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

•The weld lies on top of the material and does not flow out.
Remedy: Increase the setting of the voltage selector switch
to a higher value.
•Holes are burnt in the material. Welding current too high.
Remedy: Reduce the current.
•Welding wire seems to bounce the workpiece.
Remedy: Reduce wire feed speed control so that wire has
time to fuse. (This fault can also be caused by contaminated
material or a poorly connected earth return).
•Arc tends to run up towards the contact nozzle. The cause of
this is probably a low wire feed speed- the setting has to be
increased. The wire slipping in the feed rollers pressure can
also cause it. It can be adjusted by adjusting the Pressure
Arm. A third cause could be a faulty contact tip, replace it.
On releasing the torch switch, welding will stop.
Self-Hold Function:
When the self-hold switch is ON, the arc is produced when the torch switch is
ON and then self-hold is maintained even though the torch switch is turned
OFF. To stop the welding, press torch switch once again and release it.
Welding will be stopped.
SPOT WELDING
In most cases spot welding is done from one side to join two overlapping
plates.
For spot welding, select the timer setting (t1) by switching on and setting the
spot welding timer on the front panel. The spot welding time can be set
Steplessly between 0.2 to 2 seconds.
SPOT WELDING PROCESS
The torch switch is pressed and welding starts. When the set spot weld time (t1)
has elapsed the process is automatically interrupted without the torch switch
needing to be released.
A new welding process commences when the torch switch is pressed again.
In spot welding Maximum plate thickness is about 2 mm. If the plates are of
different thickness, weld from thin side.
STITCH WELDING
This form of welding is suitable when working with very thin or inferior plate or
when the gap size is large since it gives cooler weld.
8

Switch on the potentiometer (t1) and then set for welding time (graded 1-
10). Switch on the potentiometer (t2) and then set it for interval duration
(off time) (graded 1-10) Both welding time and interval duration can be
set Steplessly between 0.2 and 2 sec.
Welding voltage and current are set as described earlier.
Stitch welding process
The torch switch is pressed to start the welding process. When the
set welding time has elapsed, the process is automatically
interrupted and start, again after the set interval duration and the
process is repeated. The stitch welding process continuous as long
as the torch-switch is pressed. The molten pool of metal is cooler
and the risk of burning through is considerably reduced.
9

MAITENANCE & INSPECTION
The maintenance and inspection should be carried out only after the switches
in the switch box are certainly turned OFF.
Try to maintain and inspect the set regularly as per the following guidelines.
a) Regular Inspection
Every 3-6 months, depending on operation frequency:
Inspection Portion
Inspection Point
Maintenance Method
Fuse box
Fastening &
Looseness at the
Connection.
Confirmation of proper
fuse
Refer to Equipment
Capacity.
Input and Output
Connections
Fastening &
Looseness at the
Connection.
Confirmation of
Insulation
Fasten first and Tape
Electro-magnetic
Conductor
Confirmation of
Abrasion at Contact
Points
Replace with new ones.
Interior of Welding
Power Source
Sedimentation Of
Dust. Trace of
Overheat.
Blow off dust with
Compressed Air.
b) Cautions to Insulation Voltage –Proof Test & Insulation
Resistance Measurement Test:
Careless execution of Dielectric Strength test and Insulation
Resistance Measurement will cause damage to the Power Source
since diodes and other semiconductor parts are widely used in the
unit. When these are to be performed in accordance with the bylaws
of your company, the following points should be kept in mind :
•Remove input cable from main supply and short-circuit the three
input terminals.
•Take off the cable that is connected to two output terminals
and short-circuit the two output terminals.
•Short-circuit the diode block.
•Remove the three grounding conductors. (Take off the top cover,
the remove two grounding conductors –one near the control
transformer, another near the electromagnetic contractor. Take
off the right side panel, and remove the grounding conductor
near the leg of the main transformer).
•Disconnect the Wirefeeder from the Power Source.
10

AFTER SALES SERVICE
In case of any abnormality observed during usage of the equipment, which
could not be rectified at site, please contact immediately Area Sales
Manager of the nearest unit of ESAB INDIA LIMITED with the following
details:
(1) Serial number of the equipment & type
(2) Nature of the complaint with the relevant details, if possible and the
details of Input Supply.
(3) Date of purchase of the equipment and the date of commissioning.
The qualified and trained service teams of ESAB INDIA LIMITED, located of
at the zonal head quarters render the after sales service to the customers
and also assist in intelligent selections of Welding equipment & consumable
for various application.
11

