instruction manual migmaster 251 - esab - f15-999/migmaster 251...instruction manual migmaster 251...

INSTRUCTION MANUAL

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MIGMASTER 251WELDING PACKAGES

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles ofoperation and safe practices for arc welding equipment, we urge you to read our booklet, "Precautionsand Safe Practices for Arc Welding, Cutting and Gouging." Form 52-529. Do NOT permit untrainedpersons to install, operate, or maintain this equipment. Do NOT attempt to install or operate thisequipment until you have read and fully understand these Instructions. If you do not fully understandthese Instructions, contact your supplier for further information.

Be sure this information reaches the operator.You can get extra copies through your supplier.

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USER RESPONSIBILITY

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SECTION 1 DESCRIPTION ..................................................... 71.1 General ................................................................. 71.2 Receiving-Handling .............................................. 71.3 Description ........................................................... 71.3.1 Available Packages and Contents ....................... 71.3.2 Power Source ....................................................... 71.3.3 Wire Feeder ......................................................... 71.3.4 MT-200cc Welding Torch ..................................... 71.3.5 Optional Controls ................................................. 71.3.6 Running Gear ....................................................... 71.4 Optional Accessories ........................................... 71.4.1 Spot Module ......................................................... 71.4.2 Spool-On-Gun Torch and Control Kit .................. 81.4.3 Torch Nozzles ...................................................... 81.4.4 Torch/Wire Feed Accessories .............................. 81.4.5 Dual Cylinder Kit .................................................. 81.4.6 Torch Cable Holder .............................................. 91.5 Safety ................................................................... 91.6 Duty Cycle ............................................................ 91.7 Volt/Ampere Curves ............................................. 9

SECTION 2 INSTALLATION ................................................. 102.1 Location .............................................................. 102.2 Electrical Input Connections .............................. 102.2.1 Input Electrical Requirements ............................ 102.2.2 Input Conductor Connections ............................ 112.3 Secondary Output Connections ......................... 112.4 Torch Connection ............................................... 112.5 Feeder Mechanism ............................................ 112.5.1 Drive Rolls .......................................................... 112.5.2 Welding Wire Spool ........................................... 112.5.3 Threading Welding Wire .................................... 122.5.4 Brake Drag adjustment ...................................... 122.6 Connection of Shielding Gas Supply ................. 12

SECTION NOPARAGRAPH TITLE PAGE NO.

TABLE OF CONTENTS

SECTION NOPARAGRAPH TITLE PAGE NO.

SECTION 2 INSTALLATION (cont.) ..................................... 132.7 Welding Cable Connections ............................... 132.8 Installation of the Cylinder Tray and Wheels ..... 13

SECTION 3 OPERATION ...................................................... 153.1 Controls .............................................................. 153.1.1 Power Switch (ON-OFF) .................................... 153.1.2 Secondary Welding Connections ....................... 153.1.3 Wire Feed Speed Control .................................. 153.1.4 Voltage Control .................................................. 163.2 Operating Procedures ........................................ 163.2.1 Operating Safety Precautions ............................ 163.2.2 Pre-Weld Requirements ..................................... 163.2.3 Set-Up Procedure .............................................. 173.2.4 Welding Operation ............................................. 17

SECTION 4 MAINTENANCE ................................................. 194.1 General ............................................................... 194.2 Inspection and Service ....................................... 194.3 Power Source ..................................................... 194.3.1 Fan Motor ........................................................... 194.3.2 Transformer ........................................................ 194.3.3 24 Volts Wire Feeder and Control Circuits ........ 194.3.4 Over Temperature Protection ............................ 204.3.5 Wire Feeder ....................................................... 204.3.6 Burnback Control/Adjustment ............................ 20

SECTION 5 TROUBLESHOOTING....................................... 215.1 General ............................................................... 215.2 If Wire Drive Motor Does Not Run ..................... 215.3 Drive Roll Pressure Adjustment ......................... 215.4 Solenoid Valve Replacement ............................. 21

SECTION 6 PARTS ............................................................... 266.1 General ............................................................... 266.2 ORDERING ........................................................ 26

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WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before

performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.

PROTECT YOURSELF AND OTHERS --Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.Training in the proper use of the processes and equip-ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any workarea, even if welding helmets, face shields, and gogglesare also required.

2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc andnot to expose themselves to the rays of the electric-arcor hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing

5. Protect other personnel from arc rays and hot sparkswith a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and ex-plosions. Therefore:

1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.“

3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.

SAFETY PRECAUTIONS

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5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.

6. After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when neces-sary.

7. For additional information, refer to NFPA Standard 51B,"Fire Prevention in Use of Cutting and Welding Pro-cesses", available from the National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.

1. Be sure the power source frame (chassis) is connectedto 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 fatalshock.

4. Use well-maintained equipment. Replace worn or dam-aged 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 fromwork and from ground.

