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Signature Series
Multimaster 260
MIG/TIG/STICK WELDING PACKAGE
Instruction Manual
0558005188 08/2007
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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!
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TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions ....................................................................................5
1.1 Safety - English ..................................................................................5
1.2 Safety - Spanish .................................................................................9
1.3 Safety - French .................................................................................13
2.0 Description ..........................................................................................17
2.1 General ........................................................................................19
2.2 Receiving - Handling............................................................................19
2.3 Safety ..........................................................................................19
2.4 Power Source...................................................................................19
2.5 Wire Feeder ....................................................................................19
2.6 Controls....................................................................................... 20
2.7 Built-in Toolbox................................................................................ 20
2.8 Gun Master 250 Mig Gun.......................................................................20
2.9 Running Gear.................................................................................. 20
3.0 Installation.......................................................................................... 23
3.1 Location....................................................................................... 23
3.2 Handle Assembly Installation....................................................................24
3.3 Electrical Input Connections ...................................................................25
3.4 Voltage Changeover ........................................................................... 26
3.5 Secondary Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.6 “Euro” Torch Connections ......................................................................28
3.7 Wire Feeder Mechanism ....................................................................... 29
3.8 Connection of Shielding Gas Supply.............................................................32
4.0 Operation ...........................................................................................35
4.1 Standard Controls ..............................................................................35
4.2 Optional Controls.............................................................................. 38
4.3 Mig Welding Set-up.............................................................................41
4.4 Tig Welding Set-up .............................................................................42
4.5 Handling the Tig Torch......................................................................... 44
4.6 Stick Welding Set-up........................................................................... 45
5.0 Maintenance.........................................................................................47
5.1 Maintenance and Service .......................................................................47
5.2 Inspection and Service..........................................................................47
6.0 Replacement Parts .................................................................................. 49
6.1 General ....................................................................................... 49
6.2 Ordering ...................................................................................... 49
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TABLE OF CONTENTS
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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, cuess 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 cus, 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 conned, or if there is
danger of falling.
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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 conned 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 specic 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 eects 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 specic ventilation recommendations.
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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 qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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 Jeerson 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"
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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.
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SECTION 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 inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.
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 connado en lugares estrechos o
si hay posibilidad de caer al suelo.
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SECTION 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 especícas 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 especícas en la ventilación.
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SECTION 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 cualicado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado 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 modique 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"
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SECTION 1 SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
12
Page 13
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 an 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 an 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 ininammable an 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 ininammable.
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.
L es p er so n ne s se tr o uv an t à p r ox im it é do ive n t é ga l e ment 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 susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. 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 inammables 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 surchauer 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.
13
Page 14
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 an 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 eectuer 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
spéciques 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 eets 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 ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez 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 an
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 spéciques
concernant la ventilation.
14
Page 15
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
Jeerson 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 qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.
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'eectuez aucune modication.
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"
15
Page 16
SECTION 1 SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signie un danger qui peut entraîner des blessures
corporelles mineures.
16
Page 17
SECTION 2 DESCRIPTION
2.0 DESCRIPTION
Industrial Ready-To-Weld Multi-Process Package
Multimaster 260
Advanced SuperSwitch•
process welding a breeze. Simplied setup makes it
easy to select Mig, Tig, or Stick
DC welding output from 15 to 300 amps; rated 260 •
amps at 50% duty cycle
Output Pre-Set Capability for Quick Set-Up•
Two Digital Meters for Easy Fine Tuning•
Heavy Duty Four Drive Roll Stand•
Convenient, Large Capacity Built-In Tool Box •
Dual “Easy-On” Cylinder Tray•
TM
technology makes multi-
Ordering Information
The Multimaster 260 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 and tubular cored
wires. This unit is suitable for carbon steel, stainless steel, aluminum and many other alloys. It provides a power source
with built in wire feeder and undercarriage with provisions for two gas cylinders.
The following part number and description is for the Jesse James Series Multimaster 260 package.
Part Number - 0558004425, MultiMaster 260 230V Jesse James 15’ package
The following part number and description is for the basic Jesse James Series Multimaster 260 console (no accessories).
Part Number - 0558004424, MultiMaster 260 230V Jesse James console
PACKAGE CON TENTS (Standard Accessories)
Each Jesse James Series Multimaster 260 package includes:
P/N 0558004424, MM260 230V Jesse James console•
P/N 0558001649, 250 Amp “CC” 15 x 035-045 MST Gun•
P/N 21557, R-33-FM-580 Regulator / Flowmeter•
P/N 811FTF45, 87 HP HI Dep III .035•
P/N 811005313 5 lb. Stick Electrode Assortment •
P/N 13733936, Cable Plug (1/0 - 2/0)•
P/N 882F25, AF-1 Electrode Holder•
P/N 996995, Contact Tip MT M 035 (5)•
P/N 37290, Contact Tip MT M 045 (5)•
17
Page 18
SECTION 2 DESCRIPTION
Digital Meter
Status Indicators
Volts, Amps, and Wire feed speed
Wire Feed Speed
Control
Remote Control Option
Voltage/Current
Control
“Spool-on-Gun” Option
Voltage Preset
Process Selector
Optional Equipment
Pre/Post Flow/Spot/Burnback module ..................................... 0558002889
Inductance Control Module .........................................................0558002888
Remote Control Module ................................................................0558002605
FC-5B Foot Control - 30 ft. (9.1 m) cable................................................33646
Provides remote current control and contactor (on/o) control
Spool Gun Module ........................................................................... 0558002606
MT-250SG Spool Gun ..................................................................................36779
(Requires Spool Gun module)
ST-23A Spool Gun .........................................................................................19164
(Requires adapter 37301 and Spool Gun module)
HW-17V-2TL (w/valve) Heliarc Tig Torch Assembly ..........................35857
Tig weld without disconnecting the Mig torch. 60 deg. 12.5 ft.