FAULT FINDIG
Fault
Cause
Corrective Action
On switching on the Power
Source the fan does not rotate
Fuse F3(3A) has Opened.
Check and replace fuse
Fault In AC Input supply
Check the three phase AC
supply.
Power LED does not glow on
switching on the Power Source
Fuse (8A) has blown
Check & replace fuse
Fuse F2 (3A) has blown
Check & replace fuse
On pressing O.C.V. check
switch the contactor does not
energize
Fuse F2 (3A) has blown
Check & replace fuse
Thermostat opened due to
overheating
Allow the Power Source to
cool
Wire does not feed on
pressing Torch Switch
Fuse F1 (8A) has blown
Check & replace fuse
Disconnection of the wire feeder’s
control cable or improper contact of
the connector.
Check the Wirefeeder
connection to the Power
Source.
Fault of Printed Circuit board
Replace Printed Circuit board
On pressing the torch switch
no voltage is available on the
output terminals.
One of the three fuses have blown
Check and replace fuse
Fault of PCB
Replace PCB
Maximum Open circuit voltage
is not available
One phase of Input supply is
missing
Check & Correct AC Input
Supply
Main Rectifier Bridge faulty
Check and replace
The Input Supply Mains
connection SFU or MCB trips
repeatedly
Main Rectifier Bridge faulty
Check and replace
No Gas Flow
Damaged Gas hose
Replace the Gas hose
Mingled impurities in the gas
passage
Blow off the impurities etc
No operation of solenoid valve
Replace if found faulty
PCB faulty
Check and replace
Self hold switch ON Contractor
OFF by releasing torch switch
Fault of PCB
Replace PCB.
12

MM 250 WIREFEEDER UNIT
RATING
Parameter
Value
Applicable wire diameter
0.8 mm to 1.2 mm
Wire feed motor
18V, D.C. Max
Applicable wire spool
Shaft Dia
50 mm
Outer Dia
280 mm or less
Width
105 mm or less
Length of cable and hose
5 Mts
Weight (Without Inter-Connection)
6 Kgs
ACCESSORIES SUPPLIED ALONG WITH THE WIREFEEDER
Gas hose Assembly (2 Mts.)
1
Roller V groove 0.8/1.2 mm H/W
1
Hose Clip
1
Allen Key
1
CONNECTION
Connect power cable, control cable and gas hose firmly to the respective place
of welding power source.
Welding cable
:
Output terminal-Wirefeeder (+) of power source
Control cable
:
Plug socket for wire feed control of the welding
power source
Gas hose
:
Gas outlet fitting of the welding power source.
PREPARATION FOR USE
Feed roller fixing:
Select the feed roller as per the wire diameter & confirm the size of the
groove before fixing. 13

Wire Setting
Loosen the spool locknut-1
Place the Wire Spool-2
Lock with the Nut
Lift the Pressure Arm-3
and
Insert wire
2-3 cm in SUS Tube
Replace the Pressure Arm. Set
local pressure with lever knob
Wire Inching
Turn Power Source ON
Press Inch Button-4of
Wire Feeder
Release inch button
when wire comes out
1-2 cm from Torch tip
1
2
3
4
14

MOTOR AND FEEDROLL BLOCK ASSEMBLY
MAINTENANCE
•SUS Tube: Wipe of dust or dirt once a week
•Feed Roller: If the groove is badly deformed or worn out,
change the roller V-groove as per the diameter of the wire
used.
15
MOTOR
PRESSURE
ARM
FEED
ROLLER
PRESSURE
ADJUSTMENT
KNOB

WIRING DIAGRAM
16

SPARES LIST FOR MIGMATIC 250 POWER SOURCE
ITEM CODE
DESCRIPTION
SPARES HOLDING FOR
1-5
6 AND ABOVE
1651686015
CRATER PCB MIG-250
1
2
0466401001
VOLTAGE SELECTOR SWITCH
1
2
1611642018
FUSE ELEMENT 3A
2
4
1611642301
DIGITAL V/A METER
1
2
1651684041
COOLING FAN
1
2
1651685051
POWER ON LED LAMP (GREEN)
2
4
1651685055
FUSE ELEMENT 8 AMP
2
4
1651685060
GAS VALVE 2PORT/2WAY DC 24V
1
2
1651685115
POWER ON/ OFF SWITCH
1
2
1651685116
SELF HOLD ON / OFF SELECTOR SWITCH
1
2
1651685125
OUTPUT TERMINAL
2
4
1651685177
GAS CHECK / OCV CHECK SWITCH
1
2
1651685225
FUSE HOLDER
2
4
1651685236
INPUT TERMINAL BLOCK
1
2
1651686003
ASSY MAIN TRANSFORMER-AL-M250
-
1
1651686009
CONTROL PCB- MM 250
1
2
1651686086
POTENTIOMETER WITH SWITCH (TIMER)
2
4
1651686092
CHOKE RESISTOR
1
2
1651686104
SHUNT 300A
1
2
1651686109
CONTACTOR 25A/110V AC COIL
1
2
1651686122
CONTROL TRANSFORMER (M)-M250
1
2
1651686460
DIODE BRIDGE PTS 400
1
2
4651686002
ASSY CHOKE
-
1
SPARES LIST FOR MIGMATIC 250 WIRE FEEDER
ITEM CODE
DESCRIPTION
SPARES HOLDING FOR
1-5
6 AND ABOVE
1651685206
POTENTIOMETER 5K
1
2
1651686013
CONNECTOR 8 PIN SOCKET
1
2
1651686903
MOTOR WITH FEED UNIT ASSEMBLY
1
2
1651688375
WIRE INCH SWITCH
1
2
17