ESAB MIGMATIC 250 User manual

MIGMATIC 250
MIG/MAG Power Source
Instruction manual

MIGMATIC 250
Instruction manual
For
Installation, Operation & General maintenance

CONTENTS
Item
Page No.
SAFETY
1-2
MIGMATIC 250 POWER SOURCE
Assembling
3
Accessories List
3
Rating
3
Cautions for Installation
4
Items for Installation
5
Front Panel
6
Welding Operation
7-9
Maintenance & Inspection
10
After Sales Service
11
Fault Finding
12
MIGMATIC WIRE FEEDER
Rating
13
Accessories List
13
Connection
13
Preparation for use
13-14
Maintenance
15
WIRING DIAGRAM
16
SPARES LIST FOR POWER SOURCE AND WIRE FEEDER
17
TORCH PSF 250
Rated Specification and Accessories
18
Operation
18-19
Maintenance
20
List of Consumables & Accessories
21
WELD DEFECTS, POSSIBLE CAUSES & CORRECTIVE ACTIONS
22-24

SAFETY
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 recommendations should be observed in addition to the
standard regulations that apply to the workplace.
Trained personnel well acquainted with the operation of the welding equipment must
carry out all the work. 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:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding
2. The operator must ensure that:
• no unauthorized person is stationed within the working area of the equipment when
it is started up.
• no one is unprotected when the arc is struck
3. The workplace must:
• be suitable for the purpose
• be free from drafts
4. Personal safety equipment
• Always wear recommended personal safety equipment, such as safety glasses,
flameproof clothing, and safety gloves.
• Do not wear loose—fitting items, such as scarves, bracelets, rings, etc., which could
become trapped or cause burns.
5. General precautions
• Make sure the return cable is connected securely.
• Only a qualified electrician may carry out work on high voltage equipment.
• Appropriate fire extinguishing equipment must be clearly marked and close at hand.
• Lubrication and maintenance must not be carried out on the equipment during
operation.
1

Read and understand the instruction manual before installing or operating.
ESAB can provide you with all necessary welding protection and accessories.
WARNING
Arc welding and cutting can be injurious to yourself and others. Take
precautions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’
hazard data.
ELECTRIC SHOCK –Can kill
• Install and earth the welding unit in accordance with applicable
standards.
• Do not touch live electrical parts or electrodes with bare skin, wet
gloves or wet clothing.
• Insulate yourself from earth and the workpiece.
• Ensure your working stance is safe.
FUMES AND GASES –Can be dangerous to health
• Keep your head out of the fumes.
• Use 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.
• Protect your eyes and body. Use the correct welding screen and filter
lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE –Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk.
MALFUNCTION –Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding
Do not dispose of electrical equipment together with normal waste!
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 the local representative. By applying this Directive you
will improve the environment and human health
2

ASSEMBLING
The complete Installation should consist the following instruments.
Description
Type
Quantity
1.
Welding Power Source
MIGMATIC 250 Power
Source
1
2.
Wire Feeder
MIGMATIC WIRE FEEDER
with accessories
1
3.
Welding Torch
PSF 250
1
4.
CO2Regulator cum Flowmeter or
CO2Regulator with Flowmeter
1
5.
CO2Heater Core
1
ACCESSORIES LIST FOR MIGMATIC 250 MIG/MAG WELDING POWER SOURCES
Fuse, element 3A
2 piece
Fuse, element 8A
1 piece
Instruction Manual
1 piece
RATING OF MIGMATIC 250 MIG/MAG WELDING POWER SOURCE
Characteristics
Constant Potential Type
Input
Supply Voltage phase & frequency
3 phase, 415 V ±10 %, 50 Hz
Maximum Input Current
13 Amps
Maximum Rating
9.5 KVA at 60% duty cycle
Output
Output current range
40-250 Amps
Max. Output current at 60% Duty Cycle
250 Amps
Max. Output Current at 100% Duty Cycle
190 Amps
Open circuit voltage control
16-34 volts DC
Type of Welding Voltage Control
In 10 Steps single Knob control
Welding time
0.2-2 Sec.
Interval time
0.2-2 Sec.
Class of Insulation
Class ‘H’
Cooling
Forced Air Cooled
Approximate dimension (LXWXH) in mm
620*390*580
Weight (Approximate)
78 kg.
3