HW-17 Torch Accessory Kit ..................................................................... 999126
Work Cable & Clamp .....................................................................................35881
Electrode Holder Assembly - 175 amp (15 ft.) ...................... 0558001786
Includes holder, cable and quick connector
Electrode Holder Assembly - 300 Amp (15 ft.) ...................................21226
Includes holder, cable and quick connector
Specifications
Rated DCCV or DCCC Output (10 min base)
50% duty cycle (NEMA Class I) ..................................260 amps @ 27 vdc
Output Current Range
Mig (GMAW) ................................................................................. 35-300 amps
Tig (GTAW) .................................................................................... 10-300 amps
Stick (SMAW)................................................................................40-300 amps
Open Circuit Voltage
Mig (MGAW)...........................................................................................39.0 vdc
Tig (TGAW).................................................................................................20 vdc
Stick (SMAW).............................................................................................70 vdc
Primary Input Voltage & Current @ 260 amp rated load
208/230 vac, 60 Hz, 1 ph ............................................................57/52 amps
Wire Feed Range ..............................................65-675 ipm (1.6 - 17.3 m/min)
Net Weight ................................................................................250 lbs. (112.5 kg)
Shipping Weight .....................................................................290 lbs. (130.5 kg)
W x L x H ................... 25.3 in. (64 cm) x 39.5 in. (100 cm) x 33.5 in. (85 cm)
Tee Connector (1 male/ 2 female) ...................................................13792804
Primary Extension Cord (25 ft.) .................................................................37833
TIG Welding Handbook ............................................................................ 781F29
MIG Welding Handbook ........................................................................... 791F18
18
Page 19
SECTION 2 DESCRIPTION
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 person nel with the design and operation of this equipment. All information presented here should be read careful ly 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 led with the carrier.
The carrier will furnish a copy of the bill of lading and the freight bill on request, if the need to le a damage claim arises.
When requesting information regarding this equipment, make sure that you include product name, part num ber, and
serial number.
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 person nel hazards are reduced if proper safety precautions are taken. If you are unsure
of yourself in any situa tion, ask your supervisor or other experi enced person nel 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 POWER SOURCE
The power source is a secondary chopper DC output designed for single phase primary connec tions. An ouput controlled
fan provides proper cooling during normal welding operations and shuts o four minutes after welding stops. The fan will
automatically re-start when welding resumes and proper machine temperatures will be maintained.
2.5 WIRE FEEDER
The four (4) roll drive wire feeder is built into the power source cabinet, housed separately from the welding machine electrical components. 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 675 ipm (inches per minute).
19
Page 20
SECTION 2 DESCRIPTION
2.6 CONTROLS
The Multimaster 260 can be used to weld solid and ux 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.
2.7 BUILT-IN TOOL BOX
The Multimaster 260 is designed with a lockable storage space on the left side of the machine for welding accessories such
as contact tips, gas nozzles, small grinder, spare parts, welding hood and protective clothing. (Figure 1B)
2.8 GUN MASTER 250 MIG GUN
This air-cooled welding gun is supplied complete and ready to weld .035 in. hard wire. The gun accommodates .045 inch wire
by changing the contact tip. Other wire sizes can be used. Refer to Section 6, for other wire size and alloy accessories.
2.9 RUNNING GEAR
The Multimaster 260 is equipped with running gear with swivel front wheels and a dual gas cylinder support.
20
Page 21
SECTION 2 DESCRIPTION
Choice of Argon or CO
Simple To Use Weld
Controls
Large, Easy To Read
Digital Displays for Wire
Speed, Amps and Volts
Flowmeter
6’ Gas Hose
Regulator/
2
Eyetech Automatic
Helmet
(Optional)
Cylinder Safety
Chain
Welding Gloves
(not shown,
optional)
Simple and quick
polarity change-over
15’ Gun Master
250 Mig Gun
15’ Work Cable
and Clamp
Factory Installed
Two Cylinder Easy
Load Running Gear
Stick Electrode
Holder
(Optional)
HW-17 Tig Torch
(Optional)
Figure 1A - Components
21
Page 22
SECTION 2 DESCRIPTION
Inductance Burnback
Preow/postow
Hinged Wire
Compartment Door
Handle
Spot (Options)
4 Roll
Drive Stand
Adaptable
Spindle Assembly
2 Cylinder
Low Mount Tray
Wheel Kit
Installed
Tool Box with Small
Parts Tray
Voltage Switch
Compartment
Figure 1B - Components
22
Page 23
SECTION 3 INSTALLATION
3.0 INSTALLATION
3.1 LOCATION
Several factors should be considered when selecting an installation site. 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.
The installation site should permit easy removal of the machine’s outer enclosure for maintenance. Installing or placing any
type of ltering device will restrict the volume of intake air, thus subjecting the internal components to overheating. Warranty is void if any type of ltering device is used.
20”
Figure 2 - Dimensions
32”
42”
23
Page 24
SECTION 3 INSTALLATION
3.2 HANDLE ASSEMBLY INSTALLATION
The Multimaster 260 is factory assembled except for the front handle assembly which is mounted to the machine upside
down for shipping purposes. The handle assembly consists of two brackets and a cross bar. To install the handle in its proper
position, do the following:
A. Remove the two sheet metal screws from the brackets on each side of the front handle assembly. See Figure 3A.
B. Remove front handle assembly and reverse sides with the mounting brackets. This will put the handle assembly in the
proper orientation. Reattach brackets using the sheet metal screws removed in Step A. See Figure 3B.