7. Do not stand directly on metal or the earth while workingin tight quarters or a damp area; stand on dry boards oran insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)for specific grounding recommendations. Do not mis-take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —May be dangerous. Electric current flow-ing through any conductor causes lo-calized Electric and Magnetic Fields(EMF). Welding and cutting current cre-ates EMF around welding cables andwelding machines. Therefore:

1. Welders having pacemakers should consult their physi-cian before welding. EMF may interfere with some pace-makers.

2. Exposure to EMF may have other health effects which areunknown.

3. Welders should use the following procedures to minimizeexposure 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.�# ��%��%�� #

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FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can cause asphyxiation.Therefore:

1. Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel,copper, zinc, lead, beryllium, or cadmium unless posi-tive mechanical ventilation is provided. Do not breathefumes from these materials.

2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene, a highly toxicgas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation is notadequate. Stop work and take necessary steps to im-prove ventilation in the work area. Do not continue tooperate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)for specific ventilation recommendations.

5. WARNING: This product, when used for welding orcutting, produces fumes or gases whichcontain chemicals known to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety Code �25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, ifmishandled, can rupture and violentlyrelease gas. Sudden rupture of cylin-der, valve, or relief device can injure orkill. Therefore:

1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition. Followmanufacturer's operating instructions for mounting regu-lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chainor strap to suitable hand trucks, undercarriages, benches,walls, post, or racks. Never secure cylinders to worktables or fixtures where they may become part of anelectrical circuit.

3. When not in use, keep cylinder valves closed. Havevalve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitablehand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,"Precautions for Safe Handling of Compressed Gases inCylinders", which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington,VA 22202.

EQUIPMENT MAINTENANCE -- Faulty orimproperly maintained equipment cancause injury or death. Therefore:

1. Always have qualified personnel perform the installa-tion, troubleshooting, and maintenance work. Do notperform any electrical work unless you are qualified toperform such work.

2. Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.

3. Maintain cables, grounding wire, connections, powercord, and power supply in safe working order. Do notoperate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keepequipment 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 positionand in good repair.

6. Use equipment only for its intended purpose. Do notmodify it in any manner.

ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices for elec-tric arc welding and cutting equipment, askyour supplier for a copy of "Precautions andSafe Practices for Arc Welding, Cutting andGouging", Form 52-529.

The following publications, which are available from theAmerican Welding Society, 550 N.W. LeJuene Road, Mi-ami, 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"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 Hand-

book.8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have HeldHazardous Substances."

MEANING OF SYMBOLS - As used through-out this manual: Means Attention! Be Alert!Your safety is involved.

Means immediate hazards which, ifnot avoided, will result in immediate,serious personal injury or loss of life.

Means potential hazards which couldresult in personal injury or loss of life.

Means hazards which could result inminor personal injury.

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a. Éloigner suffisamment tous les matériaux combus-tibles du secteur où l’on exécute des soudures ou descoupes à l’arc, à moins de les recouvrir complètementd’une bâche non-inflammable. Ce type de matériauxcomprend notamment le bois, les vêtements, la sciure,l’essence, le kérosène, les peintures, les solvants, legaz naturel, l’acétylène, le propane et autres sub-stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-cent peuvent tomber dans des fissures du plancher oudans des ouvertures des murs et y déclencher uneignition lente cachée. Veiller à protéger ces ouverturesdes étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérationsde gougeage ou autres travaux à chaud à la surfacede barils, bidons, réservoirs ou autres contenantsusagés, avant de les avoir nettoyés de toute trace desubstance susceptible de produire des vapeursinflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, ilconvient de disposer d’un matériel d’extinction prêt àservir immédiatement, tel qu’un tuyau d’arrosage, unseau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteurde façon à vous assurer qu’aucune étincelle ou projec-tion de métal incandescent ne risque de provoquerultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arcau plasma exige l’emploi de tensions à viderelativement importantes; or, celles-ci risquent decauser des dommages corporels graves et mêmemortels en cas d’utilisation inadéquate. La gravité duchoc électrique reçu dépend du chemin suivi par lecourant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-sion venir au contact direct de la peau ou devêtements humides. Veillez à porter des gants biensecs.

b. Si vous devez effectuer un travail sur une surfacemétallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secset des chaussures à semelles de caoutchouc et envous tenant sur une planche ou une plate-formesèche.

c. Mettez toujours à la terre le poste de soudage/coupageen le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Nesurchargez jamais le câble. Utilisez toujours unéquipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas enservice. une mise à la masse accidentelle peut eneffet provoquer une surchauffe de l’équipement et undanger d’incendie. Ne pas enrouler ou passer le câbleautour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce enun point aussi proche que possible de la zone detravail. Le branchement des câbles de masse àl’ossature du bâtiment ou en un point éloigné de lazone de travail augmente en effet le risque de pas-sage d’un courant de sortie par des chaînes delevage

