETUP GUIDE

TO SET WELD PARAMETERS

1. Find the type and thickness of material to be welded. Set recommended Slope Tap (Steep or Flat).

2. Find the filler metal wire diameter to be used.

3. Find the suggested wire speed, tap, and range settings by following the wire diameter row across (to the right) to the plate thickness column.

4. Set the wire feed speed knob, tap selector, and range selector to the positions indicated.

- For 100% CO

Bold italic text setting data indicates

7.5

proper joint preparation and/or multi-

pass weld sequence required.

** Important - see note below.

Short Circuiting Arc Transfer

75% Argon/ 25% CO

1.5 1.7 2.6 3.1 4.0 6.2

1 2 3 4 6 1

1 1 1 1 1 2

2.0 2.5 3.3 3.7 5.0 5.2 7.1 7.5 8.2

3 4 6 7 1 2 4 5 6

1 1 1 1 2 2 2 2 2

1.6 2.1 2.5 2.7 4.0 4.5

3 4 5 6 8 2

1 1 1 1 1 2

1.6 1.8 2.1 2.3 2.8

4 5 6 7 2

1 1 1 1 2

Wire

Size

Type

Material

.045"

CS*

Use only recommended joint preparation and weld sequence procedures found in AWS, ANSI, ASME, ASNT publications and codes.

1/8" 3/16" 1/4" 3/8"

shield gas, increase tap setting by 1 or 2 positions as required.

Examples of joint preparation and weld sequence

3/8" 1/2" +

7.0 7.5 4 7 3 3

4.3 4.5 8 4 2 3

Dual Shield 710X Flux Core

100% CO

1/8" 3/16" 1/4" 3/8"

below use Flat Slope Tap

5.2 5.4 6.3 7.0

5 6 5 1

2 2 2 3

4.0 4.5 5.0 5.4

8 1 2 5

2 3 3 3

1/2" 5/8" +

3.3 3.5 5.2 5.5

2 3 8 2

2 2 2 3

5.5 6.0 2 3 3 3

Spray Arc Transfer

90% Argon/ 10% CO

All Spray Arc Settings

Core Weld C-6 Metal Core

92% Argon/ 8% CO

3/16" 1/4" 3/8"

4.5 4.8 5.5

8 1 3

2 3 3

1/2" 5/8" +

8.5 8.5 5 7 3 3

5.6 5.7 6 6 3 3

1/2" 5/8" +

5.0 5. 2 4 3 3

TABLE 4.2 Weld Condition Setup Guide - Carbon Steel

SECTION 4 OPERATION

TABLE 4.3 Weld Condition Setup Guide - Aluminum

TABLE 4.4 Weld Condition Setup Guide - Stainless Steel

SECTION 5 SERVICE

5.1 MAINTENANCE

If uninsulated cable and parts are not replaced, an arc caused by a bared cable or part touching a grounded

Be sure the branch circuit or main disconnect switch is o or electrical input circuit fuses are removed before attempting any inspection or work on the inside of the welding machine. Placing the power switch on the welding machine in the OFF position does not remove all power from inside of the equipment.

surface may damage unprotected eyes or start a re. Body contact with a bared cable, connector, or uncovered conductor can shock, possible fatally.

Keep power cables dry, free of oil and grease, and protected at all times from damage by hot metal and sparks. Clean dirt and metal particles from drive roll groove weekly; replace roll if badly worn.

Inspection, troubleshooting and repair of this equipment may ordinarily be undertaken by a competent individual having at least general experience in the maintenance and repair of semi-conductor electronic equipment. Maintenance or repair should not be undertaken by anyone not having such qualications.

Shut OFF shielding gas supply at source.

To aid in checking and servicing, use Schematic.

5.2 INSPECTION AND SERVICE

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

Regularly check cylinder valves, regulators, hoses, and gas connections for leaks with soap solution.

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

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

The electrode wire and all metal parts in contact with it are electrically energized while welding. Inspect these parts periodically for defective insulation and other electrical hazards.

5.2.1 POWER SOURCE

5.2.1a RECTIFIER

It is recommended that the rectier be cleaned occasionally by blowing it out with compressed air. This cleaning operation is necessary so that maximum cooling will be accomplished by the air stream. This should be done periodically, depending upon the location of the unit and the amount of dust and dirt in the atmosphere.

The hermetically sealed silicon diode rectiers are specially designed for welding machine use and will not age or deteriorate in use. The four diodes are mounted on heat sinks. A periodic cleaning of dust and dirt from these is necessary to insure cooling of the rectiers. Access is by removal of top cover and side panels. Should any diode accidentally be damaged and need replacement, it can be quickly removed from the heat sink. The replacement diode should be of the same type as the one removed, and should be locked securely to the sink, preferably with a torque wrench set for maximum of 25 ft. lbs. and a minimum of 20 ft. lbs. Excessive torque will distort the mechanical structure and may break the hermetic seal, whereas too little torque will result in improper electrical connections.