Handle Bracket
Figure 3A - Handle Assembly Removal
Sheet metal Screws
Sheet metal
Screws
Handle Bracket
Figure 3B - Handle Assembly Installation
24
Page 25
SECTION 3 INSTALLATION
3.3 ELECTRICAL INPUT CONNECTIONS
In order to provide a safe and convenient means to completely remove all electrical power from the machine, it is highly
recommended that a line disconnect switch be installed in the input circuit of the machine.
Before making electrical input connections to the welding machine, “Machinery
Lockout Procedures” should be employed. If the connections are to be made from
WARNING
3.3.1 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.
a line disconnect switch, the switch should be padlocked in the o position. If the
connection is to be made from a fusebox, remove the fuses and padlock the cover
closed. If no locking facilities are available, attach a red tag to warn others not to
energize the circuit.
Typical Installation - User
Supplied Power Discon-
nect Box, Receptacle and
Plug
Input Conductor and Fuse Size
Primary
Input
Volts
208 57 90 8 8
230 52 90 8 8
460 26 30 12 12
575 20 30 12 12
Full
Load
Line
Amperes
Fuse
Size
Recommended
Primary
Input
Conductor
Size
Ground
Conductor
Size
25
Page 26
SECTION 3 INSTALLATION
3.3.2 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 congura tion (208/230 vac model only).
The receptacle should be wired to a separately fused disconnect or circuit breaker by an electrician. This disconnect or
breaker can be wired to a single phase system or two conductors of a three phase system. A third conductor for grounding
must be connected between the disconnect and the receptacle.
The termi nal labeled GRD is connected to the power source chassis and is for ground
WARNING
3.4 VOLTAGE CHANGEOVER (Figure 4)
purposes only. This 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 machine chassis.
The voltage changeover terminal board is located in the tool compartment on the left side of the machine. As shipped from
the factory, the Multimaster 260 is congured for the highest connectable voltage. If using the other input voltages, the links
on the terminal board (TB) inside the unit must be repositioned for the appropriate input voltage. See gures 4A - 4E for
60Hz input voltage congurations. To gain access to the terminal board, open the access panel on the left side. To change
voltages, perform the following:
A. Remove the left screw ONLY and swing plexiglass door upward.
B. Adjust the copper bar links to the primary voltage being used.
C. Swing clear panel down and secure with screw.
Clear Panel Hinges on
corner screw
Remove this
screw only
This screw must
remain in place
Do Not Remove
Figure 4 - Voltage Changeover Terminal Board
208/230 Version Shown Installed
26
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SECTION 3 INSTALLATION
Figure 4A -
Input Terminal Board
230/460/575 Vac Model
230 Vac Conguration
Figure 4B -
Input Terminal Board
230/460/575 Vac Model
460 Vac Conguration
Figure 4C -
Input Terminal Board
230/460/575 Vac Model
575 Vac Conguration
Figure 4D -
Input Terminal Board
208/230 Vac Model
208 Vac Conguration
Figure 4E -
Input Terminal Board
208/230 Vac Model
230 Vac Conguration
27
Page 28
SECTION 3 INSTALLATION
3.5 SECONDARY OUTPUT CONNEC TIONS (Figure 5)
The Multimaster 260 Welding System is completely self-contained so that the front panel gun/torch connections are internally connected to the welding polarity (DCEP or DCEN) via the secondary output terminals depending on the welding
process being used.
Figure 5 - Polarity Set-up
3.6 TORCH CONNECTIONS (Figure 6)
The torch (GUNMASTER 250), which is supplied as standard equipment with the Migmaster 250 System, is provided with a
euro-type adapter which directly connects to the torch tting 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 sections 3.3 or 4.1.3). To connect the spool-on-gun torch (ST-23A) see Section 4.2.2.
Figure 6 - Gun Connector
28
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SECTION 3 INSTALLATION
3.7 WIRE FEEDER MECHANISM
3.7.1 DRIVE ROLLS (Figure 7 and 9)
The drive roll has two grooves: the small groove feeds .035 in. diameter wire, the large groove feeds .045 in. wire. The groove
nearest the gear motor feeds the wire. If the required groove is not correctly positioned, perform the following:
A. Release the pressure drive roll lever.
B. Remove the two (2) screws holding the drive rolls to the gears.
C. Reverse the drive roll on the drive roll shaft.
D. Replace the screws and tighten.
E. Secure the pressure drive roll assembly.
Feed Roll Release Screws
Figure 7 - Wire Feeder Mechanism
29
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SECTION 3 INSTALLATION
3.7.2 WELDING WIRE SPOOL INSTALLATION
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
CAUTION
Install a spool of welding wire on the spindle as follows:
A. Remove the locking pin from the spindle (Figure 8).
B. Place wire spool on the spindle to rotate clockwise as wire is unwound; spindle brake pin must engage hole in spool.
C. Replace the locking pin into the spindle hole closest to the spool.
torch. Hold onto the wire coming o 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.
Spool Spindle
Figure 8 - Spindle Assembly
Locking Pin
3.7.3 THREADING WELDING WIRE
A. Turn o power switch.
B. Release pressure drive roll assembly. Check that proper wire diameter grooves are in the inner position.
Before threading welding wire, make sure chisel point and burrs have been re-
CAUTION
moved from wire end to prevent wire from jamming in gun or liner.
C. Feed the wire from the spool through the inlet guide, across the drive roll grooves and center guide into the outlet
guide and EURO connection tube.