CAUTIONS FOR INSTALLATION
Capacity of Equipment
•Provide a Switch Box per one Welding Power Source and use
designated fuse. Of 32 Amps.
•Tolerance of Power Voltage Variation is ± 10% of rated input
voltage.
•In case SFU is not used, use 63 Amps MCB.
Installation Place
•Install in the place where less moisture and dust exit. Avoid
direct sunlight and rain, and maintain ambient temperature within
–10º to 45º C.
•If there are any walls, then the Welding Power Source and feeder
unit has to be kept at a distance of more than 20 cm from the wall.
•In case more than one system has to be installed side by side,
then the minimum gap between the adjacent systems has to be
maintained at 20 cm.
•Keep the Gas Cylinder in a separate stand.
•Use a shield to protect the welding arc in case of excessive air
draft.
Ventilation
Adequate ventilation is recommended at the place of Installation.
•In case of the area is more than 300 square meters (per unit), no
ventilation is required, provided the room is not completely air
tight.
•In case of the area is less than 300 square metes and the torch is
used in fixed condition, and if the welding is continuously
performed, adequate ventilation is recommended with the help of
vent fan or exhaust duct.
4
Input Voltage
415 VAC ±10 %
Number of Phase & Frequency
3 phase, 50 Hz
Maximum rating of Equipment
9.5 KVA
Capacity of Fuse (B Class)
16 Amps HRC
Output Cable
More than 38 mm2

ITEMS FOR INSTALLATION
No.
Item
1.
MIGMATIC 250 Welding Power Source
2.
Wire feeder (Migmatic)
3.
Welding Torch PSF 250
4.
Base Metal
5.
Gas Regulator
6.
Gas cylinder
7.
Switch Box
8.
Return Cable with Earth Clamp
9.
Inlet Gas Hose from Gas cylinder to Welding Machine
10.
CO2Heater with cable for connection to socket on Machine
5

List of Items
Item No.
Description / Code
1
Power ON Lamp / 1651685051
2
Power ON-OFF Selector Switch / 1651685115
3
Voltage Selector Switch. / 0466401001
4
Gas Check Switch / 1651685177
5
Self-Hold ON/ OFF Selector Switch / 1651685116
6
OCV Check Switch / 1651685177
7
Gas Outlet to Welding Torch /
8
Socket for Wirefeeder Control cable connection /
9
Output Power Terminals / 1651685125
10
Digital V/ A Meter / 1611642301
11
Stitch Welding Timer Control /
12
Spot Welding Timer control
13
Control Fuses
6
1
2
3
4
5
6
7
8
9
10
11
12
13

WELDING OPERATION
The welding operation can be adjusted from the front panel of the power
source.
1. The ON/OFF switch on the front panel switches on the Power Source.
This will cause the light emitting diode on the front panel to light up.
Cooling fan will start rotating.
2. Gas Supply Check:
To ensure the gas supply before welding and purge the air out of gas
line, Gas Check switch is pressed to ‘check’ position. The shielding gas
will start flowing. After confirmation of gas flow the switch is released
and it will automatically return-to weld position.
3. Welding Voltage Adjustment
The welding voltage (OCV) is set by turning the voltage selector switch.
The value of voltage set can be seen on the Voltmeter provided on the
front panel by operating the ‘OCV Check’ Switch.
Caution:
a) Keeping the ‘O.C.V. check’ switch pressed, do not turn the
welding voltage selector switch. For correct operation every time the
voltage selector switch is turned from 0 to 10 or reverse, the ‘O.C.V.
check’ switch should first be released.
b) The welding voltage selector switch should not be operated on
load, i.e. while welding torch switch must be released before the
voltage is adjusted.
Welding Current Control
The wire feed speed control potentiometer on the wire feeder unit does
welding current control.
SEAM WELDING
•The welding voltage and current are selected as described
above. The torch switch is pressed and the welding process
starts.
•First do a sample weld on a clean piece of plate. Some of the
common problems, which may be encountered during CO2
welding, are described below.
7