5.2.1b FAN MOTOR

All models are equipped with an exhaust fan and rely on forced draft for adequate cooling for high duty cycles and overloads. Lubricate the fan motor with a few drops of SAE20 non-detergent oil every three months.

SECTION 5 SERVICE

5.2.1c TRANSFORMER

Occasional blowing out of the dust and dirt from around the transformer is recommended. This should be done periodically depending upon the location of the unit and the amount of dust and dirt in the atmosphere. The welding machine case cover should be removed and a clean, dry air stream should be used for this cleaning operation.

5.2.1d WIRE FEEDER AND CONTROL CIRCUITS

To avoid shock, do NOT touch electrode wire or parts in contact with it, or uninsulated cable or connections.

B. Check all gas (and water) hoses and connections,

owmeters, and regulators for possible sources of leakage, breakdown or intermittent failure.

The 24-volts circuit is protected by a 10 amp fuse in a panel mounted fuseholder, accessible from the wire feeder compartment. Failure of this fuse will shut o the contactor, shielding gas and wire feeder.

If it should become necessary to replace this or any other fuse in the welding machine, ensure that the proper size fuse is used as a replacement.

5.2.1e OVER-TEMPERATURE PROTECTION

The machine is equipment with a thermostat. On continued high current application, if the thermostat reaches an abnormally high temperature, it will deenergize the contactor. This thermostat will reset itself automatically after the transformer windings have cooled to a safe level. While deenergized, neither the contactor, shielding gas nor wire feeder can be operated. If the thermostat opens, allow the equipment to idle with fan running for approximately 15min. before attempting to weld again.

5.2.2 WIRE FEEDER

When soft wire is fed, the drive rolls may pick up metal from the wire surface. Accumulation on the rolls may score the wire with resulting unwanted friction and improper feeding.

C. Isolate trouble to one part of the welding installa-

tion: primary power supply, power source, Feeder or wire guide train (casing, drive rolls, liners and contact tip). If this inspection indicates trouble in the Feeder, use Troubleshooting Guide, Table 5.1 and schematic diagram.

5.3.1 IF MOTOR DOES NOT RUN:

A. Check for blown fuse. If blown, check that motor is

not binding before replacing fuse.

B. Check for continuity across speed potentiometer (POT)

and wiper contact. Voltage from center tap to MIN end should vary from 0 to 5.4 VDC as pot- entiometer is rotated clockwise.

C. Check wiring for continuity. Then turn power ON and

check for 30 volts d.c. across input terminals 8 and 9 on the feeder printed circuit board connector (PL1).

D. Press torch trigger, and check for voltage across motor

(Pins 4 to 7) of speed control board; should vary from 1 to 24 VDC as speed control potentiometer is rotated clockwise.

5.3.2 DRIVE ROLL PRESSURE ADJUSTMENT

Inspect the rolls regularly and clean them with a ne-wire power brush. Avoid roughening, or removing the hardness of groove surfaces in grooved rolls. Any roughening may score the wire, just as the accumulation being removed may do.

5.3 TROUBLESHOOTING

If welding equipment doesn’t work right despite compliance 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.

Adjust the drive roll pressure knob until no wire slippage occurs. DO NOT OVERTIGHTEN - EXCESSIVE PRESSURE CAN CAUSE WIRE FEEDING PROBLEMS.

General Replacement

The exploded views in the Parts Section indicate generally, in numbered parts sequence, the disassembly of the wire drive and feeder parts.

Reassemble in reverse order.

SECTION 5 SERVICE

5.3.3 SOLENOID VALVE REPLACEMENT

When replacing the gas solenoid valve, the inlet (with the word IN) must face the rear of the Unit.

Many troubleshooting situations require that the power remain On and that power terminals in the equipment carry voltage. Exercise extreme caution when working on “LIVE” equipment. Avoid contact with electrical components, except when testing with an appropriate instrument.

Do not make any repairs to equipment unless you are fully qualied, as described in the maintenance section.

TABLE 5.1 TROUBLESHOOTING GUIDE

WELD CONDITION POSSIBLE CAUSE REMEDY

1. No weld or control power. a. Primary input power not available. a. Check for Voltage at primary input. 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 rectier. b. Check diodes and replace if req’d. c. Open in wiring c. Check all wiring.

3. Fan does not run. a. See Weld Condition 1. a. Repair or replace cable or switch as necessary. b. Malfunctioning fan motor (M1) b. Replace fan motor (M1).

4. Erratic welding current. a. Poor workpiece connection. a. Check workpiece grounding connection. b. Loose welding connections. b. Check all connections. c. Wrong polarity. c. Check for correct polarity.