Make sure that the proper “outlet guide tube” is inserted into the front-panel gun tting for the size and type of wire
being used, see Table for wire feed accessories.
To ensure proper wire feeding, it is important that the wire be kept clean and that the drive rolls be periodi cally
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.
30
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SECTION 3 INSTALLATION
3.7.4 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.
When the power switch is on, and gun trigger is depressed, the electrode wire
WARNING
becomes electrically hot, and the wire drive rolls will rotate.
Pressure Roll Assembly
Pressure Release
Lever
Figure 9 - Threading the Wire
Threading the wire
through the inlet guide
31
Page 32
SECTION 3 INSTALLATION
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
WARNING
weaken the threaded joint to the regulator body. This may cause the cap to y o
and possibly injure personnel in area.
Flow Tube
Cylinder Valve
Connection
Nut
Control Valve
Pressure
Gauge
Figure 10 - R-33 Regulator
Never stand directly in front of or behind the regulator when opening the cylin-
WARNING
der valve. Always stand to one side.
3.8 CONNECTION OF SHIELDING GAS SUPPLY
3.8.1 R-33-FM-580 Regulator
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 provides the recommended ow ranges for the R-33-FM-580 regulator.
Argon 10-50 cfh
Helium 150-230 cfh
C-25 10-50 cfh
Table 2 - Typical Flow Rates
A. With the cylinder cap in place, CAREFULLY slide the cylinder of gas onto the Multimaster 260 cylinder rack.
B. Secure the cylinder to the unit using the chain provid ed.
C. Unscrew the cylinder cap.
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SECTION 3 INSTALLATION
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.
E. Attach the regulator to the cylinder valve. Align the regulator so that the owmeter is vertical and then tighten the
connection nut with a 1-1/8 in. open end or adjustable wrench. To prevent damaging the O-ring seals and plastic tube,
do not use the owmeter tube as a ‘handle’ when attaching the regulator.
F. Close the ow control valve on the owmeter.
G. Attach the gas hose from the rear of the Multimaster 260 to the regulator outlet connection.
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.
3.8.2 TO REGULATE FLOW
Flow is controlled by adjusting the owmeter valve until desired ow is indicated by the ball oat in the owmeter tube.
Always take the reading across the TOP of the ball.
33
Page 34
SECTION 3 INSTALLATION
34
Page 35
SECTION 4 OPERATION
4.0 OPERATION
Comply with all ventilation, re and other safety requirements for arc welding as
WARNING
4.1 STANDARD CONTROLS
4.1.1 POWER ON/OFF SWITCH & LAMP
The main power switch is located on the front panel in the upper left-hand corner. This switch energizes the main transformer, control circuitry and illuminates the Power “ON” lamp. (Figures 12 &13)
4.1.2 FAULT LAMP (Figure 12)
The fault lamp is congured for future use and is not currently activated.
established in the SAFETY Section at the front of this manual.
4.1.3 TEMP LAMP (Figure 12)
The TEMP lamp illuminates if an over temperature condition occurs within the Multimaster 260. This condition may be caused
by excessive duty cycle or over-current conditions. When an over temperature condition occurs, the welding output is turned
o and the unit must be allowed to cool. The machine will automatically reset when the temperature falls to a safe level.
4.1.4 PROCESS SELECTOR SWITCH (Figure 12)
The three position process selector switch is located in the upper righthand corner of the control panel. The process selector
switch provides the visual indication of which process (Mig, Tig or stick) has been selected.
4.1.5 SECONDARY WELDING CONNECTIONS
The secondary output welding terminals, POS (+) and NEG (-) are located in the lower right of the front panel, directly beneath
the Euro Connector (Figure 13). See 4.4, 4.5, and 4.6 for Setup Guides for specic application.
4.1.6 DIGITAL DISPLAYS (WFS, AMPS & VOLTS)
The digital displays located on the left side of the control panel are multi-functional depending on the welding process
being used.
4.1.7 MIG WELDING
In the Mig process mode, the digital displays will read preset wire feed speed in inches per minute and preset arc volts when
the PRESET button is pressed. Once welding begins, the displays will show average welding current and volts in the top and
bottom display, respectively. The displays have a “HOLD” circuit that retains the welding conditions. After welding stops, the
display will continue to show the last welding current and voltage sampled for 10 seconds, then returns to “0”.
35
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SECTION 4 OPERATION
4.1.8 TIG and STICK WELDING
In the TIG and STICK process mode, you must depress and hold the PRESET button while presetting the welding current in
the top display. Releasing the preset button causes the display to return to zero. Once welding begins, the display will show
average welding current and volts in the top and bottom display, respectively. After welding stops, the display will again
return to zero. There is no “HOLD” circuit for the display when using the TIG and STICK process modes.
4.1.9 WIRE FEED SPEED CONTROL (Figure 12)
The wire feed speed control potentiometer allows wire feed speed adjustments between 65 and 675 inches per minute
(IPM). Selecting the Mig process and pressing the PRESET switch allows the wire feed speed to be preset in the top digital
display by turning the wire speed knob.
4.1.10 VOLTAGE/CURRENT TRIM (Figure 12)
The arc voltage is controlled with this knob when the Process selector switch is in the MIG position. The Mig arc voltage
can be preset by pressing the preset button and reading the preset arc volts in the bottom digital display while turning this
knob.
The arc current is controlled with this knob when the WELD PROCESS SWITCH is in the TIG or STICK position. The welding
current can be preset in amperes by pressing the preset button and reading the preset amps in the top digital display while
turning this knob. The actual arc voltage will be displayed during welding.
4.1.11 BURNBACK CONTROL (Figure 11)
The burnback control is located inside the wire spool compartment above the wire feed motor. The control knob adjusts
the time between when the wire feed brake is applied and the welding contactor is turned “o”. This determines how far
the wire will burnback towards the contact tip after welding is stopped. If the wire is sticking in the weld pool then turn the
knob clockwise a small amount and retest. Continue this procedure until the wire clears the top of the weld pool or burns
back the desired amount.
Figure 11 - Burnback Control
36
Page 37
SECTION 4 OPERATION
Power “ON”
Lamp
Temperature
Lamp
Fault
Lamp
Digital Meters
Amps/Volts/WFS
WFS - IPM
Lamp
Amps
Lamp
Figure 12 - Control Panel
Preset
Button
Weld Process
Switch
Voltage Set - MIG
Current Set - STICK/TIG
Wire Feed
Speed Trim
IPM
Main Power
Switch
Remote Control Module
(Optional,
blank panel shown)
Spool Gun Control Module
(Optional,
blank panel shown)
Mig Gun
EURO
Connection
Positive Output
Connection
Polarity Switching
Connector
Negative Output
Connection
Figure 13 - Front Panel
37
Page 38
SECTION 4 OPERATION
4.2 OPTIONAL CONTROLS
4.2.1 INDUCTANCE TRIM (OPTIONAL) P/N-0558002888 (Figure 14)
Inductance is used to optimize short circuiting arc performance by changing the current rise and fall time of each short
circuit. This results in improved spatter control, weld bead wetting and arc stability. It is HIGHLY RECOMMENDED that the
Inductance Trim option be used for optimum short arc welding performance with stainless steel wires.
The INDUCTANCE TRIM is installed inside the wire spool compartment, above the wire feed motor, to the left of the Burnback
adjustment. The “easy to set” dial is calibrated by wire alloy (Carbon Steel and Stainless Steel) and Shielding gas:
100% CO
Argon - 25% CO
Argon - 8 to 15% CO
2
2
2
Trimix (Stainless Helium Mixtures)
The short circuiting Mig arc performance will change from a high short circuit frequency, fast reacting arc, to a lower short
circuit frequency, soft and less spattering arc as the dial is turned clockwise. The optimized arc performances will vary depending on shielding gas, wire diameter and alloy. Gases and alloys other than those indicated can also be optimized with
this control. The operator can adjust this control as desired to optimize personal preferences of welding characteristics.
Figure 14 - Inductance Trim
38
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SECTION 4 OPERATION
4.2.2 PREFLOW/POSTFLOW/SPOT/BURNBACK (OPTIONAL) P/N-0558002889 (Figure 15)
This optional control is mounted in place of the standard burnback control inside the wire spool compartment. A description
of the module follows:
A. Preow/Postow - The PREFLOW control sets the time of the preow shielding gas before the wire starts feeding (0-1.5
sec.). The POSTFLOW control sets the time the shielding gas remains “ON” after the arc is turned “OFF” (0-7.5 sec.).
B. Spot Weld Time - This dial sets the spot weld time from 0 to 5 seconds and is controlled by a current detect switch. The
timer does not start until current is detected to insure consistent results.
Preow
Time
Postow Time
Spot Time
Burnback
Time
Continuous
“ON”
Spot “ON”
Trigger Latch
“ON”
Figure 15 - Preow/Postow/Spot/Burnback
C. Burnback Timer - See 4.1.11
D. Spot Weld Switch Position - With the toggle switch in the SPOT (left) position, the SPOT timer is turned “ON”, and the
spot weld time is controlled by the SPOT WELD TIMER dial.
E. Continuous Position - With the toggle switch in the CONTINUOUS (center) position, the welding continues as long as
the Mig gun trigger is depressed.
F. Trigger Lock Position - With the toggle switch in the TRIGGER LOCK (right) position, the welding process begins when
the gun trigger is depressed. Once the welding process has started, the gun trigger may be released without aecting
the welding process. To stop the welding operation, the gun trigger must be depressed a second time. This allows a
continuous weld without having to continuously depress the gun trigger.
39
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SECTION 4 OPERATION
4.2.3 REMOTE CONTROL MODULE (OPTIONAL) P/N-0558002605 (Figure 16)
This optional control panel mounts to the front of the power source to the right of the main power switch (see Figure 13).
The remote receptacle can be used for a variety of options, such as a Tig current control, foot pedal control or manual hand
current control. The module includes a toggle switch to select between PANEL or REMOTE control of the welding current
and contactor. See Instruction Literature F15-618.
Figure 16 Remote Control Module
4.2.4 SPOOL GUN CONTROL MODULE (OPTIONAL) P/N-0558002606 (Figure 17)
This module mounts to the front panel just left of the Mig Gun trigger connectors and allows the use of either the MT-250SG or ST-23A spool guns with the Multimaster 260. The module has a switch to select either spool gun or regular Mig gun
operation. See Table 3 for MIG Spool Gun Paramaters. See Instruction Literature F15-619.
Figure 17 - Spool Gun Control Module
40
Page 41
SECTION 4 OPERATION
4.3 MIG WELDING SET-UP
When the PROCESS switch is placed in the MIG position the
Multimaster 260 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 Table 3 for the process being used.
Step 2. Place the WELD PROCESS 1 switch in the MIG (cen-
ter) position then press the PRESET button.
Step 3. Turn the Wire Speed Knob 3 to the desired speed
in the top digital display window.
Step 4. Turn the VOLTAGE 4 knob to the desired arc voltage
in the bottom digital display window.
Step 5. Set the shielding gas ow rate to 35 cfh by pulling
the gun trigger and turning the adjustment knob on
the R33-FM 580 Flowmeter.
Step 6. Pull the gun trigger and start welding. Trim the wire
speed and volts as needed for the desired arc characteristics.
Table 3 - MIG PARAMETERS CHART
Figure 18 - MIG Polarity Connection
3
Figure 19 - Mig Front Control Panel
2
1
4
Note 1: When using 100% CO2 sheilding gas, add 2 volts to the data table value.
41
Page 42
SECTION 4 OPERATION
Table 3 - MIG PARAMETERS CHART (Cont’d)
Note 1: When using 100% CO2 sheilding gas, add 2 volts to the data table value.
4.4 TIG WELDING SETUP
When the PROCESS switch is placed in the TIG position, the Multimaster 260 turns “ON” the weld contactor so that power
is immediately available to the output connection. The Touch TIG starting system is then enabled.
Step 1. Determine the weld parameters based on the metal thickness in Table 4 or use the ESAB TIG Welding Handbook
(optional) for suggested welding parameters.
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 20.
Step 3. Place the WELD PROCESS 1 switch in the TIG (left) position.
When the WELD PROCESS switch is moved to the TIG or STICK position, electrode
CAUTION
Step 4. While holding the PRESET 2 button, turn the VOLTAGE/CURRENT knob to the desired weld current on the top
digital display window.
Step 5. Set the shielding gas ow rate to 20 cfh by opening the manual gas valve on the Heliarc torch and adjusting the
control knob on the R-33-FM-580 owmeter.
becomes electrically “HOT”. Do not allow the electrode to contact ground potential
until you are ready to make a weld.
Step 6. Touch the tungsten electrode to the workpiece momentarily to establish the welding arc. Trim the current as desired
by turning the VOLTAGE/CURRENT 4 knob.
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SECTION 4 OPERATION
NOTE: The Wirespeed 3 knob has no eect in the TIG mode.
4
3
2
1
Figure 20 - TIG Polarity Connection
Table 4 - TIG PARAMETERS CHART
Figure 21- TIG Front Control Panel
43
Page 44
SECTION 4 OPERATION
Comply with all ventilation, re and other safety requirements for arc welding as
WARNING
4.5 HANDLING THE TIG TORCH
Starting the Arc
There is nothing dicult or technical about starting an arc in the proper manner. We recommend the particular procedure
outlined briey below, to ensure maximum protection of the workpiece from the atmosphere at the start of welding operations. In DC welding, when striking an arc the electrode must touch the workpiece in order for the arc to start. As soon as
the arc is struck, withdraw the electrode approximately 1/8 inch above the workpiece to avoid contaminating the electrode
in the molten puddle.
To strike an arc, rst turn on the power supply and hold the torch in a horizontal position about 1 inch above the workpiece
or starting block, as shown in Example A below. Then quickly swing the end of the torch down toward the workpiece, so
that the end of the electrode touches the plate. The arc will then strike. Once the electrode “scratches” the plate retract the
torch approximately 1/8”. This will establish the arc.
The arc can be struck on the workpiece itself or on a heavy piece of copper or scrap steel, and then carried to the starting
point of the weld. Do not use a carbon block for starting the arc, as the electrode becomes contaminated causing the arc
to wander. When starting to weld with a hot electrode, the action must be very rapid as the arc tends to strike before the
torch is in proper welding position.
established in the SAFETY Section at the front of this manual.
To stop an arc, merely snap the electrode quickly back up to the horizontal position. This motion must be made rapidly so
the arc will not mar or damage the weld surface or workpiece.
The use of hand or foot controls allows the operator to strike the arc, vary welding current and terminate the arc without
moving the torch. This is strongly recommended for proper TIG welding.
Example A
Example B
44
Page 45
SECTION 4 OPERATION
4.6 STICK WELDING SET-UP
When the PROCESS switch is placed in the STICK position, the Multimaster 260 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.
Step 1. Choose the weld parameters based on the Stick Electrode and diameter being used from Table 5 - STICK PARAM-
ETERS CHART.
Step 2. Be sure to set the polarity to DCEP (Electrode Positive) by placing the Electrode Holder cable in the Positive con-
nection terminal on the front of the power source.
Step 3. Place the WELD PROCESS 1 switch in the STICK (right) position.
Step 4. While holding the PRESET button, turn the VOLTAGE/CURRENT 4 knob to the desired weld current in the top digital
display window.
When the WELD PROCESS switch is moved to the TIG or STICK position, electrode
CAUTION
Step 5. Strike the electrode and start welding. Trim the welding current as needed for the desired puddle control.
becomes electrically “HOT”. Do not allow the electrode to contact ground potential
until you are ready to make a weld.
NOTE: The Wirespeed 3 knob has no eect in the STICK mode.
Figure 22 - STICK Polarity Connection
Table 5 - STICK PARAMETERS CHART
3
2
Figure 23 - STICK Front Control Panel
NOTE: Due to built in “Arc Force” control the “Actual” current while weld-
ing may dier from the “Pre-set” value. If the welding voltage falls
below 23 volts, the actual welding current will be greater than the
preset value.
4
1
45
Page 46
SECTION 4 OPERATION
46
Page 47
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
WARNING
WARNING
Shut OFF shielding gas supply at source.
5.2 INSPECTION AND SERVICE
ATTEMPT ING 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 UN DERTAKEN BY A COMPETENT INDIVIDUAL HAV ING AT LEAST GENERAL
EXPERIENCE IN THE MAINTENANCE AND REPAIR OF SEMI-CONDUC TOR ELECTRONIC
EQUIPMENT. MAINTENANCE OR REPAIR SHOULD NOT BE UNDERTAKEN BY ANYONE
NOT HAVING SUCH QUALIFICATIONS.
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 elec trical connections. Loose power connections overheat during welding.
Immediately replace all worn or damaged power cables and connectors. Check for frayed and cracked insu lation, 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
WARNING
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.
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 FATAL SHOCK.
47
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SECTION 5 MAINTENANCE
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 rectiers are mounted on heat sinks. A periodic cleaning of dust and dirt from these is neces sary to insure
cooling of the rectiers. Should any rectier need replacement, it can be quickly re moved 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 lters on this unit as they would restrict the volume of intake air. Output
CAUTION
ratings on this unit are based on an unobstructed supply of cooling air drawn over
its internal components. Warranty is void if any type of ltering 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 atmo sphere. 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 PRO TECTION
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 auto matically after the heat sink or transformer windings have cooled to a
safe level. While de-energized, the contactor can not be oper ated. 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 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 accumula tion being removed may do.
NOTE:
Schematics and Wiring Diagrams on 11” x 17”
inside the back cover of this manual.
paper are included
48
Page 49
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
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
49
Page 50
SECTION 6 REPLACEMENT PARTS
23
22
20, 21
19
18
24
1
2,3
9
4
5,6
*
10
11
17
16
15
Figure 24 - Right Side Front View
12
14
TORCH ADAPTOR ASSEMBLY
(Internal View)
13
26,27
TORCH ADAPTOR ASSEMBLY
*
(External View)
50
Page 51
SECTION 6 REPLACEMENT PARTS
Figure 24 - Right Side Front View (Con’t)
QTY. ITEM CIRCUIT
No. REQ. NO. DESCRIPTION SYMBOL
1 952895 1 SWITCH PB NORMALLY OPEN S2
2 672831 1 SWITCH TOGGLE SPDT S3
3 951474 1 SWITCH SEAL BLACK
4 0558005430 1 BRACKET RH HANDLE
5 13730632 2 POT LIN 10.0K 2.00W .88L R1,R2
6 0558001019 2 KNOB 1.57 DIA. 0
7
8
9 0558001082 1 COMPACT/NAS TORCH ADAPTOR includes:
23610528 1 HOUSING
0558001837 1 O-RING
23612350 1 POWER LUG
0558001836 1 CONNECTION TUBE NUT
10 0558001854 2 RECESSED HANDLE
11 0558002550 1 POLARITY CABLE ASSEMBLY (plug - p/n 13733936)
12 0558001576 2 WHEEL SPOKE 10” x 2.252” POLY
13 0558001699M 1 AXLE REAR
14 13733935 2 PANEL RECEPT
15 950396 2 CASTER WHEEL
16 0558002592M 1 COVER BOTTOM RIGHT
17 0558005427 1 COVER BOTTOM FRONT
18 1 REMOTE CONTROL & SPOOL GUN (OPTIONS NOT SHOWN)
19 0558001574 1 SWITCH POWER 40A 600V S1
20 0558002542 1 PANEL CONTROL KYDEX
21 0558954007 1 OVERLAY FRONT PANEL MM260 JESSE JAMES
22 0558001033 1 PCB BOX
23 0558001702Y 1 BRACKET LH HANDLE
24 0558005428 1 HANDLE SHAFT NICKEL-PLATED
25
26 0558001836 1 NUT, CONNECTION TUBE
27 0558001837 1 O-RING
51
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SECTION 6 REPLACEMENT PARTS
35
23
24
36
21
22
34
33
29
25
26
28
27
Figure 25 - Left Side Front View of Multimaster 260
QTY. ITEM CIRCUIT
No. REQ. NO. DESCRIPTION SYMBOL
21 0558001692M 1 DOOR TOP LEFT (HINGE & HINGE BRACKET NOT INCLUDED)
22 0558002593M 1 COVER TOP FRONT
23 38196 1 PCB ASSY. DISPLAY PCB2
24 38182 1 PCB CONTROL MAIN PCB1
25
26 0558002592M 1 COVER BOTTOM RIGHT
27 0558002544M 1 COVER BOTTOM LEFT
28 0558001686M 1 BASE PLATE
29 0558001696M 1 CYLINDER TRAY
30
31
32
33 0558002546M 1 TOOL BOX DOOR (HINGE & HINGE BRACKET NOT INCLUDED)
34 0558001856M 2 UPPER CYLINDER SUPPORT BRACKET
35 0558001692M 2 DOOR HINGE BRACKET
36 0558002545M 1 REAR TOP COVER
52
Page 53
SECTION 6 REPLACEMENT PARTS
64,65
66
61
67, 68
69
QTY. ITEM CIRCUIT
No. REQ. NO. DESCRIPTION SYMBOL
60 0558001710M 1 FAN MOUNT
61 0558002490 1 MOTOR M1
62 950592 1 FAN BLADE
63 0558001577 1 MAIN TRANSFORMER 208/230V T1
0558001580 1 MAIN TRANSFORMER - 230/460/575V T1
64 99511915 2 DIODE REV 200V 250A D1,2
65 99511916 2 DIODE FWD 200V 250A D3,4
66 0558002562 4 DIODE HEATSINK, SMALL
67 0558002563 2 DIODE HEATSINK
68 9510711 1 THERMAL SWITCH TS2
69 951085 1 THERMAL SWITCH TS1
60
62
Figure 26 - Inside Left View of Multlimaster 260
53
63
Page 54
SECTION 6 REPLACEMENT PARTS
49
51
(Not Shown)
52
40
48
46
43
42
47
50
54
Page 55
SECTION 6 REPLACEMENT PARTS
41
44
45
Figure 27 - Inside Right & Rear View of Multimaster 260 (cont.)
