f15-690 migmaster 210...3. aws c5.2 - "recommended practices for plasma arc cutting" 4....
TRANSCRIPT
MigMaster 210
F15-690 062002
Instruction Manual
2
These INSTRUCTIONS are for experienced operators. If you are not fully familiar withthe principles of operation and safe practices for arc welding and cutting equipment, weurge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, andGouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintainthis equipment. Do NOT attempt to install or operate this equipment until you have read andfully understand these instructions. If you do not fully understand these instructions, con-tact your supplier for further information. Be sure to read the Safety Precautions beforeinstalling or operating this equipment.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained inthis manual and accompanying labels and/or inserts when installed, operated, main-tained and repaired in accordance with the instructions provided. This equipment mustbe checked periodically. Malfunctioning or poorly maintained equipment should not beused. Parts that are broken, missing, worn, distorted or contaminated should be re-placed immediately. Should such repair or replacement become necessary, the manu-facturer recommends that a telephone or written request for service advice be made tothe Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior writtenapproval of the manufacturer. The user of this equipment shall have the sole responsi-bility for any malfunction which results from improper use, faulty maintenance, damage,improper repair or alteration by anyone other than the manufacturer or a service facilitydesignated by the manufacturer.
3
Safety Precautions 2-6
Introduction 7
Technical Data 7
Installation 8-9
Seam Welding 10
Spot Welding 10
Welding Process 11
Changing Setup for Different Materials 11
Common Welding Faults 12
Assembly Diagram 13
Dimension Diagram 13
Recommended Welding Parameters 14
Electrical Diagram 15
Spare Parts Lists 16-23
Mig
Mas
ter
210
CONTENTS
4
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 causeburns. Training in the proper use of the processes andequipment is essential to prevent accidents. There-fore:
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-sleeve shirt, cuffless trousers, high-topped shoes, and awelding helmet or cap for hair protection, to protectagainst arc rays and hot sparks or hot metal. A flame-proof apron may also be desirable as protection againstradiated heat 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 andcan fly far. Bystanders should also weargoggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hotslag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials includewood, cloth, sawdust, liquid and gas fuels, solvents,paints and coatings, 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, or
SAFETY PRECAUTIONS
10/98
portable fire extinguisher. Be sure you are trained in itsuse.
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 FireProtection Association, BatterymarchPark, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact withlive electrical parts and ground cancause severe injury or death. DO NOT
use AC welding current in damp areas, if movement isconfined, or if there is danger of falling.
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 recommenda-tions. Do not mistake the work lead fora ground cable.
ELECTRIC AND MAGNETIC FIELDS— May be dangerous. Electric cur-rent flowing through any conductorcauses localized Electric and Mag-
netic Fields (EMF). Welding and cutting current createsEMF around welding cables and welding machines. There-fore:
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.D. Connect the work cable to the workpiece as close as
possible to the area being welded.E. Keep welding power source and cables as far away
from your body as possible.
5
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 isnot adequate. Stop work and take necessary steps toimprove 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 injureor kill. 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,Miami, 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 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 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.
SP98-10
6
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 incandescentpeuvent tomber dans des fissures du plancher ou dansdes ouvertures des murs et y déclencher une ignitionlente cachée. Veiller à protéger ces ouvertures desétincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérationsde gougeage ou autres travaux à chaud à la surface debarils, bidons, réservoirs ou autres contenants usagés,avant de les avoir nettoyés de toute trace de substancesusceptible de produire des vapeurs inflammables outoxiques.
d. En vue d’assurer la prévention des incendies, il convientde disposer d’un matériel d’extinction prêt à servirimmédiatement, tel qu’un tuyau d’arrosage, un seau àeau, 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 vide relative-ment importantes; or, celles-ci risquent de causer desdommages corporels graves et même mortels en casd’utilisation inadéquate. La gravité du choc électriquereçu dépend du chemin suivi par le courant à travers lecorps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous tensionvenir au contact direct de la peau ou de vêtementshumides. Veillez à porter des gants bien secs.
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-forme sèche.
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 en effetprovoquer une surchauffe de l’équipement et un dan-ger 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 passaged’un courant de sortie par des chaînes de
PRÉCAUTIONS DE SÉCURITÉAVERTISSEMENT: 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 à l’arc,peuvent s’avérer plus graves que celles résultant d’uneexposition prolongée au soleil. Aussi convient-ild’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 proximité defaçon 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 sans rebord,des chaussures à embout d’acier et un casque desoudage ou une calotte de protection, afin d’éviterd’exposer la peau au rayonnement de l’arc électriqueou du métal incandescent. ll est également souhaitabled’utiliser un tablier ininflammable de façon à se protégerdes étincelles et du rayonnement thermique.
c. Les étincelles ou les projections de métal incandescentrisquent de se loger dans des manches retroussées,des bords relevés de pantalons ou dans des poches.Aussi convient-il de garder boutonnés le col et lesmanches et de porter des vêtements sans poches àl’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. Les personnesse trouvant à proximité doivent également porter deslunettes 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 peuvent provoquerde graves incendies au contact de matériaux combus-tibles solides, liquides ou gazeux. Aussi faut-il observerles précautions suivantes:
a. Éloigner suffisamment tous les matériaux combustibles
9/97
7
levage, 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 toute fuited’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 ventilationnaturelle 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’hydrocarbure chlorérésultant d’opérations voisines de dégraissage ou depulvérisation. La chaleur dégagée ou le rayonnementde l’arc peut déclencher la formation de phosgène --gaz particulièrement toxique -- et d’autres gaz irritants,à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de lagorge constatée au cours de l’utilisation de l’équipementdénote un défaut de ventilation. Arrêtez-vous detravailler 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 que sil’interrupteur correspondant du panneau avant se trouveplacé en position ON (Marche). Veillez à manœuvrercette commande en vérifiant si le couvercle est bien enplace, de façon à assurer l’efficacité de la ventilationainsi réalisée. Ne jamais débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou decoupage peuvent s’avérer toxiques. Aussi est-ilnécessaire de disposer en permanence d’un dispositifadéquat de ventilation de type aspirant, afin d’élimi-nerdu voisinage de l’opérateur tout dégagement de fuméevisible.
f. Consultez les recommandations particulières en matièrede ventilation indiquées à l’alinéa 6 de la norme Z49.1de 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 desdommages corporels graves, voire mortels en
déclenchant 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 poste desoudage et de coupage. N’effectuez aucune réparationélectrique sur l’équipement à moins d’être qua-lifié àcet effet.
b. Ne procédez jamais à une tâche d’entretien quelconqueà l’intérieur du poste de soudage/coupage, avant d’avoirdébranché l’alimentation électrique.
c. Maintenez en bon état de fonctionnement les câbles, lecâble de masse, les branchements, le cordond’alimentation et le poste de soudage/coupage. N’utilisezjamais le poste ou l’équipement s’il présente unedéfectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et deséquipements accessoires. Gardez-les à l’écart dessources de charleur, notamment des fours, de l’humidité,des flaques d’eau maintenez-les à l’abri des tracesd’huile ou de graisse, des atmosphères corrosives etdes 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 publications sui-vantes, tenues à votre disposition par l’American WeldingSociety, 550 N.W. LeJuene Road, Miami, FL 32126:
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.
9/97
8
Introduction
Semi-automatic welding (MIG/MAG)
MIG is the abbreviation for METAL INERT GAS andconcerns welding with an inactive shielding gas, gene-rally Argon or a mixture of gases (MIXED-GAS).
MAG means METAL ACTIVE GAS and it concerns weldingwith an active shielding gas, generally carbon dioxide(CO
2).
The MigMaster 210 is an advanced, compact, stepswitched welding power sources designed for professionalwelders and suitably qualified trades people. The unit isintended for Mig/Mag welding utilizing solid wire with ashielding gas. They can also be used with gasless weldingwires using reverse polarity feature.
Ideal for welding on thin sheet metal through to mediumfabrication tasks. The MigMaster 210 satisfies the needof high capacity for repair and maintenance welding. Thisunit has been designed, tested and manufactured forindustrial use, using quality components, to provide a longservice life.
Features include a rugged all steel construction, withwheels for ease of handling, handy rubber matted top fortool storage, and a powerful integrated feed system. Themachine is fan-cooled, thermostatically protected, andincludes seam, spot and stitch welding.
The MigMaster 210 has space for a standard 12- inchspool (33 lbs.).
The MigMaster 210 is a Single Phase 200/230v 60Hz machine.
Optional Accessories• Wire Feed Rollers of various sizes
• Shielding Gas supply
• Tips
• Nozzles
• Spool Gun Option .......................... P/N 0558002850
Consumable ItemsFrom time to time depending on usage the following itemsmay need to be replaced due to normal wear and tear.
• Replacement wear parts for the Mig gun such ascontact tips, gas nozzles, wire liners, etc.
• Wire feed guides
• Wire feed rolls
Complete Assemblies (CC Style)0558001643 Gun Master 250cc 10 ft X 0230558001644 Gun Master 250cc 10 ft X 035-0450558001645 Gun Master 250cc 12 ft X 035-0450558001649 Gun Master 250cc 15 ft X 035-045
Torch Options & Accessories
Liner Selection
Steel & Flux Core0558001675 .023 X 10,12,15' Liner37031 .030 X 10,12,15' Liner37032 .035/.045 X 10,12,15' Liner
NOTE: All Liners are 15’ and can be trimmed to fit.
The MigMaster 210 complies with international standards SS483 01 11, ISO R700, NF A 85 013 and VDE 0542.
IP - The code describes the degree of protection provided by thecasing, against the penetration of fixed objects and water.
Equipment mark IP 21 is designed for indoor use.
Technical Data
Standard Duty Tips20543 023 Standard Duty Tip20544 030 Standard Duty Tip996995 035 Standard Duty Tip
TORCH TIPS
MigMaster 210
Main supply 1-phase
Frequency (Hz) 60
Voltage (V) 208/230
Fuse slow (A) 16
Permissible Loading @ :
20% 210A / 24.5V
60% 120A/ 20V
100% 90A / 19V
Open circuit voltage (V) 18-37
Voltage steps 10
Inductance outlet 2
Wire feed speed (ipm) 40-680
Welding time :
Spot time (sec) 0.2-2
Interval time (sec) 0.2-2
Efficiency h 0.69
Power factor l 0.87
Operating voltage (V AC) 42
Class of enclosures IP 21
Weight (lbs.) 146
Dimensions (LxWxH) 33 x 14.8 x 29 inches
NozzlesStandard Duty0558001610 3/8" Standard0558001609 3/8" Standard0558001612 1/2" Standard0558001611 1/2" Standard0558001613 1/2" Standard0558001614 5/8" Standard0558001615 5/8" Standard
Spot0558001602 Spot Nozzle
Std. Duty Tip/Noz. Adapter0558001608
1/8" RecessFlush
1/8" RecessFlush
1/8" Stick OutFlush
1/8" Stick Out
Brass
9
Installation
Recommended Wire Sizes (inches) MigMaster 210
Mild Steel .023 -.035
Stainless Steel .030 - .035
Cored (gasless) .035
UnpackingAfter unpacking, fit the wheels and gas bottle rack according tothe guide shown on page 13. Remove any covers over themachine to ensure adequate cooling.
Electrical Connections
First make sure that the power supply is appropriatelyfused (see Technical Data on page 8). Check that theunit is connected for the appropriate main voltage. Asstandard, the MigMaster 210 is connected for 230v-1phase supply. Reconnecting should be done accordingto the wiring diagrams on page 15. When connecting thepower plug, it is absolutely essential that the green/yellowwire of the primary cable is connected to the earth screwof the plug. The remaining two wires, live and neutral,should be connected to the remaining two terminals inthe correct order.
Electrical connections should be made by a fullyqualified person.
Return Welding Cable And ClampThe return cable should be firmly connected to the requiredoutlet terminal on the front of the machine. The clampshould be clamped securely to the workpiece. Ensure allconnections are clean and tight to avoid welding defects.
Connecting The Welding Gun (See Fig. 1, pg.9)The gun is connected to the Euro connector on the frontof the machine. Carefully align gas connection tube andtrigger connection pins with Euro adaptor on Mig gun.Push in and tighten the lock nut. Be careful to line up gunfittings correctly before tightening to avoid damagingtrigger pins and gas connection. Ensure that the Mig gunis fitted with a wire conduit and contact tip suitable for thesize and type of wire being used. Refer to the Gun Manualfor spare parts
Feed RollsMake sure that the correct feed roll and grooves are usedfor the dimension and type of wire being used. Each feedroll has grooves for two dimensions of filler wire. Thefeed roll must be fitted with its size marking facing you.The feed roll can be changed or replaced by removing thescrew in the centre of the hub.
“V’” groove rolls as supplied as standard for solid wire,and serrated rolls for use with cored wire to ensure positivefeeding.
Welding WireSelect a welding wire of the appropriate type andsize for the job at hand. See ESAB’s consumablecatalogue, available from your nearest ESAB Dis-tributor, for a range of quality welding filler materialsand their recommended welding parameters.
Fit the reel on to the hub so that the wire runs off at thebottom into the wire guide. Two catches on the hub holdthe reel in place. It is in the lock position when the arrowson the hub align with the arrows on the two catches (seeFig. 2). To disengage the locking mechanism, twist thecenter knob to the left (see Fig. 3). On a new reel, theouter end of the wire is inserted through a hole and bentover.
As with any work area, make sure safety glasseswith side shields are worn when handling orchanging wire or clipping wire off at the spool orat the end of the torch. Hold onto the wire comingoff the spool with one hand before clipping.Serious eye injury can result due to the springi-ness of the wire which can quickly unravel, or acut wire end which may shoot across the room.
When loosening the wire from the hole, take care to holdthe coil so that it does not spring out and unravel. Cut offthe bent end of the wire, straighten the tip and then file offany sharp edges so that the wire can run easily throughthe soft wire guide of the welding conduit without
Fig. 1 - Mounted Welding Wire Reel
Fig. 2 - Locked Fig. 3 - Unlocked
10
damaging it. These precautions are very necessary. Asharp wire tip can quite easily pierce both the wire guideand the wall of the welding conduit and thus seriouslyimpair the function of the gun.
Feed the wire into the protruding wire guide on the inletside of the feed unit and then by hand feed the wire up tothe roll. Before the wire is fed further into the guide nozzleof the feed unit, the pressure arm and roller must be liftedup.
Keep your fingers clear of the drive rolls;they will start turning when the torch triggeris pressed.
The wire can now be fed in by hand through the guidenozzle and into the welding conduit and the pressure rollcan be lowered again. The contact pressure of the feedroll is adjusted at the factory, but if necessary it can bemodified by means of the screw on the pressure arm. Arule of thumb for this type of secondary adjustment is thatthe pressure must not be harder than makes it possible tostop the forward travel of the wire through the Mig gun bypressing the contact nozzle against a piece of wood orequivalent so that the rollers of the feed unit slip. If thepressure is too high when welding, the result may be thatthe wire will build up and jam in the outlet nozzle of thefeed unit should the tip of the wire stick. This istroublesome to straighten out and, with correct settings,also unnecessary.
Mild Steel
Stainless
(Argon + CO2) (Argon + CO
2 + Oxygen)
(Argon + CO2 + Oxygen) (Argon + Oxygen)
Fig. 4 - Feed Roll With Wire Inserted
Another drawback of excessive feed pressure is that thewelding wire can be rolled flat which causes unnecessarywear on the wire guide and that contact in the gun will bejeopardized.
Set the voltage selector switch on front of machine to po-sition 1. The wire feed can be turned to one of the centersettings. Straighten out the gun hose. Wire is fed forwardeither by pressing the inch button on the wire feed unit(cold wirefeed), or by pressing the gun trigger. Take carewhen the wire emerges from the gun since the point cancause injury.
Gas SelectionSelect the appropriate shielding gas for the type of mate-rial to be welded and filler metal being used. The shieldinggas is used to protect the molten weld pool from beingcontaminated by the surrounding air. The shielding gasalso contributes to arc stability, weld strength andappearance so care should be taken to ensure that thecorrect gas type/mixture is selected for the metal beingwelded. Contact your local ESAB distributor or gassupplier for recommendations.
Typical Gas Selections
11
Recommended Output Inductance Tap Connections for Short-Arc Welding
Notes: The above chart shows the recommended output inductance tap connection for Mig Short Circuiting Transfer.For Mig Spray Arc Transfer (stainless or carbon steel) - use low tapFor Flux Cored Wire (all types) - use low tapNR - Not Recommended* The best connection (high tap or low tap) depends on the specific welding application and personal preference.
Stainless Steel
Solid Wires Carbon Steels Solid Wires
Helium/Argon Based
Shielded Gases Argon Based Shielding Gases CO2 Shielding Gas
Welding .023" .030" .035" .045"
Current All Wire Diameters (0.6mm) (0.8mm) (0.9mm) (1.2mm) All Wire Diameters
≤ ≤ ≤ ≤ ≤ 100 amps high tap high tap high tap high tap high tap low tap
125 amps high tap high or low* high or low* high or low* high or low* low tap
150 amps high tap N R low tap low tap low tap low tap
≥≥≥≥≥ 200 amps high tap N R N R low tap low tap low tap
Figure 1 - Output Connections and Guidelines
12
Lift the gas cylinder carefully onto the tray at the rear ofmachine. Fasten the cylinder securely using the suppliedchain. Attach gas hose to a gas regulator on gas cylinder.For normal operation using the GunMaster 250, gas flowshould be set to approximately 21 - 25 cfh. Avoid excessivegas flow as this can lead to weld defects. (Gas is notrequired when using self shielded/gasless wires)
Gas flow can be checked without welding by setting thevoltage selector switch on the front of the machine in theupright position pointing to the gas flow symbol. In thisposition gas flow can be checked and the welding linespurged without wire feeding or welding voltage being pre-sent.
Joint PreparationThe joint to be welded must be prepared. During welding,those parts of the workpiece are heated by the arc andmelt, this molten material mixes with the weld metal ofthe wire or electrode. To make sure that fusion is goodand to avoid impurities in the molten pool, it is necessaryto clean the surfaces of the joint carefully. Therefore, usea wire brush to remove rust, paint and other forms ofcontamination where welding is to be carried out. Thearea to be welded must also be dry.
Fit-up between the parts to be welded together must beadjusted so that the joint gap is uniform from end to end.In the case of light-gauge materials, welding can eitherbe done from one side or both, depending on the strengthrequired. For heavier materials, start with a root beadand then fill up the joint with a sufficient number of passes.
A new welding process commences when thetrigger is pulled again. Max plate thicknesswhen spot welding is about 14 gage. If theplates are of different thickness, weld fromthe thin side.
Interval (Stitch) Welding (- - -)This form of welding is particularly suitablewhen working with very thin or inferior plateor when the gap size is large since it givesa cooler weld.
The spot welding control knob is used toset the welding time. The interval timecontrol knob is used to set the pause time.
Both welding time and pause time can be setsteplessly between 0.2 and 2 sec. For weldingvoltage and wire feed speed settings, see therecommendation table on page 14.
Pull the trigger to start the welding process.When the set welding time has elapsed,the process is automatically interrupted andstarts again after the pause time haselapsed.
The process continues as long as thetrigger is pulled. The molten pool of metalis cooler and the risk of burning throughis considerably reduced.
Burn-back TimeThe Power Compact has adjustableburnback time from 0-250ms. This ispreset when supplied from ESAB. Thepotentiometer is located inside themachine above the feed unit. Use a smallscrewdriver and adjust carefully.
How To Select Welding Data – Seam Welding
VOLTAGE
WIRE
FEED SPEED
Switch the power supply on by means ofthe main switch. This will cause the light-emitting diode in the switch to light up.
Set the voltage-setting switch to the correctposition1-10.(see recommendation tableon page 13).
Note!Do not adjust the voltage control whilewelding. Stop welding, click switch tonew position and begin welding again.The recommendation table also showsthe best inductance output forconnection of the return cable.
Set the wire feed speed (current) with thepotentiometer graded 1-10.
(See recommendation table on page 14)
Note!
Wire feed speed (current) can be adjustedwhile welding.
Pulling the trigger on the gun starts the welding process,releasing the trigger stops it.
First do a sample weld on a clean piece of plate.
According to the results adjust as follows:
Caution! In most cases, the preset value should be used.
SPOT WELD
TIME
STITCH WELD
TIME
BURN BACK
POT
Spot Welding (•••)In most cases, spot welding is done from oneside to join two overlapping plates.
For spot welding purposes, the gun mustbe fitted with a spot welding nozzle.
If spot welding is required, use the spotwelding control knob to set time. The spotwelding time can be set steplesslybetween 0.2 and 2 sec. For weldingvoltage and wire feed speed settings, seethe recommendation table on page 13.
Pull the trigger. When the set spot weldtime has elapsed, the process isautomatically interrupted without thetrigger needing to be released.
ON
OFF
13
Welding Process
A factor which influences the depthof penetration is how the weldinggun is moved during welding.Trailing welding (welding towardsthe body) increases the penetra-tion depth.
If instead the gun is pushed awayfrom the body, penetration depthis reduced.
A short arc gives a deeperpenetration.
In the case of down-welding,penetration depth is heavilyreduced and is at a minimumin vertical down-welding. Inup-welding penetration isdeep.
A long arc gives shallower pene-tration. A long arc also increasesthe risk of welding spatter.
Changing Set Up For DifferentMaterials
Stainless SteelStainless steel uses similar set ups as required for mildsteel. You may want to use a new steel liner to avoidcontamination from particles left behind when weldingwith mild steels. The gas mixture required will be diffe-rent and may differ according to the grade and thicknessof the stainless steel being welded. Seek advice fromyour local ESAB distributor or gas supplier.
Gasless / Self shielded wiresAs the name implies, no gas is required for these wires.Mainly only used when welding outdoors where wind mayaffect shielding gas coverage.
Gasless wires and some cored wires require that thewelding polarity be changed to reverse polarity.
With the reverse polarity feature, change the short leadcoming out the front of the machine from the ‘positive’gun terminal to one of the two ‘negative’ terminals (A orB). The return cable should now be connected to thepositive gun terminal. (See illustration on page 9).
OverloadThe machines are fitted with thermostats which shut downthe unit should it become overheated. The LED on thefront panel will light to show that the thermostat hastripped. The thermostats will automatically reset oncethe unit has cooled.
MaintenanceMinimal maintenance is required to keep yourMigMaster 210 in good working order. Keep the drivemechanism free of dust and dirt by regular cleaningwith a brush. Remove the covers and blow out unitusing soft, dry compressed air at least once per year.Keep the cables and leads in good working conditionand away from grease, oil, solvents or water. Havean electrical technican immediately replace anydamaged or worn cables. Replace the Mig gun wearparts and lead as required due to normal usage wearand tear.
14
Note! Faults in the electrical parts such as the control circuits, relays, switches,transformers, etc. This should only be attended to by a qualified service technician.
Common Welding Faults
FaultsWire does not move forwarddespite rotation of feed rollers.
Irregular wire feed.
Arc will not strike.
Arc too long and irregular.
Arc to short.
Porosity
Inadequate joint fill.
Lack of fusion.
Spatter.
Uneven joint
Poor Penetration
Possible Causes1. Pressure roller inadequately loaded.
2. Dirt in wire guide or contact nozzle.
1. Faulty worn contact tip.
2. Dirt in groove of feed roller.
3. Feed roller groove worn.
1. Poor contact between return clamp and workpiece.
2. Voltage switch in the wrong (gas purge) position.
Voltage too high.
Voltage too low
1. Incorrect gas flow.
(Recommend 8-10 l/min).
2. Inadequate gas shielding due to spatter in thenozzle.
3. Breezy workplace.
4. Welding distance too long.
5. Incorrect gun angle.
6. Damp, oily or rusty workpiece.
1. Welding speed too high.
2. Voltage too low relative to welding speed.
1. Irregular movement of gun.
2. Voltage too low.
1. Voltage too high or too low.
2. Gas nozzle dirty.
1. Wire tip too long.
2. Current too high relative to voltage.
3. Welding speed too low.
Current too low relative to voltage.
15
Dimension Diagram
Assembly Diagram
R-Pin
Figure 2 - Assembly and Dimensional Diagrams
11.8”
18.75”
Spacers
16
Recommended Welding ParametersMigMaster 210
Figure 3 - Welding Parameters
17
MigMaster 210 Electrical Drawing (1~ 208 / 230V)
Figure 4 - Electrical Diagram
The input terminal board at (K11) on Fig. 4 shows the 230V and 208V (dotted lines for the 208V change over).Change over is made by removing the right side panel below the wire feed compartment and switching the primarytransformer taps on the terminal block. Both voltage taps (the 230V currently connected, and the (unused 208V(200V) alternate) are marked with the input voltage requirement. All units are supplied from the factory for the highestvoltage (230VAC). Before switching the voltage taps, verify the actual voltage requirement as well as the currentvoltage connection to be certain re-connection is necessary. If voltage tap re-connection is necessary re-connect asindicated in the Electrical diagram above.
Only qualfied personnel should make these changes. Make certain the primary power has been disconnectedand all safety procedures have been followed before proceeding with these instructions.
Input Electrical Change Over - 230V to 208V
Inp
ut
Ele
ctri
cal
Ch
ang
e O
ver
- 23
0V t
o 2
08V
(20
0V)
OK
C50
* W
ith a
Sho
rt L
ead
18
MigMaster Spare Parts List - Spare parts should be ordered from your nearest ESAB supplier.When ordering, indicate model, serial number, description and part number according to the spare parts list.