5. Welding output Voltage a. Low line Voltage and / or current a. Use correct Voltage. too low.

SECTION 5 SERVICE

WELD CONDITION POSSIBLE CAUSE REMEDY

b. Welding cables too long or too b. Use correct cable size. small. c. Loose connection. c. Check all welding cable connections. d. Malfunctioning capacitor bank. d. Check capacitors for low leakage resistance.

6. Stringy irregular bead, a. Torch moved too fast. a. Move Torch slower along seams. poor penetration. b. Controls are not set properly for b. Reset control properly. metal gauge thickness. c. Wrong polarity. c. Check for correct polarity.

7. Bead not centered. a. Nozzle not aligned. a. Move Torch nozzle parallel to and centered over seam.

8. Bead too large. a. Torch moved too slowly. a. Move Torch faster along seam.

9. Unstable arc, excess a. Incorrectly set controls. a. Reset controls. spatter, weld porous. b. Shield gas ow is too low or b. See Condition 10. stopped. c. Torch nozzle is too far from work. c. Maintain 1/4" (.6 mm) wire protrusion; hold closer to work. d. Faulty regulator or adapter. d. Check ow at outlet; replace faulty item. e. Faulty gas solenoid valve (SOL). e. Replace solenoid valve. f. Wrong polarity. f. Check polarity.

10.Shield gas ow low or a. Cylinder valve closed. a. Turn o 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 ow at outlet; replace faulty item. d. Faulty gas solenoid valve. d. Replace solenoid valve.

11.Wire stubs on work a. Controls not set properly for a. Reset controls properly. while welding. metal gauge, thickness.

12.Wire burns back into a. Contact tip loose. a. Firmly tighten with pliers. contact tip. b. Tip too close to work. b. Maintain 1/4" (.6 mm) wire protrusion; hold Torch further from work. c. Wire feed slipping. c. Increase pressure on pressure roll by adjusting pressure knob. d. Contact tip damaged. d. Trim back tip 1/16" (1.6 mm) max. Replace if still faulty. e. Voltage setting too high. e. Adjust setting.

f. Optional Burn Back module time f. Reduce time setting Setting too long.

SECTION 5 SERVICE

WELD CONDITION POSSIBLE CAUSE REMEDY

13. Wire sticks into the puddle a. Incorrect termination technique. a. Pull the gun back slightly after at the end of weld. releasing the gun trigger. Install and adjust optional Burn Back module.

b. Voltage setting too low. b. Increase voltage setting.

c. High wire feed speed conditions. c. Install and adjust optional Burn Back module.

14.Wire does not feed; motor a. Kink, etc. in wire, or wire bound a. Straighten; or feed wire until running (drive roll turns). on reel. clear and cut o. b. Wire freezing to contact tip b. Free freeze, or remove contact (burnback). tip feed wire until clear cut end free, and replace tip. c. Clogged liner. 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 POT outside terminals. d. Malfunctioning speed control board. d. Check board voltages (Para 5.3.1 b. and c.)

16.Wire feed does not stop. a. Torch trigger switch. a. Check continuity of Torch trigger circuit; check to see if trigger lever is stuck in “ON” position. b. Malfunctioning relay (K3). b. Check for proper action.

17.Gas continues to ow a. Gas solenoid valve stuck open. a. Tap solenoid or click on and o after trigger release. to clear valve.

SECTION 5 SERVICE

SECTION 6 REPLACEMENT PARTS

6.0 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.

6.2 Ordering

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 to indicate any special shipping instructions when ordering replacement parts.

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

Note

Items listed in the following Bill of Materials that do not have a part number

shown are not available from ESAB as a replaceable item and cannot be

ordered. Descriptions are shown for reference only. Please use local retail

hardware outlets as a source for these items.

Note

Replacement Parts, Schematics and Wiring Diagrams are

printed on 279.4mm x 431.8mm (11” x 17”) paper and are

included inside the back cover of this manual.

SECTION 6 REPLACEMENT PARTS

2, 3

FIGURE 6.5b Migmaster 275 LEXAN HUB KIT

ITEM QTY. PART CKT.

NO. REQ. NO. DESCRIPTION (HUB 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 Washer, 53001, Stl ZPC, .375 14 1 0558003320 Washer, D-Type

6, 7

0558005764 SPINDLE REPLACEMENT KIT

Spindle Replacement Kit includes items, order other items separately

SECTION 6 REPLACEMENT PARTS

9 or 10

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

Item No. ESAB Part Number Description

1 0558008450 2R-Wire Drive System (includes Items 2 thru 10) 2 0558008593 Gear Adaptor, Upper 3 0558008594 Gear Adaptor, Lower 4 0558008595 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)

SECTION 6 REPLACEMENT PARTS

REVISION HISTORY

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.

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (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 WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4462

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

visit us on the web at http://www.esabna.com

The ESAB web site oers

Comprehensive Product Information

Material Safety Data Sheets

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Instruction Literature Download Library

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Customer Feedback & Support

0558008552 07 / 2009

ESAB Migmaster 275 Welding Package Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual