ESAB MultiMaster 160 Instruction Manual

MultiMaster 160

Mig / Tig / Stick Welding Package

Instruction Manual

F15-678-D 07 / 2005

BE SURE THIS INFORMATION REACHES THE OPERATOR

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

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.

Copies of this manual can be obtained by any of the following;

Contacting your local ESAB supplier.

Downloading a copy from the ESAB web site at

www.esabna.com

Sending a written request to

ESAB WELDING & CUTTING PRODUCTS

ATTN: LITERATURE DEPT.

411 S EBENEZER ROAD

FLORENCE SC 29501

2

Table of Contents

SECTION NO. PAGE NO.

SECTION 1.0 - SAFETY PRECAUTIONS.........................................................................................................................................3

SECTION 2.0 - INTRODUCTION ....................................................................................................................................................... 9

SECTION 3.0 - INSTALLATION ......................................................................................................................................................13

SECTION 4.0 - OPERATION ............................................................................................................................................................ 16

3.1 LOCATION..........................................................................................................................................................13

3.2 ELECTRICAL INPUT CONNECTIONS ............................................................................................................. 13

3.2.1 INPUT ELECTRICAL REQUIREMENTS........................................................................................................... 13

3.2.2 INPUT PLUG ......................................................................................................................................................13

3.3 SECONDARY OUTPUT CONNECTIONS.........................................................................................................13

3.4 WIRE FEEDER MECHANISM ........................................................................................................................... 13

3.4.1 DRIVE ROLLS ....................................................................................................................................................13

3.4.2 WELD WIRE SPOOL INSTALLATION ..............................................................................................................13

3.4.3 THREADING THE WELDING WIRE .................................................................................................................14

3.4.4 SPOOL BRAKE DRAG ADJUSTMENT.............................................................................................................14

3.5 CONNECTION OF SHIELDING GAS SUPPLY ................................................................................................ 14

3.5.1 R-33-FM-580 REGULATOR (OPTIONAL) ........................................................................................................ 14

3.5.2 TO REGULATE FLOW.......................................................................................................................................15

4.1 STANDARD CONTROLS...................................................................................................................................16

4.1.1 POWER ON/OFF SWITCH ................................................................................................................................16

4.2.2 TEMP LAMP .......................................................................................................................................................16

4.1.3 PROCESS SELECTOR SWITCH ...................................................................................................................... 16

4.1.4 SECONDARY WELDING CONNECTIONS.......................................................................................................16

4.1.5 WIRE FEED SPEED CONTROL ....................................................................................................................... 16

4.1.5 VOLTAGE CONTROL ........................................................................................................................................16

4.1.7 CURRENT CONTROL .......................................................................................................................................16

4.1.8 HOT START .......................................................................................................................................................16

4.2 OPERATING PROCEDURES............................................................................................................................18

4.2.1 MIG WELDING SET-UP.....................................................................................................................................18

4.2.2 TIG WELDING SET-UP .....................................................................................................................................19

4.2.3 STICK WELDING SET-UP.................................................................................................................................20

SECTION 5.0 - MAINTENANCE ......................................................................................................................................................21

SECTION 6.0 - REPLACEMENT PARTS

5.1 MAINTENANCE AND SERVICE .......................................................................................................................21

5.2 INSPECTION AND SERVICE............................................................................................................................21

5.2.1 POWER SOURCE..............................................................................................................................................21

5.2.1.1 RECTIFIERS AND TRANSISTORS ..................................................................................................................21

5.2.1.2 FAN MOTOR ......................................................................................................................................................21

5.2.1.3 TRANSFORMER ................................................................................................................................................21

5.2.1.4 OVER-TEMPERATURE PROTECTION............................................................................................................21

5.2.2 WIRE FEEDER...................................................................................................................................................21

........................................................................................................................................23

6.1 REPLACEMENT PARTS ................................................................................................................................... 23

6.2 GENERAL...........................................................................................................................................................23

6.3 ORDERING.........................................................................................................................................................23

3

Table of Contents

4

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 fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld­ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.

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

trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

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

FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex­plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non­flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro­duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.

5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.

6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces­sary.

7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro­cesses", available from the National Fire Protection Asso­ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move­ment is confined, or if there is danger of
falling.

1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.

4. Use well-maintained equipment. Replace worn or dam­aged cables.

5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from
work

and from ground.

7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

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

ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow­ing through any conductor causes lo­calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre­ates EMF around welding cables and
welding machines. Therefore:

1. Welders having pacemakers should consult their physi­cian before welding. EMF may interfere with some pace­makers.

2. Exposure to EMF may have other health effects which are
unknown.

3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure

them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded.
E. Keep welding power source and cables as far away

from your body as possible.