�� AVERTISSEMENT: Ces règles de sécurité ont pour objetd’ assurer votre protection. Veillez à lire et à observer lesprécautions énoncées ci-dessous avant de monter l’équipement ou de commercer à l’utiliser. Tout défautd’observation de ces précautions risque d’entraîner desblessures graves ou mortelles.1. PROTECTION INDIVIDUELLE-- Les brûlures de la

peau et des yeux dues au rayonnement de l’arcélectrique ou du métal incandescent, lors du soudageau plasma ou à l’électrode ou lors du gougeage àl’arc, peuvent s’avérer plus graves que cellesrésultant d’une exposition prolongée au soleil. Aussiconvient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaquesprotectrices et des verres filtrants appropriés afin devous protéger les yeux, le visage, le cou et les oreillesdes étincelles et du rayonnement de l’arc électriquelorsque vous effectuez des soudures ou des coupesou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximitéde façon à ce qu’elles ne regardent pas l’arc et à cequ’elles ne s’exposent pas à son rayonnement, ni àcelui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tuniqueépaisse à manches longues, des pantalons sansrebord, des chaussures à embout d’acier et uncasque de soudage ou une calotte de protection, afind’éviter d’exposer la peau au rayonnement de l’arcélectrique ou du métal incandescent. ll est égalementsouhaitable d’utiliser un tablier ininflammable defaçon à se protéger des étincelles et du rayonnementthermique.

c. Les étincelles ou les projections de métal incandes-cent risquent de se loger dans des manchesretroussées, des bords relevés de pantalons ou dansdes poches. Aussi convient-il de garder boutonnés lecol et les manches et de porter des vêtements sanspoches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arcélectrique les autres personnes travaillant à proximitéà l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécuritélorsque vous vous trouvez dans un secteur où l’oneffectue des opérations de soudage ou de coupage àl’arc. Utilisez des lunettes de sécurité à écrans ouverres latéraux pour piquer ou meûler le laitier. Lespiquetures incandescentes de laitier peuvent êtreprojetées à des distances considérables. Lespersonnes se trouvant à proximité doivent égalementporter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasmaproduisent un niveau de bruit extrêmement élevé (de100 à 114 dB) et exigent par conséquent l’emploi dedispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections delaitier incandescent ou d’étincelles peuventprovoquer de graves incendies au contact dematériaux combustibles solides, liquides ou gazeux.Aussi faut-il observer les précautions suivantes:

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des câbles de grue ou divers chemins électriques.g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement detravail, des câbles, du porte-électrode et du poste desoudage/coupage. Réparez immédiatement toutefuite d’eau.

4. VENTILATION-- La respiration prolongée des fuméesrésultant des opérations de soudage/coupage, àl’intérieur, d’un local clos, peut provoquer des mal-aises et des dommages corporels. Aussi convient-ild’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate del’emplacement de travail en maintenant une ventila-tion naturelle ou à l’aide de moyens mécaniques.N’effectuez jamais de travaux de soudage ou decoupage sur des matériaux de zinc, de plomb, deberyllium ou de cadmium en l’absence de moyensmécaniques de ventilation capables d’empêcherl’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou decoupage à proximité de vapeurs d’hydrocarburechloré résultant d’opérations voisines de dégraissageou de pulvérisation. La chaleur dégagée ou lerayonnement de l’arc peut déclencher la formation dephosgène -- gaz particulièrement toxique -- et d’autresgaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de lagorge constatée au cours de l’utilisation del’équipement dénote un défaut de ventilation. Arrêtez-vous de travailler afin de prendre les mesures néces-saires à l’amélioration de la ventilation. Ne poursuivezpas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisationsoù circule de l’hydrogène. L’armoire de commande estmunie d’un ventilateur destiné à empêcher la forma-tion de poches d’hydrogène, lesquelles présentent undanger d’explosion; ce ventilateur ne fonctionne quesi l’interrupteur correspondant du panneau avant setrouve placé en position ON (Marche). Veillez àmanœuvrer cette commande en vérifiant si lecouvercle est bien en place, de façon à assurerl’efficacité de la ventilation ainsi réalisée. Ne jamaisdébrancher le ventilateur.

e. Les fumées produites par l’opération de soudage oude coupage peuvent s’avérer toxiques. Aussi est-ilnécessaire de disposer en permanence d’un dispositifadéquat de ventilation de type aspirant, afin d’élimi-ner du voisinage de l’opérateur tout dégagement defumée visible.

f. Consultez les recommandations particulières enmatière de ventilation indiquées à l’alinéa 6 de lanorme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipemententretenu de façon défectueuse ou inadéquate risquenon seulement de réaliser un travail de mauvaisequalité mais, chose plus grave encore, d’entraîner

des dommages corporels graves, voire mortels endéclenchant des incendies ou des chocs électriques.Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-lifié l’installation, le dépannage et l’entretien du postede soudage et de coupage. N’effectuez aucuneréparation électrique sur l’équipement à moins d’êtrequa-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretienquelconque à l’intérieur du poste de soudage/coupage, avant d’avoir débranché l’alimentationélectrique.

c. Maintenez en bon état de fonctionnement les câbles,le câble de masse, les branchements, le cordond’alimentation et le poste de soudage/coupage.N’utilisez jamais le poste ou l’équipement s’il présenteune défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage etdes équipements accessoires. Gardez-les à l’écartdes sources de charleur, notamment des fours, del’humidité, des flaques d’eau maintenez-les à l’abri destraces d’huile ou de graisse, des atmosphères corro-sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tousles panneaux de l’armoire de commande en veillant àles garder en bon état.

f. Utilisez le poste de soudage/coupage conformément àson usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVESÀ LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur lesrègles de sécurité à observer pour le montage etl’utilisation d’équipements de soudage et de coupageélectriques et sur les méthodes de travailrecommandées, demandez un exemplaire du livret N°52529 “Precautions and Safe Practices for Arc Weld-ing, Cutting and Gouging” publié par ESAB. Nousconseillons également de consulter les publicationssui-vantes, tenues à votre disposition par l’AmericanWelding Society, 550 N.W. LeJuene Road, Miami, FL32126:

a. “Safety in Welding and Cutting” AWS Z49.1b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.d. “Recommended Safe Practices for Plasma Arc Cut-

ting” AWS-A6. 3.e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

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• Mig Welding Process Handbook• One 10# Sample Spool .035 87 HP Wire

1.3.2 POWER SOURCEThe power source consists of a single phase trans-former, single phase full wave controlled rectifier, stabi-lizing reactor, filtering capacitors and internal outputconnections for polarity reversal.

1.3.3 WIRE FEEDERThe wire feeder pushes 0.023, 0.030, 0.035 and 0.045 in.wire at speeds up to 700 IPM. Dynamic braking preventsexcessive wire overrun. A double grooved drive roll(0.035 and 0.045 in.) provides a convenient means ofchanging the setup for either wire size.

The wire feeder is built into the power source cabinet,and is housed in a compartment separated from thewelding machine components. Machine ventilation is notdrawn through this compartment, thus helping to keepthe wire and feeding mechanism clean.

1.3.4 MT-200cc WELDING TORCHThe lightweight air cooled welding gun included in se-lected systems is supplied complete and ready to weld0.035 in. steel wire. It is built with a one piece serviceconduit and includes a 45 degree gooseneck. Changingthe contact tip to 0.045 in. allows the use of the largerwire.

1.3.5 OPTIONAL CONTROLSThe Migmaster 251 System can be used to weld hardand aluminum wire with an optional MT-250SG spool-on-gun torch. An optional spot control allows a welder tospot weld within a range of 0.1 to 5.0 seconds. Theoptional spool-on-gun adaptors and control, when usedin conjunction with the optional MT-250SG torch, permitsaluminum wire welding with the machine.

1.3.6 RUNNING GEARThe Migmaster 251 is equipped with a running gear withswiveled front wheels and a gas cylinder support. Therear wheels are packed loose for shipping, but are easilyinstalled, (see Section 2.8).

1.4 OPTIONAL ACCESSORIES

1.4.1 SPOT/BURNBACK/TRIGGER LATCH MODULE,P/N 36694This easy-to-install, plug-in module mounts in place ofthe upper blank cover plate of the upper-right front panellocation in the unit. It enables the operator to use theMigmaster 251 for Spot or Continuous welding opera-tions.

1.1 GENERAL

This manual has been prepared especially for use infamiliarizing personnel with the design, installation, op-eration, maintenance, and troubleshooting of this equip-ment. All information presented here in should be givencareful consideration to assure optimum performance ofthis equipment.

1.2 RECEIVING-HANDLING

Prior to installing this equipment, clean all packing mate-rial from around the unit and carefully inspect for anydamage that may have occurred during shipment. Anyclaims for loss or damage that may have occurred intransit must be filed by the purchaser with the carrier. Acopy of the bill of lading and freight bill will be furnishedby the carrier on request if occasion to file claim arises.

When requesting information concerning this equip-ment, it is essential that Part, Serial and Model Numbersof the equipment be supplied.

1.3 DESCRIPTION

The Migmaster 251 is a portable Welding System de-signed for fine wire, (0.023, 0.030, 0.035 and 0.045 in.)welding using the short arc method, as well as for sprayarc aluminum, short arc and spray arc stainless steel andspray arc cored wires. It incorporates a running gear withprovisions for one gas cylinder. It also has provisions foroptional spot module, spool-on-gun control module, dualcylinder kit, and torch cable wrap.

1.3.1 AVAILABLE PACKAGES AND CONTENTSThe following Migmaster 251 “Consisting of” Packagesare available:

MM-251, 200/230/460 Vac 60 Hz, 12' Torch .............. P/N 36691T12MM-251, 200/230/460 Vac 60 Hz, 15' Torch .............. P/N 36691T15MM-251, 230/460/575 Vac 60 Hz, 12' Torch .............. P/N 36692T12MM-251, 230/460/575 Vac 60 Hz, 15' Torch .............. P/N 36692T15MM-251, 220/400(380/415) Vac 50 Hz, 12' Torch ..... P/N 36693T12MM-251, 220/400(380/415) Vac 50 Hz, 15' Torch ..... P/N 36693T15

Depending on the primary input voltage of the Migmaster251, and the torch length, each package includes thefollowing:

• One (1) Migmaster 251 Power Source/Wire Feederequipped with a dual-groove feed roll (for .035/.045 wire),an 8 ft. primary input power cable, 10-ft. work cable withclamp, a 6 ft. shielding gas supply hose with fittings andrunning gear with gas cylinder support.• One (1) Ready-to-Weld MT-200cc Welding Torch, 12or 15 ft., set up for .035/.045 wire.• One (1) R-33-FM-580 Regulator-Flowmeter (60 Hz)or (1) R-33-FM-320 Regulator-Flowmeter (50 Hz).

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If a Spotwelding operation is to be used, it is recom-mended that you also order a #12S Spotweld Nozzle,P/N 999625.

1.4.2 SPOOL-ON-GUN TORCH, P/N 36779SPOOL-ON-GUN KIT, P/N 36695

The Migmaster 251 unit is equipped for an optionalcontrol for the Spool-On-Gun welding torch. This is a highperformance, 250 ampere continuous duty spool-on-guntorch designed for the mig welding process. It is com-pletely portable (up to 30-ft.), air-cooled and hand oper-ated, and weighs less than three (3) pounds. The gun isequipped with thirty (30) foot lines.

1.4.3 TORCH NOZZLESA No. 8 Nozzle (1/2" I.D.), P/N 998893 to fit the MT-200ccTorch, is included in the Migmaster 251 package. Thisslip-on type nozzle includes a permanently mountedinsulator/spatter shield. The following standard duty slip-on nozzles, also equipped with the insulator/spattershield, are available:

No. 6 Nozzle, Tapered (3/8" I.D.) ............ P/N 998895No. 10 Nozzle (5/8" I.D.) ......................... P/N 998894No. 12 Spotweld Nozzle (3/4" I.D.) ........... P/N 17316

Additionally, the following heavy-duty slip-on nozzles,also equipped with the insulator/spatter shield, are avail-able:

No. 8 Nozzle (1/2" I.D.) ........................... P/N 999471No. 10 Nozzle (5/8" I.D.) ......................... P/N 999472No. 12 Nozzle (3/4" I.D.) ......................... P/N 999473No. 12 Spot Nozzle (3/4" I.D.) ................ P/N 999625

New Long Life MT Nozzles. Three nozzles have apatented coating to reduce weld spatter and extend thelife of the nozzle.

No. 6 XL Nozzle, (MT Std.) ................. P/N 998895XLNo. 8 XL Nozzle, (MT Std.) ................. P/N 998893XLNo. 10 XL Nozzle, (MT Std.) ............... P/N 998894XLNo. 8 XL Nozzle, (MT HD) .................. P/N 999471XLNo. 10 XL Nozzle, (MT HS) ................ P/N 999472XL

1.4.4 TORCH/WIRE FEED ACCESSORIES -- SeeTables 1.2 and 1.3.

1.4.5 DUAL CYLINDER KIT, P/N 36701Permits mounting 2 cylinders of gas to the Migmaster 251- one for MT-200cc and the other for Spool-on-Gun.

TABLE 1-1. SPECIFICATIONS

POWER SOURCE MIGMASTER 251Rated Output 250 Amps @ 30 Volts d.c.Duty Cycle, 40%

Primary Input, Volts AC 200/230/460; 230/460/575; 220/400(380/415)Primary Input, Amperes 72/62/31; 62/31/25; 66/36(38/35)Output Current Range 30 to 300 Amps.Maximum Open Circuit Volts 36 v.d.c.

FEEDER

Feed Type PushWire Sizes, Hard & Cored 0.023 inch (.6mm) 0.035 inch (.9mm)

0.030 inch (.8mm) 0.045 inch (1.2mm)Feed Rate 20-700 IPM

MT-200cc TORCH

Cooling AirGooseneck Angle 45 degreesRated 60% Duty Cycle(DCRP) Amps: 200 w/Argon Mixtures, 300 w/CO

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Length 12 or 15ft

PHYSICAL

Net Weight *200 lbs (91 Kg.)Height *29.75 inches (756 mm)Width *18.0 inches (457 mm)Depth *40.5 inches (1030 mm)

*Includes running gear & cylinder tray.

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(S) Short contact tips are recommended for proper wire stick out for flux cored wire welding.(M) Medium contact tips are recommended for proper wire stick out in spray transfer Mig

welding.(L) Long contact tips are recommended for good visibility and proper wire stick in dip transfer

Mig welding.

1.4.6 TORCH CABLE HOLDER, P/N 33952GYFour mounting holes are provided on the left side formounting the torch cable holder so that torch cable canbe wrapped out of the way when not operating. Mountingscrews are supplied with the holder.

1.5 SAFETY

Before the equipment is put into operation, the safetysection at the front of this manual should be read com-pletely. This will help avoid possible injury due to misuseor improper welding applications.

The symbol which precedes safety notes appear-ing throughout this manual means “Attention! Be Alert!Your safety is involved.” The definitions relating to theDANGER, WARNING and CAUTION safety notationsare described at the end of the Safety Section in the frontof this manual -- read them and their specific text refer-ences carefully.

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* Recommended for use with soft cored wires that areeasy to flatten. Order both lower drive roll and upperpressure roll.

1.6 DUTY CYCLE AND CURVES (Figure 1.1)

The duty cycle of the equipment is the percentage of a 10minute period which it can operate safely at a givenoutput current. The Migmaster system is rated at 40%duty cycle. This means that the equipment can be safelyoperated at 250 amperes for four minutes out of every 10.This cycle can be repeated indefinitely (See Figure 1.1).

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2.2 ELECTRICAL INPUT CONNECTIONS

It is recommended that a line disconnect switch beinstalled in the input circuit to the welding machine.This would provide a safe and convenient means tocompletely remove all electrical power from thewelding machine whenever it is necessary to performany internal function on the unit.

Before making electrical input connections to thewelding machine, “Machinery Lockout Procedures”should be employed. If the connections are to bemade from a line disconnect switch, the switchshould be padlocked in the off position. If the con-nection is made from a fusebox, remove the fusesfrom the box and padlock the cover in the closedposition. If locking facilities are not available, attacha red tag to the line disconnect switch (or fuse box)to warn others that the circuit is being worked on.

2.2.1 INPUT ELECTRICAL REQUIREMENTSThe power source is a single-phase unit and must beconnected to a single-phase power supply. The unitshould be operated on a dedicated circuit to preventimpairment of performance due to an overloaded circuit.The primary input voltage requirements are noted on theunit’s rating plate.

2.1 LOCATION

A proper installation site should be selected for thewelding machine, if the unit is to provide dependableservice and remain relatively maintenance free.

A proper installation site permits freedom of air move-ment into and out of the welding machine, and also leastsubjects the unit to dust, dirt, moisture, and corrosivevapors. A minimum of 18 inches (46 cm) unrestrictedspace must be maintained between the welding machineside and rear panels and the nearest obstruction.

The installation site should also permit easy removal ofthe welding machine outer enclosure for maintenancefunctions.

CAUTION: Do not place any filtering device over theintake air passages of the welding ma-chine as this would restrict the volume ofintake air and thereby subject the weldingmachine internal components to an over-heating condition and subsequent failure.Warranty is void if any type of filteringdevice is used.

If a forklift vehicle is used for lifting the unit, be sure thatthe lift forks are long enough to extend completely underthe base.

Do not operate the machine without the running gearinstalled.

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TABLE 2.1 Recommended Input Fuse Size

FullPrimary Load

Input Line FuseVolts Amperes Size

208 72 90230 62 90380 38 50400 36 50415 35 50460 31 40575 25 30

2.2.2 INPUT CONDUCTOR CONNECTIONSThe Migmaster 251 units are provided with a three-conductor, 600 volt primary input cable. The 200/230/460 volt units are equipped with a 230 volt, 50 amp plugready for plugging into an approved 230 volt, 50 ampservice.

The 220/400 and 230/460/575 volt units are providedwith a 600 volt cable and should be connected as follows:(1) connect the ground lead (green) of the cable to anapproved ground and (2) connect each of the remainingleads (black and white) to separately fused lines of thedisconnect or breaker. See Table 2.1 for recommendedfuse sizes to use in the disconnect.

To connect a 200/230/460 volt unit to 460 input, removethe plug, strip cable and connect as stated above for 220/400 and 230/460/575 volt units.

The units leave the factory with their primary electricalinput requirements internally connected as follows: 230volts for 200/230//460 volt units; 400 volts for the 220/400volt units; 575 volts for 230/460/575 volt units. If a unit isto be operated from another input voltage, the links on theinput terminal board must be reset for that particular inputvoltage. Remove right side panel from unit and locate theinput terminal board (see Figure 2.2). Always verify theinput voltage and check the link arrangement regardlessof factory setting. The voltage links are setup byreconfiguring the copper link bars to the silk-screenedvoltage designation for the desired voltage.

2.3 SECONDARY OUTPUT CONNECTIONS

The Migmaster 251 Welding System is completely self-contained so that the front panel torch fittings are inter-nally connected to the welding polarity (D.C. Reverse orD.C. Straight) via the secondary output terminals lo-cated inside the wire feeding compartment (see Fig.3.1). The unit comes set up for D.C.R.P. welding.

2.4 TORCH CONNECTION

The MT-200cc torch is supplied as standard equipmentwith the Migmaster 251 System. It is provided with aeuro-type adapter which directly connects to the torchfitting mounted on the front panel. Line up matchingholes, push on and tighten locking collar.

2.5 WIRE FEEDER MECHANISM

2.5.1 DRIVE ROLLSThe drive roll has two grooves: the small groove feeds0.035 in. diameter wire, the large groove feeds 0.045 in.wire. The groove nearest the gear motor feeds the wire.If the required groove is not in that position:

A. Release the pressure drive roll lever and lift theassembly upward.

B. Remove the thumb screw holding the drive roll tothe gear.

C. Reverse the drive roll on the drive roll shaft.

D. Replace the screws and tighten.

E. Secure the pressure drive roll assembly.

2.5.2 WELDING WIRE SPOOL

As with any work area, make sure safety glasses withside shields are worn when handling or changingwire or clipping wire off at the spool or at the end ofthe torch. Hold onto the wire coming off the spoolwith one hand before clipping. Serious eye injurycan result due to the springiness of the wire whichcan quickly unravel, or a cut wire end which mayshoot across the room.

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Install a spool of welding wire on the hub as follows:

A. Unscrew spool nut from hub.

B. Place wire spool on hub to rotate clockwise aswire is unwound; hub pin must engage hole inspool.

C. Replace nut.

2.5.3 THREADING WELDING WIRE

A. Turn off power switch.

When the power switch is on, and gun trigger isdepressed, the electrode wire becomes electricallyhot, and the wire feed rolls are activated.

B. Release pressure drive roll assembly and lift upward. Check that proper wire diameter groove isin the inner position.

CAUTION: Before threading welding wire through cas-ing, make sure chisel point and burrs havebeen removed from wire end to prevent wirefrom jamming in gun casing or liner.

C. Feed the wire from the spool through the inletguide, across the drive roll groove and into gunoutlet guide.

Make sure that the proper “outlet guide tube” is insertedinto the front-panel torch fitting for the size and type ofwire being used, see Table 1.3 for wire feed accessories.

To insure proper wire feeding, it is important that the wirebe kept clean and that the drive rolls be periodicallycleaned of any chips or scale that might be carried intothe torch liner and cause sticking.

D. Lower pressure roll assembly and secure. Feedwire through to gun tip with gun trigger (powerON).

PINCH HAZARD. Keep fingers away from drive standwhen wire feed rolls are activated.

2.5.4 BRAKE DRAG ADJUSTMENTBrake disc friction should provide enough drag to keepthe wire spool or core from spinning freely after wire feedstops. If adjustment is required, turn adjusting screwclockwise to increase drag, counterclockwise to de-crease it. Drag should be just low enough to limit wireoverrun.

2.6 CONNECTION OF SHIELDING GAS SUPPLY

The R-33-FM-580 Regulator-Flowmeter is designed foruse with an argon or argon-mix cylinder of shielding gas.It is adjustable for delivering up to 50 cfh through thetorch. To set up the system do the following:

Do not adapt R-33-FM-580 for use with CO2. Reliefdevice may rupture if CO2 is used with the R-33-FM-580. For CO2 service, order R-33-FM-320, P/N 21558.

a� !�� "#$%&&'�� (�� )*+cylinder rack.

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c. Unscrew the cylinder cap.

d. Open the cylinder valve slightly, just for aninstant, to blow away any dirt or dust which mayhave accumulated in the cylinder valve outlet.Be sure to keep your face away from thevalve outlet to protect your eyes.

e. Attach the regulator to the cylinder valve, tightenthe union nut securely with a 1-1/8-in. open endor an adjustable wrench.

f. Attach the gas hose from the rear of theMigmaster 251 to the regulator outlet connec-tion (see Fig. 2.1 and 2.3).

Fig. 2.3 R-33-FM-580 Regulator-Flowmeter (Illustrated)

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g. Slowly open the cylinder valve a fraction of aturn. When the regulator pressure gauge pointerstops moving, open the cylinder valve fully.

Never stand directly in front of or behind the regula-tor when opening the cylinder valve. Always stand toone side.

h. Using soapy water, test for leakage about thecylinder valve stem, the regulator inlet connec-tion, and the hose connections at the regulatorand at the Migmaster 251 for leakage. Correctany leaks before starting work.

i. ,�� -�� cylinder, shut down the regulator as follows:

1. Close the cylinder valve.

2. Release gas from the regulator by closingthe torch trigger lever.

3. When pressure gauge drops to zero, theregulator is de-pressurized and shutdown.

j. Each regulator is equipped with a porous metalinlet filter, P/N 71Z33, pressed into the regulatorinlet nipple. No regulator should be connectedto a cylinder or station valve unless it containsthis filter. You can replace the filter if you havereason to do so. To remove a filter refer to theregulator instruction literature for details.

k. Regulators in need of repair should be returnedto your Welding Equipment distributor or to anauthorized repair station.

If welding is performed in a confined area, shieldinggas leaks could result in a buildup of shielding gasconcentration, displacing oxygen, thereby endan-gering personnel entering the area.

2.7 WELDING CABLE CONNECTIONS

Connect the work clamp solidly to the workpiece or worktable. Clamp onto a bare metal area.

A good electrical connection to the work is essentialto proper welding operation and to prevent electricshock.

Welding cables should be kept as short as possible andbe of adequate current carrying capacity. Resistance ofthe welding cables and connections causes a voltagedrop which is added to the voltage drop of the arc.Excessive cable resistance may result in a reduction ofthe maximum usable current output of the equipment.

The proper operation of this equipment is to a largeextent dependent on the use of welding cables andconnections which are in good condition and of adequatesize.

2.8 INSTALLATION OF THE CYLINDER TRAYAND WHEELS (See Figure 2.4)

The unit’s running gear is factory assembled except forthe rear wheels which are packed in the cylinder tray ofunit. The rear gear consists of 2-wheels, 6-washers, 2-cotter pins, and an axle. To install the gear, refer to Fig.2.4 and do the following:

a. Remove 4 screws (item 1) from the sides of the baseusing a 3/8 wrench. Keep these screws for later.

b. Remove 4 lag bolts and 4 metal clips (item 2)attaching the wooden skids to the base of the ma-chine.

c. Cut the 4 cable ties that hold the wheels and axle inthe cylinder tray.

d. Slide the Cylinder tray (item 3) out until the threadedholes in the cylinder tray line up with the rearmostholes in the base.

e. Using the screws removed in the first step, re-attachthe cylinder tray with the base, now using the rearbase holes.

f. Slide the axle (item 5) through the cylinder tray.

g. Add 2 washers (item 6) to each end of the axle.

h. Add 1 wheel (item 4) to each end of the axle.

i. Add an additional washer on the outside of eachwheel on the axle.

j. Install a cotter pin (item 7) through each end of theaxle.

k. Attach the chain through the slots in the cylindersupport.

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3.1 CONTROLS (See Setup Chart in Weld SetupGuide, located on the door of Migmaster WireCompartment.)

3.1.1 POWER SWITCHA line switch on the front panel energizes the primary ofthe main transformer. The white READY light will lightup.

When the unit overheats or exceeds the duty cycle, thewhite light will shut off and output operations will shutdown. The fan will continue to run to cool the unit down.

3.1.2 SECONDARY WELDING CONNECTIONSThe solid state contactor is used to control the weldingoutput. This contactor is turned on and off when the torchtrigger is operated.

The secondary output welding terminals, POS.(+) andNEG(-), are located in the right side wire feeding com-partment and are used to set the welding polarity(D.C.R.P. or D.C.S.P.) in which the machine will operate(see Setup Chart in Weld Setup Guide, located on the

door of Migmaster Wire Compartment.). As shipped fromthe factory, the Migmaster 251 is set up to operate inD.C.R.P. (TORCH fitting is connected to Positive, andWORK cable/clamp is connected to Negative output). Toweld using D.C.S.P., simply mount the WORK cable tothe Positive output and the TORCH fitting cable to theNegative output terminal.

Because of the charged capacitor bank in the sec-ondary circuit, the output voltage will take a fewseconds before falling to zero volts.

The gas valve shuts off when the solid state contactoropens.

3.1.3 WIRE FEED SPEED CONTROLWire feed speed is controlled by the wire speed controlknob on the front panel. The solid state control allows forinfinitely variable speeds up to 700 IPM.

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This wire speed dial is used to set the speed at which thewelding wire is fed out from the torch and hence thewelding amperage. The panel-face numbers on the dialindicate wire feed speed.

3.1.4 VOLTAGE CONTROLThis dial permits fine tuning the arc voltage (or heat) tothe weld.

Power source contactor becomes energized themoment the torch trigger is depressed. Arcing canoccur if the wire is brought to a ground. Keep thetorch always away ground until welding is to begin.

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IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

A. CUSTOMER SERVICE QUESTIONS:Order Entry Product Availability Pricing DeliveryOrder Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548

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Western Distribution Center Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM ESTWarranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM ESTPerformance Features Technical Specifications Equipment Recommendations

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F. WELDING EQUIPMENT TRAINING:Telephone: (843)664-4428 / Fax: (843) 679-5864Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

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ESAB Welding & Cutting Products, Florence, SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES

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