ESAB MIGMASTER 250 User manual

Instruction Manual
F15-087-P 03/2008
Welding Package
MigMaster 250

2
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions 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 imme-
diately. 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 ser-
vice facility designated by the manufacturer.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
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 be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!

3
TABLE OF CONTENT
SECTION NO. .................................................................................................................................................................................................PAGE NO.
SECTION 1 - SAFETY PRECAUTIONS ..................................................................................................................................................................... 3
SECTION 2 - INTRODUCTION.................................................................................................................................................................................11
2.1 GENERAL........................................................................................................................................................................................................11
2.2 RECEIVING-HANDLING..............................................................................................................................................................................11
2.3 DESCRIPTION, Available Packages/Contents....................................................................................................................................11
2.4 OPTIONAL ACCESSORIES .........................................................................................................................................................................12
2.5 SAFETY............................................................................................................................................................................................................14
SECTION 3 - INSTALLATION....................................................................................................................................................................................15
3.1 LOCATION......................................................................................................................................................................................................15
3.2 ELECTRICAL INPUT CONNECTIONS ......................................................................................................................................................15
3.3 SECONDARY OUTPUT CONNECTIONS.................................................................................................................................................18
3.4 TORCH CONNECTIONS..............................................................................................................................................................................18
3.5 WIRE FEEDER MECHANISM......................................................................................................................................................................18
3.6 CONNECTION OF THE SHIELD GAS.......................................................................................................................................................19
3.7 WELDING CABLE CONNECTIONS ..........................................................................................................................................................20
3.8 ASSEMBLE REAR WHEELS.........................................................................................................................................................................20
3.9 INSTALLING OPTIONAL SPOT/STITCH/ANTI-STICK MODULE......................................................................................................20
3.10 INSTALLING OPTIONAL DIGITAL METER .............................................................................................................................................21
SECTION 4 - OPERATION.........................................................................................................................................................................................23
4.1 CONTROLS.....................................................................................................................................................................................................23
4.2 PROCESS SETUP...........................................................................................................................................................................................24
4.3 OPERATING PROCEDURES .......................................................................................................................................................................27
SECTION 5 - SERVICE ................................................................................................................................................................................................31
5.1 MAINTENANCE.............................................................................................................................................................................................31
5.2 INSPECTION AND SERVICE.......................................................................................................................................................................31
5.3 TROUBLESHOOTING ..................................................................................................................................................................................32
SECTION 6 - REPLACEMENT PARTS .....................................................................................................................................................................41
6.1 SPARE PARTS ................................................................................................................................................................................................41
6.2 REPLACEMENT PARTS................................................................................................................................................................................41
6.3 ORDERING .....................................................................................................................................................................................................41

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TABLE OF CONTENT

5
1.0 Safety Precautions 1.1 Safety - English
WARNING: These Safety Precautions are for your
protection.Theysummarizeprecaution-
ary information from the references
listed in Additional Safety Information
section.Beforeperforminganyinstalla-
tion 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.Thearc,likethesun,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 equInches per
minute (ipm)ent 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. Useafaceshieldttedwiththecorrectlterand
coverplatestoprotectyoureyes,face,neck,and
ears from sparks and rays of the arc when oper-
atingorobservingoperations.Warnbystanders
nottowatchthearcandnottoexposethemselves
to the rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy
long-sleeveshirt,cuesstrousers,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
alsobe desirable asprotection against radiated
heat and sparks.
4. Hotsparksormetalcanlodgeinrolledupsleeves,
trouser cus, or pockets. Sleeves and collars
should be kept buttoned, and open pockets
eliminated from the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-ammable partition
or curtains.
6. Use goggles over safety glasses when chipping
slag or grinding. Chipped slag may be hot and
cany far.Bystanders should also weargoggles
over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slagorsparkscan also causeresand
explosions. Therefore:
1. Removeallcombustiblematerialswellawayfrom
the work area or cover the materials with a pro-
tective 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
orcrevicesinoorsorwallopeningsandcausea
hiddensmolderingreorresontheoorbelow.
Make certain that such openings are protected
from hot sparks and metal.“
3. Donotweld,cutorperformotherhotworkuntil
the work piece has been completely cleaned so
that there are no substances on the work piece
whichmightproduceammableortoxicvapors.
Do not do hot work on closed containers. They
may explode.
4. Have re extinguishing equInches per
minute (ipm)ent handy for instant use, such as a
garden hose, water pail, sand bucket, or por-
table re extinguisher. Be sure you are trained
in its use.
5. Do not use equInches per
minute (ipm)ent beyond its ratings. For example,
overloadedweldingcablecanoverheatandcre-
ate 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 Stan-
dard 51B, "Fire Prevention in Use of Cutting and
WeldingProcesses",availablefromtheNational
Fire Protection Association, Battery
march Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severeinjury or death. DO NOT useACweld-
ingcurrentindampareas,ifmovementisconned,
or if there is danger of falling.
SECTION 1 SAFETY PRECAUTIONS