5

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.
Therefore:

1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless posi­tive mechanical ventilation is provided. Do not breathe
fumes from these materials.

2. Do not operate near degreasing and spraying opera­tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im­prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.

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

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

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

2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.

3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.

§25249.5 et seq.)

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

1. Always have qualified personnel perform the installa­tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.

2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.

3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position
and in good repair.

6. Use equipment only for its intended purpose. Do not
modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec­tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.

The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi­ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

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

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

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

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

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

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

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.

6

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaques

protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité

de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.

c. Les étincelles ou les projections de métal incandes-

cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité

lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma

produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combus-

tibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres sub­stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-

cent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations

de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il

convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur

de façon à vous assurer qu’aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-

sion venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.

b. Si vous devez effectuer un travail sur une surface

métallique ou dans un secteur humide, veillez à assu­rer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.

c. Mettez toujours à la terre le poste de soudage/coupage

en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne

surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en

service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un dan­ger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en

un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de pas­sage d’un courant de sortie par des chaînes de

7

levage, des câbles de grue ou divers chemins
électriques.

g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.

4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des mal­aises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate de

l’emplacement de travail en maintenant une ventila­tion naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtez­vous de travailler afin de prendre les mesures néces­saires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations

où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la forma­tion de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage ou

de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’élimi­ner du voisinage de l’opérateur tout dégagement de
fumée visible.

f. Consultez les recommandations particulières en

matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise

qualité mais, chose plus grave encore, d’entraîner des
dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-

lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretien

quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.

c. Maintenez en bon état de fonctionnement les câbles,

le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et des

équipements accessoires. Gardez-les à l’écart des
sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corro­sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tous

les panneaux de l’armoire de commande en veillant à
les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément à

son usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur les

règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Weld­ing, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:

a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc Cutting”

AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.

f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.

g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

8

SECTION 2 INTRODUCTION

Table 1 Multimaster 160 Specifications

Input

Primary Input Volt age....................................................................... 208 Vac, 1-Phase

......................................................................................................... 230 Vac, 1-Phase

Primary Input Current ....................................................................... 30 Amp @ 208 Vac

......................................................................................................... 27 Amp @ 230 Vac

Frequency ........................................................................................ 50/60Hz

Power Factor .................................................................................... 0.81

Nominal Power - MIG ....................................................................... 5.4KVA

Nominal Power - electrode ............................................................... 6.3KVA

Nominal Power - TIG........................................................................ 3.9KVA

Protective Fuses............................................................................... 20A time-lag

Degree of Protection ........................................................................ IP 21

Insulation Class ................................................................................ F

Operating Temperature .................................................................... From 14°F to 104°F (-10°C to +40°C)

Output

Duty Cycle - MIG .............................................................................. 160A - 60%

Duty Cycle - electrode ...................................................................... 160A - 60%

Duty Cycle - TIG DC......................................................................... 160A - 70%

OCV.................................................................................................. 75V

Arc Voltage - MIG............................................................................. 13.0 - 23.0

Arc Voltage - electrode..................................................................... 20.2 - 26.4

Arc Voltage - TIG .............................................................................. 10.2 - 16.4

Regulation range - MIG .................................................................... 20 - 160

Regulation range - electrode ............................................................ 5 - 160A

Regulation range - TIG..................................................................... 10 - 160A

Hot Start ........................................................................................... Adjustable

Arc Force.......................................................................................... Automatic (built-in)

Antisticking .......................................................................................Automatic (built-in)

Ignition - electrode............................................................................ Scratch

Ignition - TIG.....................................................................................Lift-arc

Wire Spool........................................................................................ 5/15/20kg (12/33/44 lb)

Wire .................................................................................................. Metal, fluxed core (no gas)

Dimensions

Length .............................................................................................. 22.4” (560mm)

Width ................................................................................................ 9.2” (230mm)

Height ............................................................................................... 15.4” (385mm)

Weight .............................................................................................. 33lbs(15Kg )(net)

Ordering Information

MultiMaster® 160 cvcc Multi-Process Packages

Multimaster packages listed below include power source with built­in wire feeder with .030/.035 drive roll, primary input cable, welding
gun, work cable with clamp, FREE #10 spool of .030 Coreshield
15 wire, and #1 sample 6013LV 1/8” stick electrodes.

Multimaster® 160 w/13-ft. MXL 200 ...........................................0558002772

Multimaster® 160 w/13-ft. MXL 200 & Stinger ........................... 0558002773

Multimaster® 160 w/13-ft. MXL 200 & Stinger/HW-17/Reg ............0558002774

®

9

SECTION 2 INTRODUCTION

Optional Equipment

MultiMaster® 160 Options & Accessories

Replacement Work Cable - 10 ft. ........................................................ 0369857881

Electrode Holder and Work Cable Kit - 25mm 10 ft............................. 0349501078

Replacement AF-1 Electrode Holder only ................................................... 882F25

HW-17V 25 ft. w/25mm Connector ...................................................... 0558002690

Kit, Accessory HW-17 ................................................................................. 999126

R-33 FM-580 Reg/Flowmeter ........................................................................ 21557

Primary Extension Cord (25 ft.) 50 amp ........................................................ 37833

Feedroll .023”/.030” V for Hard Wire .............................................................. 21155

Feedroll .030”/.030” Serrated for Core Wire .................................................. 21160

MXL 200cc 10 ft. (3m) x .023”-.030” ................................................... 0700200002

MXL 200cc 13 ft. (4m) x .023”-.030” ................................................... 0700200003

Gas Nozzle - Standard 7/16” (12mm) ................................................. 0700200054

Gas Nozzle - Straight 5/8” (16mm) ..................................................... 0700200057

Gas Nozzle - Conical 3/8” (9.5mm) .................................................... 0700200060

Contact Tip, .023” (0.6mm) .................................................................. 0700200063

Contact Tip, .030” (0.8mm) .................................................................. 0700200064

Contact Tip, .035” (0.9mm) .................................................................. 0700200065

Contact Tip, .040” (1.0mm) .................................................................. 0700200066

MXL 200 Tip Adapter - Short ............................................................... 0700200072

MXL 200 Tip Adapter - Long ................................................................ 0700200067

MXL 200 Nozzle Spring ....................................................................... 0700200078

Steel Liner .023”-.030” (0.6-0.8mm) x 13ft. (4m) ................................. 0700200086

Steel Liner .035”-.045” (0.9-1.2mm) x 13ft. (4m) ................................. 0700200088

Teflon Liner .023”-.030” (0.6-0.8mm) x 13ft. (4m) ............................... 0700200090

Teflon Liner .035”-.045” (0.9-1.2mm) x 13ft. (4m) ............................... 0700200092

Gas Meter ...................................................................................................... 19043

25mm Connectors - quick-acting twist lock connectors
for attaching output power cables or torches to power source:

Gas / Power Adapter for Heliarc HW-9 and 17 Torches ............................... 37158

Male Quick Connector................................................................................... 37159

10

SECTION 2 INTRODUCTION

2.1 GENERAL

This manual has been prepared for experienced weld­ers. 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.

This manual is intended for use in familiarizing personnel
with the design and operation of this equipment. All infor­mation presented here should be read carefully before
installing and using this equipment.

2.2 RECEIVING-HANDLING

Upon receipt of this equipment, clean all packing material
from around the unit and immediately inspect for any dam­age that may have occurred during shipment. Any claims
for loss or damage occurring in transit must be filed with
the carrier. The carrier will furnish a copy of the bill of
lading and the freight bill on request, if the need to file a
damage claim arises.

When requesting information regarding this equipment,
make sure that you include product name, part number,
and serial number.

and tubular cored wires. This unit is suitable for carbon
steel and stainless steel. It provides a power source with
built in wire feeder.

2.4.2 P ACKAGE CONTENTS (Standard Accessories)

Each Multimaster 160 package includes:

• Power source with built-in wire feeder.

• Gun Master 250 Mig Gun with .035" accessories.

• Dual groove feed rolls for .030/.035” core wire

• 10' work cable and clamp.

• 8' primary cable with plug.

• Mig Welding Handbook and set-up guide.

• Tig Welding Handbook

• Coreshield 15—.035 x 10# Spool

• L V 6013 Stick Electrodes 1#

2.4.4 POWER SOURCE

The power source is a DC output designed for single phase
primary connections. An output controlled fan provides
proper cooling during normal welding operations If the duty
cycle is exceeded, the unit will automatically shut down
and the Over Temperature light will illuminate. Once the
unit reaches a safe operating temperature, the unit will
automatically reset and welding can resume..

2.3 SAFETY

The safety section at the front of this manual should be
read completely before attempting to install and operate
this equipment. Both equipment and personnel hazards
are reduced if proper safety precautions are taken. If you
are unsure of yourself in any situation, ask your supervi­sor or other experienced personnel for help.

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.

2.4 DESCRIPTION

The Multimaster 160 is a DC welding system designed
for Mig (GMAW), Tig (GTAW) or Stick (SMAW) welding.
In the Mig mode this unit is capable of operating with short
arc or spray arc transfer and handles both solid wires

2.4.5 WIRE FEEDER

The wire feeder is built into the power source cabinet.
Cooling air is not drawn through the wire feeder compart­ment or electronic controls reducing exposure to dirt and
dust which improves product performance and reliability .

The wire feeder pushes wire at speeds from 65 to 650
ipm (inches per minute).

2.4.6 CONTROLS

The Multimaster 160 can be used to weld solid and flux
cored wires. The operator selects the process desired on
a three position switch located on the front panel. A de­tailed description of the power source controls is included
in Section 4 (Operation) of this manual.

2.4.8 MXL 200 MIG GUN

This air-cooled welding gun is supplied complete and ready
to weld .030 in. flux cored wire. Other wire sizes and types
can be used. Refer to Section 2, for other wire size and
alloy accessories.

11

SECTION 2 INTRODUCTION

Drive Motor

Inlet Guide

MIG Gun

Connector

Hinged Wire

Compartment Door

with Setup Chart

2 Roll

Drive Stand

MIG Polarity Changeover

Connectors

Handle Strap

Wire Spindle

Assembly

Primary Input

Cable

Figure 1 - Components

12

SECTION 3 INSTALLATION

3.0 INST ALLA TION

3.1 LOCA TION

Several factors should be considered when locating the
unit for use. Adequate ventilation is necessary to provide
cooling, and the amount of dirt and dust to which the
machine is exposed should be minimized. There should
be at least 18 inches of unrestricted space between the
machine’s side and rear panels and the nearest obstruc­tion to provide freedom of air movement through the power
source.

Installing or placing any type of filtering device will restrict
the volume of intake air , thus subjecting the internal com­ponents to overheating. Warranty is void if any type of
filtering device is used.

9.2”

230 mm

3.2.2 INPUT PLUG

The input power cord is provided with an attachment plug.

The
plug will mate with a 250 volt, 50 Amp receptacle con­forming to NEMA 6-50R configuration. The receptacle
must be wired to a separately fused disconnect or circuit
breaker by a qualified electrician.

3.3 SECONDARY OUTPUT CONNECTIONS

The Multimaster 160 Welding System has an internal Po­larity changeover for the MIG Process located under the
Hinge Cover. Front panel output recept acles make for easy
polarity changeover for TIG and STICK. See Sections

4.2.1, 4.2.2 and 4.2.3 for specific details on Connect Leads
and Cables for your application. Also the MIG torch con­nections are external allowing easy changes.

3.4 WIRE FEEDER MECHANISM

3.4.1 DRIVE ROLLS (Figure 5 and 7)

When viewing the drive roll, the stamped designation fac

ing
you is the groove in use. The drive roll has two grooves:
the small groove feeds .030 in. diameter wire, the large
groove feeds .035 in. wire. The groove nearest the gear
motor feeds the wire. If the required groove is not cor­rectly positioned, perform the following:

15.4”

385 mm

22.4”

560 mm

Figure 2 - Dimensions

3.2 ELECTRICAL INPUT CONNECTIONS

A cord with plug att ached is provided. Connect the plug to
a properly grounded and protected (fuse or circuit breaker)
230 V ac receptacle.

Before making any connections to the power supply
output terminals, make sure that all primary input
power to the machine is deenergized (off) and that
input power cable is unplugged.

A. Release the pressure drive roll lever.
B. Remove the screw holding the drive roll.
C. Reverse the drive roll on the drive roll shaft.
D. Replace the screw and tighten.
E. Secure the pressure drive roll assembly.

3.4.2 TORCH INSTALLATION

A Mig torch with a euro-type adapter is supplied as standard
equipment with the Multimaster 160 System. This torch
connects directly to the fitting mounted on the front panel.
Line up matching holes, push on and tighten locking collar.
As shipped from the factory, the euro or common connec­tor type torches are set-up for D.C.R.P. welding polarity
(See Figure #3).

3.2.1 INPUT ELECTRICAL REQUIREMENTS

The primary input voltage requirements are shown on the
power source nameplate. The power source is designed
to be operated from 208/230 vac single phase 50/60 Hz.

Figure 3 - Torch Connection

13

SECTION 3 INSTALLATION

3.4.3 WELDING WIRE SPOOL INSTALLA TION

As with any work area, make sure safety glasses with
side shields are worn when handling or changing wire
or clipping wire off at the spool or at the end of the
torch. Hold onto the wire coming off the spool with
one hand before clipping. Serious eye injury can re­sult due to the resilience of the wire which can quickly
unravel, or a cut wire end which may shoot across the
room.

Install a spool of welding wire on the spindle as follows:
A. Unscrew red plastic nut.

B. Place wire spool on the spindle to rotate counter-

clockwise (wire feeds off of the top) as wire is un­wound; spindle brake pin must engage hole in spool.

C. Spool spacer is used when running a 10# Spool of

Wire. Place wire on first, followed by spacer, and then
plastic nut.

D. Replace the locking nut.

3.4.4 THREADING WELDING WIRE

A. Turn off power switch.
B. Release pressure drive roll assembly. Check that

proper wire diameter grooves are in the inner position.

C. Feed the wire from the spool through the inlet guide,

across the drive roll grooves into the outlet guide and
cc connection tube.

To ensure 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.

D. Lower pressure roll assembly and secure. Turn the

power “on” and feed wire through to gun tip using the
gun trigger to start wire feeding.

When the power switch is on, and gun trigger is de­pressed, the electrode wire becomes electrically hot,
and the wire drive rolls will rotate.

3.4.5 SPOOL BRAKE DRAG ADJUSTMENT

Spool brake disc friction should provide enough drag to
keep the wire spool from spinning freely after wire feed
stops. If adjustment is required, turn the adjusting screw
inside the spindle housing clockwise to increase drag or
counterclockwise to decrease it. Drag should be just
enough to limit wire overrun.

Pressure Release Lever

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

Inlet Guide

Feed Roll Release Screw

Figure 4 - Wire Feeder Mechanism

Threading the wire through
the inlet guide

Figure 5 - Threading the Wire

3.5 CONNECTION OF SHIELDING GAS SUPPL Y

3.5.1 R-33-FM-580 Regulator (OPTIONAL)

The R-33-FM-580 regulator is an adjustable regulator de­signed for use with Argon, Helium, and C-25 (75% Ar­gon/25% CO2) gas service. Table 2 table provides the
recommended flow ranges for the R-33-FM-580 regula­tor.

14

SECTION 3 INSTALLATION

E. Attach the regulator to the cylinder valve. Align the

regulator so that the flowmeter is vertical and then

Argon 10-50 cfh
Helium 150-230 cfh
C-25 10-50 cfh

T able 2 - Typical Flow Rates

tighten the connection nut with a 1-1/8 in. open end
or adjustable wrench. To prevent damaging the O­ring seals and plastic tube, do not use the flowmeter
tube as a 'handle' when attaching the regulator.

Cylinders must be secured in a safe fashion. For additional
information, refer to CGA Standard P-1, “Precautions for
Safe Handling of Compressed Gases in Cylinders”.

Wire
Spool

Locking Nut

Figure 6 - Wire Spool Assembly

Cylinder
Pressure
Gauge

Cylinder Valve

Outlet

Connection

Figure 7

F. Close the flow control valve on the flowmeter.
G. Attach the gas hose from the rear of the Multimaster

160 to the regulator outlet connection.

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

Unscrew the cylinder cap.

Do not clamp regulator cap in a vise or grip it with a
pair of pliers. Distortion of cap can jam the internal
parts and cause excessively high delivery pressure
as well as weaken the threaded joint to the regulator
body . This may cause the cap to fly off and possibly
injure personnel in area.

D. Open the cylinder valve slightly, for an instant, to blow

out any dust or dirt that may have collected in the valve
outlet. BE SURE to keep your face away from the
valve outlet to protect your eyes.

H. Open the cylinder valve SLOWLY a fraction of a turn.

This will prevent damage to the gauge and critical
components in the regulator. When the gauge needle
stops moving, then open the cylinder valve fully.

I. Using a leak test solution, such as P/N 998771 (8 oz.

ctr) or soapy water, test for leakage around the cylin­der valve stem, the regulator inlet connection, and
the hose connections at the regulator. Correct any
leaks before starting work.

3.5.2 TO REGULATE FLOW

Flow is controlled by adjusting the flowmeter valve until
desired flow is indicated by the ball float in the flowmeter
tube. Always t ake the reading across the TOP of the ball.

15

SECTION 3 INSTALLATION

4.0 OPERA TION

4.1 ST ANDARD CONTROLS

4.1.1 POWER ON/OFF SWITCH & LAMP

The main power switch is located on the front panel in the
lower right-hand corner. This switch energizes the main
transformer, control circuitry and illuminates the switch
face.

4.1.2 TEMP LAMP (Figure 8)

The TEMP lamp illuminates if an over temperature
condition occurs within the Multimaster 160. This condition
may be caused by excessive duty cycle or over-current
conditions. When an over temperature condition occurs,
the welding output is turned off and the unit must be
allowed to cool. The machine will automatically reset when
the temperature falls to a safe level.

4.1.3 PROCESS SELECTOR SWITCH (Figure 8)

The three position process selector switch is located in
the upper left-hand corner of the control panel. The pro­cess selector switch provides the visual indication of which
process (STICK, TIG, MIG) has been selected.

4.1.4 SECONDARY WELDING CONNECTIONS

The secondary output welding terminals, POS (+) and
NEG (-) are located in the lower front panel. Refer to Po­larity Setup.

4.1.5 WIRE FEED SPEED CONTROL (Figure 8)

The wire feed speed control potentiometer located in the
upper left-hand side, allows wire feed speed adjustments
between 65 and 650 inches per minute (IPM).

4.1.6 VOL TAGE CONTROL (Figure 9)

The arc voltage is controlled with this knob when the Pro­cess selector switch is in the MIG position. Refer to Weld
Chart and set the recommended setting.

4.1.7 CURRENT CONTROL (Figure 8)

The welding current is controlled with this knob when the
Process selector switch is in the STICK OR TIG position.
Refer to Weld Chart and set the recommended setting.

4.1.8 HOT START (Figure 8)

The Hot Start feature is used to control the amount of
starting current in the Stick welding mode. This helps
ensure positive arc strikes for difficult to start electrodes
and also allows for softer starts on thin material.

16

SECTION 4 OPERATION

Wire Feed Speed

Weld Process

Switch

Voltage Set

Current Set

Temperature

Lamp

Figure 8 - Control Panel

Wire Feed

Speed Trim

IPM

Hot Start

Main
Power
Switch

Positive Output

Connection

Negative Output

Connection

Figure 9 - Front Panel

17

SECTION 4 OPERATION

4.2 OPERATING PROCEDURES

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

4.2.1 MIG WELDING SET-UP

When the PROCESS switch is placed in the MIG position
the Multimaster 160 is set to turn ”ON” when the Mig Gun
trigger is depressed.

Step 1. Choose the weld parameters based of the wire

alloy , diameter , material thickness and shielding
gas from Table 3 - MIG PARAMETERS CHART.
Set the polarity as shown in Filgure 10 for the
process being used.

Step 2. Place the WELD PROCESS (1) switch in the MIG

(FAR RIGHT) position.

Step 3. Turn the Wire Speed Knob (2) to the desired

speed.

Step 4. Turn the VOL TAGE (3) knob to the desired arc

voltage.

Step 5. Pull the gun trigger and start welding. Trim the

wire speed and volts as needed for the desired
arc characteristics.

MIG - DCEP (Electrode Positive)

Connector

Work Cable

and Clamp

MIG Gun

Polarity

Changeover

Connector

Option: If using one, set the shielding gas flow rate to 35

cfh by pulling the gun trigger and turning the ad­justment knob on the R33-FM 580 Flowmeter.

Table 3 - MIG PARAMETERS CHART

Figure 10 - MIG Polarity Connection

2

1

3

Figure 11 - Front Control Panel -

MIG (GMAW) Process Setup

18

SECTION 4 OPERATION

4.2.2 TIG WELDING SETUP

When the PROCESS switch is placed in the TIG position,
the Multimaster 160 turns “ON” the weld contactor so that
power is immediately available to the output connection. The
Touch TIG starting system is then enabled.

When the WELD PROCESS switch is moved to the TIG
or STICK position, electrode becomes electrically
“HOT”. Do not allow the electrode to contact ground
potential until you are ready to make a weld.

Step 1. Determine the weld parameters based on the met al

thickness in Table 4 or use the ESAB TIG Welding
Handbook for suggested welding parameters.

NOTE: The Wirespeed (2) and Volume (3) knobs have no effect in the

TIG mode.

TIG - DCEN (Electrode Negative)

Step 2. Be sure to set the polarity to DCEN (Electrode

Negative) by placing the Heliarc Torch in the
Negative connection terminal on the front of
the power source as shown in Figure 12.

Step 3. Place the WELD PROCESS (1) switch in the

TIG (center) position.

Step 4. Turn the CURRENT (4) knob to the desired

weld current.

Step 5. Set the shielding gas flow rate to 20 cfh by

opening the manual gas valve on the Heliarc
torch and adjusting the control knob on the R­33-FM-580 flowmeter.

Step 6. Touch the tungsten electrode to the workpiece

momentarily to establish the welding arc. T rim
the current as desired by turning theCURRENT
(4) knob.

Work Cable

and Clamp

Figure 12 - TIG Polarity Connection

T able 4 - TIG PARAMETERS CHART

2

1

3

4

Figure 13-Front Control Panel -

TIG (GTAW) Process Setup

19

SECTION 4 OPERATION

4.2.3 STICK WELDING SET-UP

When the PROCESS switch is placed in the STICK
position, the Multimaster 160 turns “ON” the weld
contactor so that power is immediately available to the
output connection. This means that the STICK electrode
holder is “HOT”, and an arc will strike when the electrode
comes in contact with the workpiece or any other object
at ground potential.

When the WELD PROCESS switch is moved to the
TIG or STICK position, electrode becomes electrically
“HOT”. Do not allow the electrode to contact ground
potential until you are ready to make a weld.

Step 1. Choose the weld parameters based on the Stick

Electrode and diameter being used from T able 5

- STICK P ARAMETERS CHAR T.

STICK - DCEP (Electrode Positive)

Step 2. Be sure to set the polarity to DCEP (Electrode

Positive) by placing the Electrode Holder cable in
the Positive connection terminal on the front of
the power source.

In general, choose a polarity based on electrode being
used. Some can be run with straight polarity - electrode
negative. Some can be run with reversed polarity - elec­trode positive.

Reversed polarity is used when more penetration is re­quired; typically for thicker material. Straight polarity is used
when you want less penetration; typically for thinner mate­rial.

Step 3. Place the WELD PROCESS (1) switch in the

STICK (FAR LEFT) position.

Step 4. Adjust the CURRENT (4) knob to the desired weld

current in the top digital display window .

Hot Start gives you a burst of current to ensure easy
arc start. The higher the setting, the bigger the burst.

Step 5. Strike the electrode and start welding. Trim the

welding current as needed for the desired puddle
control.

Work Cable

and Clamp

Figure 14 - STICK Polarity Connection

Table 5 - STICK PARAMETERS CHART

NOTE: The Wirespeed STICK (2) and Voltage (3) knobs have no

effect in the STICK mode.

2

1

3

4

Figure 15 - Front Control Panel -

STICK (SMAW) Process Setup

20

SECTION 5 MAINTENANCE

5.0 MAINTENANCE

5.1 MAINTENANCE AND SERVICE

Be sure that the branch circuit or main disconnect
switch and Multimaster power switch are off or elec­trical input fuses are removed before attempting any
inspection or work inside the power source. Placing
the power switch on the power source in the off po­sition does not remove all power from inside the
equipment.

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 qualifications.

Shut OFF shielding gas supply at source.

5.2 INSPECTION AND SERVICE

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

Regularly check cylinder valves, regulators, hoses, and
gas connections for leaks with soap solution or leak test
solution (P/N 998771).

Check for and tighten loose hardware including electrical
connections. 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.

If uninsulated cable and parts are not replaced, an
arc caused by a bare cable or part touching a
grounded surface may damage unprotected eyes or
start a fire. Body contact with a bare cable, connec­tor, or uncovered conductor can cause a fat al shock.

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.

5.2.1 POWER SOURCE

5.2.1.1 RECTIFIERS AND TRANSISTORS

It is recommended that the internal components be
cleaned occasionally by blowing them out with low pres­sure 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 diodes and transistors are spe­cially designed for welding machine use and will not age
or deteriorate with use. The rectifiers are mounted on heat
sinks. A periodic cleaning of dust and dirt from these is
necessary to insure cooling of the rectifiers. Should any
rectifier need replacement, it can be quickly removed from
the heat sink.

5.2.1.2 FAN MOTOR

All models are equipped with an exhaust fan and rely on
forced draft for adequate cooling for high duty cycles and
overloads.

Do not use filters on this unit as they would restrict
the volume of intake air. Output ratings on this unit
are based on an unobstructed supply of cooling air
drawn over its internal components. W arranty is void
if any type of filtering device is used.

5.2.1.3 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 Power
Source case cover should be removed and a clean, dry
low pressure air stream should be used for this cleaning
operation.

5.2.1.4 OVER-TEMPERATURE PROTECTION

The Power Source is protected from high internal tem­peratures by thermal switches. When the Power Source
is operated under high current applications for long peri­ods, the thermal switches may reach a high temperature
causing it to de-energize the contactor. These thermal
switches will reset automatically after the heat sink or
transformer windings have cooled to a safe level. While
de-energized, the contactor can not be operated. But, if
the gun trigger is depressed, the unit will still feed wire
and the solenoid will operate.

5.2.2 WIRE FEEDER

As 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.

Inspect the rolls regularly and clean them with a fine-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.

21

SECTION 5 MAINTENANCE

22

C201 - C202 - CAPACIT ORS 4n7 400V

C203 - C204 - CAPACIT ORS 1000pF 250VAC

D201 - D202 - D203 - D204 - D205 - DIODES 60A 200V

CN1 - CENTRALIZED MIG TORCH CONNECTOR (0558002709)

CN2 - CN3 - CHANGE POLARITY SOCKETS

CN4 - CHANGE POLARITY PLUG

VR1 - FAN 120 X 120 220/230V 50/60Hz (0558002738)

V1 - VARISTOR 275V (0558002731)

SV1 - SOLENOID VALVE 230V (0558002719)

M1 - WIRE MOTOR 17V (0558002710)

EMI FILTER (0558002746)

S1 - ROCKER SWITCH 2X16A 250V (0558002747)

RS1 - RECTIFIER 600V 35A (0558002730)

INV8 - INVERTER PCB (0558002716)

CONTFC - CONTROL PCB (0558002717)

BOTTOM PLATE - BOTTOM PLATE 140 160 MET (0558002708)

T1 - TRANSFORMER 230V 17V 15VA (0558002732)

T2 - MAIN TRANSFORMER 10/3 (0558002733)

L1 - COIL 50uH (0558002729)

R201 - R202 - RESISTORS 10R 3W

SECTION 6 REPLACEMENT PARTS

6.1 General

Replacement Parts are illustrated on the following figures.
When ordering replacement parts, order by part number
and part name, as illustrated on the figure.

Always provide the series or serial number of the unit on
which the parts will be used. The serial number is stamped
on the unit nameplate.

6.2 Ordering

Replacement parts may be ordered from your ESAB dis­tributor or from:

ESAB Welding & Cutting Products
Attn: Customer Service Dept.
PO Box 100545, Ebenezer Road
Florence, SC, 29501-0545

Be sure to indicate any special shipping instructions when
ordering replacement parts.

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

23

SECTION 6 REPLACEMENT PARTS

7

4

15

8

17

20

19

3

16

5

Feed Motor

13

18

6

12

24

11

14

10

SECTION 6 REPLACEMENT PARTS

Spare Parts List
MultiMaster 160

Item No. Part No. Description Cct. Ref.

1 0558002626 Multimaster 160
2 0558002704 Lid with Handle/S trap (Not Shown)
3 0558002735 Knob Ø 25mm
4 0558002736 Knob Ø 22mm
5 0558002707 Connector Dinse 25 +, ­6 0558002708 Bottom Plate
7 0558002709 MIG EURO Connector
8 0558002710 Wire Feeder Assembly

Includes:

0558002795 Feed Motor

9 0558002711 Reel Hub

10 0558002738 Fan VR1 & 2

11 0558002739 Fan Grid
12 34574 Mains Power Cable w/Plug 10Ft.
13 0558002746 EMI Filter
14 0558002716 Inverter AC PCB
15 0558002717 Control PCB
16 0558002747 ON/OFF Switch S1
17 0558002719 Solenoid V alve Assembly
18 58V58 Bulkhead Adaptor for Gas Fittings
19 136Z08 Gas Inlet Nut
20 35N22 Gas Inlet Nipple
21 0558002711 Spacer for Reel Hub
22 21161 Serrated Feed Roll 0.9 - 1.0mm
23 21156 Solid Wire Feed Roll 1.0 - 1.2mm

25

SECTION 6 REPLACEMENT PARTS

68

61 62

63

67

64

66

65

Multimaster 160 - Bottom Plate

26

SECTION 6 REPLACEMENT PARTS

Spare Parts List (Con’t)

MultiMaster 160

Item No. Part No. Description Cct. Ref.

61 0558002726 Plate
62 0558002727 Sink Heat w/Diodes
63 0558002728 Output Diodes
64 0558002729 Choke
65 0558002730 Rectifier Bridge
66 0558002731 Varistor
67 0558002732 Auxiliary Transformer
68 0558002733 Transformer

27

Notes

28

Notes

29

Notes

30

Revision History

Revision “A” edition of this manual updates the Specification Table on page 7 and revises the MIG, TIG and STICK
Process Charts in Section 4 - Operation.

Revision “B” - graphics were updated to show current black painted surfaces. Minor part number updates done
in spare parts list.

Revision “C” - added block diagram on Page 22.

Revision “D” - changed “Ordering Information” and “Optional Equipment” text on pages 9 and 10.

31

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Telephone: [phone] / Fax: [phone] Hours: 8:00 AM to 7:00 PM EST

Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:

Telephone: [phone] / Fax : [phone] 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: [phone] Hours: 8:00 AM to 5:00 PM EST

Part Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS:

Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:

Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 3:30 PM EST

Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: [phone] / Fax: [phone] 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 : [phone] Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: [phone]

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

or

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

The ESAB web site offers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

F15-678-D 07 / 2005