QTY. ITEM CIRCUIT
No. REQ. NO. DESCRIPTION SYMBOL
40 1 948258 SPINDLE MOLDED (SEE FIGURE 28)
41 1 0558002543M REAR COVER
42 1 0558003076 TRANSISTOR REPLACEMENT KIT IGBT MATCHED PAIR 600V - 300A Q1-2
43 1 38186 PCB ASSY. DRIVER PCB3
44 1 0558001893 POWER CABLE 208/230V
1 0558002081 POWER CABLE 230/460/575V
45 1 0558001696M CYLINDER TRAY
46 1 951634 SOLENOID 24 SOL1
47 1 0558002556 INDUCTOR L1
48 1 0558002558 DRIVE MOTOR M2
49 1 0558001339 COMPACT 4 ROLL WDS
50 3 0558001534 CAPACITORS C1,2,3
51 1 -- INDUCTANCE CONTROL (OPTIONAL)
52 1 -- BURNBACK CONTROL MODULE (OPTIONAL)
55
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SECTION 6 REPLACEMENT PARTS
For units with serial numbers xxxJ230001 (Mid July 2002 forward)
DRIVE ROLLS
(See Drive Roll & Guide Tube Selection
Guide on Following Pages)
ITEM
1
1A
2
3
4
5
6
7
8
9
10
11
12
13
14
For units with serial numbers starting xxxJ230001 (Mid July 2002 forward)
PART NO
0558001743
0558001744
952927
0558001745
0558001746
23612368
23612477
0558001747
23612474
23612472
34609
0558001748
0558001749
0558003538
0558003539
.
NOTE: Measure hole placement
to distingush between early & current verison drive stands
Figure 28 - Auto-Lift Mini Four Roll Geared Wire Drive System - 0558001339
Q T Y.
DESCRIPTION
Feed Plate
Safety Guard
Screw, Thumb (M6X12)
Pressure Arm
Bogie
Pressure Roll
Axle Pressure Roll
Locating Pin
Nut, Pressure Roll Axle
Circlip
Retaining Screw Pressure Arm
Spring Bogie Auto Lift
Spring to Pressure Arm Auto Lift
Spacer Tube, Small
Spacer Tube, Big
ITEM
PART NO
15
16
17
18
19
20
21
22
23
24
25
26
27
28
0558001752
0558001753
0558001754
0558001755
23612386
0558001756
34608
952925
23612460
23612470
23612462
0558001757
0558001895
0558003544
0558003542
1
1
1
1
1
2
2
1
2
1
1
1
1
2
2
DESCRIPTION
.
Spacer Tube Pressure Arm Auto Lift
Spacer Tube Bogie
Axle Pressure Arm
Allen Screw
Gear Adaptor Feed Roll
Axle Gear Adaptor Feed Roll
Washer, Retaining Screw
Knurled Screw
Pressure Device W/Scale
Locating Pin, 2.5 x 12 Pressure Device
Screw Intermediate Guide
Center Guide (Hard Wire)
Center Guide for (Aluminum)
Inlet Guide (Aluminum & Steel)
Main Gear Drive
Q T Y.
1
1
1
1
2
2
3
3
1
Pkt. 5
1
1
1
1
1
56
Page 57
SECTION 6 REPLACEMENT PARTS
Drive Roll and Guide Tube Selection
Wire Type
& Diameter
Hard Wires (“V” groove)
.023 in. (0.6 mm)
.030 in. (0.8 mm)
.035 in. (0.9 mm)
.045 in. (1.2 mm)
Cored Wires (Knurled “V” groove)
.030 in. (0.8 mm)
.035 in. (0.9 mm)
.040 in. (1.0 mm)
.045 in. (1.2 mm)
.052 in. (1.4 mm)
1/16 in. (1.6 mm)
5/64 in. (2.0 mm)
Soft (aluminum) Wire (“U” groove)
.030 in. (0.8 mm)
.035 in. (0.9 mm)
3/64 in. (1.2 mm)
1/16 in. (1.6 mm)
* Two drive rolls are required for four roll drive systems.
Roll Drive*
21155
21155
21156
21156
21160
21160
21161
21161
21161
21161
21162
21158
21158
21159
21159
Guide Tube
NAS
0558001077
0558001077
0558001078
0558001078
0558001077
0558001078
0558001078
0558001078
0558001078
0558001079
0558001079
0558001896
0558001896
0558001897
0558001898
57
Page 58
SECTION 6 REPLACEMENT PARTS
80
81
82
84
83
Figure 30 - Spindle Assembly for Migmaster 260
QTY. ITEM CIRCUIT
No. REQ. NO. DESCRIPTION SYMBOL
80 1 0558002561M WIRE SPOOL MOUNT BRACKET
81 1 948258 MOLDED SPINDLE
82 1 634347 CLIP HITCH .16D X 3.25L
83 2 948255 BRAKE PADS
84 1 36756 “D” SHAFT ALUMINUM
58
Page 59
NOTES
59
Page 60
NOTES
60
Page 61
REVISION HISTORY
Original release - 04/20051.
Revision - 05/2006 - Updated Handle Assembly Installation subsection per inputs from Ray Lundy.2.
Revision - 08/2007 - Changed Specications in Sect 2 - Process: MIG (GMAW), Open Circuit Voltage 3.
(max): from: 70 Vdc to: 39.0 Vdc per D. Perkins.
61
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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
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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 Specications 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
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
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Instruction Literature Download Library
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0558005188 08/2007
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