6
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
2. Connect the work piece to a good electrical
ground.
3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equInches per
minute (ipm)ent. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur-
rent owing through any conduc-
tor causes localized Electric and
Magnetic Fields (EMF).Welding and
cuttingcurrentcreatesEMFaroundweldingcables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. ExposuretoEMFmayhaveotherhealtheectswhich
are unknown.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connecttheworkcabletotheworkpieceasclose
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,cancausediscomfortorharm,
particularly in conned spaces. Do
notbreathefumesandgases.Shield-
ing gases can cause asphyxiation.
Therefore:
1. Alwaysprovideadequateventilationintheworkarea
bynaturalormechanicalmeans.Donotweld,cut,or
gouge on materials such as galvanized steel, stain-
less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Donotoperateneardegreasingandsprayingopera-
tions.Theheatorarcrayscanreactwith chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat ir-
ritation 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 notcontinue tooperateif physical discom-
fort persists.
4. RefertoANSI/ASCStandardZ49.1(seelistingbelow)
for specic ventilation recommendations.
SECTION 1 SAFETY PRECAUTIONS

7
SECTION 1 SAFETY PRECAUTIONS
5. WARNING: Thisproduct,whenusedforwelding
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 vio-
lently release gas. Sudden rupture
ofcylinder, valve,orreliefdevicecan
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.Followmanufacturer'soperatinginstruc-
tions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, 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 con-
nected.Secureandmovecylindersbyusingsuitable
hand trucks. Avoid rough handling of cylinders.
4. Locatecylindersawayfromheat,sparks,andames.
Never strike an arc on a cylinder.
5. Foradditionalinformation,refertoCGAStandardP-1,
"PrecautionsforSafeHandlingofCompressedGases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Alwayshavequaliedpersonnelperformtheinstal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintaincables,groundingwire,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
equipmentawayfromheatsourcessuchasfurnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keepallsafetydevicesandcabinetcoversinposition
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONALSAFETYINFORMATION--For
more information on safe practices for
electric arc welding and cutting equip-
ment, 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
theAmericanWeldingSociety,550N.W.LeJueneRoad,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1-"RecommendedPracticesforPlasmaArc
Welding"
3. AWS C5.2-"RecommendedPracticesforPlasmaArc
Cutting"
4. AWS C5.3-"Recommended PracticesforAirCarbon
Arc Gouging and Cutting"

8
5. AWS C5.5 - "Recommended Practices for Gas Tung-
sten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-
book.
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 Atten-
tion! Be Alert! Your safety is involved.
Meansimmediatehazardswhich,
if not avoided, will result in im-
mediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Meanshazardswhichcouldresult
in minor personal injury.
SECTION 1 SAFETY PRECAUTIONS

9
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas
hacen resumen de información prove-
niente de las referencias listadas en la sección
"InformaciónAdicionalSobreLaSeguridad".Antes
de hacer cualquier instalación o procedimiento
de operación , asegúrese de leer y seguir las pre-
cauciones 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. Utilicegafas 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 per-
sonas 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,
zapatoalto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispascalientesprovenientesdelmetalfundido.En
ocacionesundelantal apruebadefuego esnecesario
para protegerse del calor radiado y las chispas.
4. Chispasypartículasdemetalcalientepuedealojarse
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-
pascalientescon unacortina adecuadano-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
convelocidad.Personascercanas deberánusar
gafas de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
lasamasyelarco puedenocacionar
fuegos. Escoria caliente y las chispas
puedencausar 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 cau-
sandofuegosescondidosenotrosnivelesoespacios.
Asegúresedequetodagrietayagujeroestécubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo rela-
cionadohastaquelapiezadetrabajoestétotalmente
limpia y libre de substancias que puedan producir
gasesinamablesovaporestóxicos.Notrabajeden-
troofueradecontenedoresotanquescerrados.Estos
pueden explotar si contienen vapores inamables.
4. Tenga siempre a la mano equipo extintor de fu-
ego 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. Nouse elequipofuera desurangode operación.Por
ejemplo,elcalorcausadoporcablesobrecargaenlos
cables de soldar pueden ocasionar un fuego.
6. Despuésdetermirarlaoperacióndelequipo,inspec-
cione 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
lasparteseléctricas energizadasytierra
puede causar daño severo o muerte.
NO use soldadura de corriente alterna
(AC) en áreas húmedas, de movimiento
connado en lugares estrechos o si hay
posibilidad de caer al suelo.
SECTION 1 SEGURIDAD

10
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 condi-
ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantengatodoseco,incluyendosuropa,eláreade
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúresequetodaslaspartesde sucuerpoestán
insuladas de ambos, la pieza de trabajo y tierra.
7. Noseparedirectamentesobremetalotierramien-
trastrabajaenlugaresestrechosoáreashúmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Useguantessecosysinagujerosantesdeenergizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
StandardZ49.1(listadoenla próximapágina)para
recomendacionesespecícasdecomoconectarel
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETI-
COS - Son peligrosos. La corriente
eléctrica uye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Lascorrienteseneláreadecorteysoldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1.SoldadoresuOperadoresqueuse marca-pasospara
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2.Exponerseacamposelectromagnéticos(EMF)puede
causar otros efectos de salud aún desconocidos.
3.Los soldadores deberán usar los siguientes proced-
imientos 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. Mantengalafuentedepoderyloscablesdesoldar
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 pormedionaturalomecánico.Nosolde,
corte,o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cad-
mio 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 paraformarun 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 enel área de trabajo.
No continúe operando si el malestar físico per-
siste.
4. Hagareferenciaalapublicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomen-
daciones especícas en la ventilación.
SECTION 1 SEGURIDAD