ESAB migmaster 215 pro User manual

Valid for serial no. 012, 0140349 301 164 101118
Migmasterr215 Pro
Instruction manual
Manuel d’instructions Instrucciones de uso

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Rights reserved to alter specifications without notice.
Rights reserved to alter specifications without notice.
Sous réserve de modifications sans avis préalable.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
ENGLISH 3..............................................
RANÇAIS 13.............................................
ESPAÑOL 23..............................................

ENGLISH
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TOCe
1 DIR CTIV 4........................................................
2 SAF TY 4...........................................................
3 INTRODUCTION 6...................................................
3.1 Equipment 6................................................................
4 T CHNICALDATA 6.................................................
5 INSTALLATION 7....................................................
5.1 Placing 7...................................................................
5.2 Electricalinstallation 7.......................................................
5.3 Mainspowersupply 8........................................................
6 OP RATION 9.......................................................
6.1 Connectionandcontroldevices 9.............................................
6.2 Switching--on and overheating protection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Operation 10................................................................
6.4 Wirefeedpressure 10........................................................
7 MAINT NANC 11....................................................
7.1 Inspectionandcleaning 11....................................................
8 FAULTTRACING 12...................................................
9 ORD RINGOFSPAR PARTS 12......................................
DIAGRAM 34............................................................
W ARCOMPON NTS 39.................................................
ACC SSORI S 40.......................................................

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1 DIR CTIV
D CLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-
ing power source Migmasterr215 Pro from serial number 012, 014 are constructed and tested in
compliance with the standard EN 60974--1 /--5 and EN 60974--10 (Class A) in accordance with the
requirements of directive (2006/95/EC) and (2004/108/EEC).
--------------------------------------------------------------------------------------------------------------------------------------
Kent Eimbrodt
Global Director
Equipment and Automation
Laxå 2010--03--24
2 SAF TY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sno--one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’ ha ard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROT CT YOURS LF AND OTH RS!
CAUTION!
Read and understand the instruction manual before
installing or operating.
WARNING!
Do not use the power source for thawing fro en pipes.
CAUTION!
This product is solely intended for arc welding.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
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3 INTRODUCTION
Migmaster 215 Pro is step controlled power source in a compact design, intended
for welding with solid steel, stainless steel or aluminium wire as well as tubular wire
with or without shielding gas.
The possibility of welding with homogeneous wire/shielding gas and welding with
gasless tubular wire is obtained by switching the + and -- connections on the
machine front.
SAB’s accessories for the product can be found on page 40.
3.1 quipment
The power source is supplied with:
SReturn cable 3m with return clamp
SShelf for gas cylinder
SInstruction manual
4 T CHNICAL DATA
Migmaster 215 Pro Migmaster 215 Pro
Voltage 208/230V, 1∼50/60Hz 208/230/460/575V, 1∼50/60Hz
Permissible load at
100% duty cycle 110A 110A
60 % duty cycle 160A 160A
20 % duty cycle 250A 250A
Setting range (DC) 40A/16.0V--250A/26.5V 40A/16.0V--250A/26.5V
Open circuit voltage 19.5--42V 19.5--52V
Open circuit power 200W 320W
Power factor at max load 0.92 0.92
Control voltage 42V, 50/60Hz 42V, 50/60Hz
Wire feed speed 55--748ipm (1.4--19m/min) 55--748ipm (1.4--19m/min)
Burnback time 0--0.5s 0--0.5s
Spot welding 0.4--3.5s 0.4--3.5s
Welding gun connection EURO EURO
Wire dimension range
e
Al
CW
.023--.045” (0.6--1.1mm)
.035--3/64” (0.9--1.2mm)
.030--.045” (0.8--1.1mm)
.023--.045” (0.6--1.1mm)
.035--3/64” (0.9--1.2mm)
.035--.045” (0.9--1.1mm)
Max diameter/weight
of wire bobin 12” (300mm)/33lb (15kg) 12” (300mm)/33lb (15kg)
Dimensions lxwxh 33,8x16,5x28,7”
(860x420x730mm) 33x17x32,7” (840x430x830mm)
Weight 220lb (100kg) 304lb (138kg)
Operating temperature 14÷104 (--10 ÷+40
o
C) 14÷104 (--10 ÷+40
o
C)
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nclosure class IP 23 IP 23
Application classifica-
tion
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
nclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
5 INSTALLATION
The installation must be executed by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user’s responsibility to take adequate precautions.
5.1 Placing
Position the welding power source such way that its cooling air inlets and outlets are
not obstructed.
5.2 lectrical installation
Mains voltage
The 208/230V voltage machines are factory--configured for 230V and are fitted with
appropriate marking tape on the mains cable, the multi voltage machines are factory
configured for highest rated voltage and are not equipped with mains cable.
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Welding voltage polarity
Welding voltage polarity may be changed as shown below.
5.3 Mains power supply
Check that the unit is connected to the correct mains power supply voltage, and that
it is protected by the correct fuse size. A protective earth connection must be made,
in accordance with regulations.
Rating plate with supply connection data
Migmaster 215 Pro Migmaster 215 Pro
Voltage V 208/230V, 1∼50/60Hz 208/230/460/575V, 1∼50/60Hz
Current A
at 100% duty cycle 19/17 19/17/9/7
at 60% duty cycle 30/27 30.5/27.5/14/11
at 20% duty cycle 56/50 58/53/26/21
Cable area AWG 3 x 10 3 x 10
Fuse slow A35 35/35/20/16
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6 OP RATION
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
WARNING!
Rotating parts can cause injury, take great care.
WARNING -- TIPPING RISK!
There is a risk of tipping while transportation and operation, if the welding machine leans
more than 10
o
. In that case appropriate securing has to be provided !
6.1 Connection and control devices
1Mains supply switch 5b Connector [--], low inductance, for welding gun
or return cable (welding polarity change--over)
2Orange indicating lamp, overheating 6Knob for spot welding -- ON/O and time set-
ting
2a White indicating lamp “ON” 7Knob for wire speed setting
3Welding voltage switch, 7 steps (fine) 8Digital instrument -- V/A
3a Welding voltage switch, 3 steps (coarse) 9Connector for ”spool--on gun” (control wire)
3b Welding voltage switch, 12 steps 10 Knob for burn--back time setting
(located in wire feeder compartment)
4EURO -- connector for welding gun 11 Cable with plug, connected to the welding gun
connector (welding polarity change--over)
5Connector [+] for welding gun or return
cable (welding polarity change--over) 12 Creep start switch (located in wire feeder compartment)
5a Connector [--], high inductance, for welding gun or return cable (welding polarity change--over)
208/230V 208/230/460/575V
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6.2 Switching--on and overheating protection
When machine is switched on with the illuminated switch [1], its lamp is on. If the ma-
chine is not overheated (lamp [2] is off) it is ready to work. If the internal temperature
during welding becomes too high, the welding is interrupted and disabled. This state is
indicated by permanent lighting of the orange indicating lamp [2] on the front of the unit.
It resets automatically when the temperature falls down.
6.3 Operation
Operator can manually select and set welding parameters as follows:
Srequired welding voltage ( and thus welding current) with knob [3]
Sappropriate wire feed speed with knob [7]
Sburn--back time with potentiometer [10] located in the wire feeder compartment
Sspot welding, activated by turning the knob [6] clockwise, spot welding time
increases while turning the knob [6] clockwise; set knob [6] in the left utmost
position in order to return to the continuous welding.
If the welding gun is used, welding process starts after its trigger is pressed and the wire
speed is controlled with potentiometer [7] on the front panel.
If the spool--on gun is used, welding process starts after its trigger is pressed, the spool--
on gun motor starts and wire speed is controlled with the potentiometer in the spool--on
gun grip.
Note: or spool--on gun current cable connection it is necessary to use the OKC ”T”
adapter (see Accessories in User Manual).
6.4 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder pressure roller(s). It is important that the
pressure is not too great.
Fig 1 Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against
an insulated object, e.g. a piece of wood.
When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed
roller(s) should slip.
If you hold the gun approx. 50 mm from the piece of wood, the wire should be
fed out and bend (fig. 2).
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