Description Part No. Symbol
1 Platform 0367204003
2 Rubber mat 0320539006
3 Upper Right Side Panel 0558002420
4 Lower Right Side Panel 0558002421
5 Rubber Wheel (2 Req’d) 0229206402
6 R-Pin Locking (2 Req’d) 0558002422
7 Swivel castor (2 Req’d) 0369729001
8 OKC-50 Cable connector 0160362881
9 Front panel with text 0558002423
10 Indicator lamp (temp) 0369733001 K38
11 Switch (on/off) 0193317004 K5
12 Knob (voltage) 0318113003
13 Knob (timers) 0466175001
14 Left Side panel with text 0558002424
15 Knob (wire feed) 0466175002
16 Fixing handle (right) 0369559001
17 Fixing handle (left) 0369559002
18 Pipe handle 0369567002
Item No.
MigMaster Spare Parts List (Figure 5)
Note: To replace entire Reverse Polarity 0558002432
19
1 2
3
4
5
6
7
8
9
10
11
12
13
14
15
1617
18
MigMaster 210 Spare Parts (Figure 5)
Figure 5 - MigMaster 210 Front View
20
Item No.
MigMaster 210 Spare Parts (Figure 6)
19 Diode bridge complete 0558002425 K2
20 Thermostat 0320918001 K31, 1
21 Resistor spiral 0367768001 K15
22 Auxiliary transformer 0367524001 K9
23 Secondary fuse (slow) 3.15A 0567900112
24 Connection block 0040705501
25 Middle plate 0466217001
26 Control PC Board 0558002745 M8
27 Switch (voltage) 0466356001 K6
28 Contactor 0193356101 K8, 4
29 Transformer (1 phase) 0367540880 K1
30 Bottom plate 0367214001
31 Inductor 0321105881 K12
32 Gas cylinder platform 0558002426
33 Rear axle 0558002427
34 Resistor 50 OHM, 50W 0192579211 M12
35 Capacitor 20,000µF 50V 0367525001 K88
36 Capacitor 1µF 0046006704 K27
37 Resistor 5.6K OHM 0191093146 K27
38 Connection block 2 pole 0193275001
39 Fan 230V 0365539001 K28
40 Air inlet grill 0319498038
41 Rear Panel 0558002428
72 Wheel Spacer (2 Req’d) 0558002429
Description Part No. Symbol
21
MigMaster 210 Spare Parts (Figure 6)
19 20 21 2223 2425
26
27
28
293031
32
33
3435
37
36
38
39
40
41
Figure 6 - MigMaster 210 Internal Right Side View
72
22
Item No.
MigMaster 210 Spare Parts (Figure 7)
Description Part No. Symbol
42 Solenoid valve 0193054002
43 Gas hose 6 ft. (No Fittings) 0190315102
43A Nipple, Push 35N22
43B Nut,Hose 136Z08
44 Wire reel hub 0146967881
45 Connection block 8 pole 0162781007 K11
46 Inching button 0193793001 K5, 1
47A Wire feed unit 0369951882
47B Wire Feed Motor 0466489001 M4
48 Rubber hose 0191954101
49 Adjusting board 0481748882
50 Chain 0321173001
51 Support bracket 0318170001
52 Main cable (16 ft.) 0367764881
71 Support For Front Wheels 0558002430
23
MigMaster 210 Spare Parts ( Figure 7)
42 43 44
45
46
47B
48
4950
51
52
Figure 7 - MigMaster 210 Internal Left Side View
Burn BackTime
47A
71
Item No. Description Part No.
MigMaster 210 Spare Parts (Figure 8)
54 Pressure device 0368749880
55 Pressure arm compl. 0367529001
56 Rivet 0211501348
57 Locking washer 0192859009
58 Nozzle in 0367206001
59 Wire guide in (5.12 in.) 0157349001
60 Screw 0212108041
61 Bracket 0369306001
62 Feed roller .023/.030-.035 Fe, SS 0367556001
Optional Feed roller .030 - .035 Cored 0558002433
63 Insulating washer 0153043002
64 Nozzle out 0466063880
65 Power clamp 0369735001
66 Nut (M8) 0212602009
53 Wire Feeder Motor 0466489001
*
*
Supplied With Machine
67 Power sleeve 0369950001
68 Insulating sleeve 0368750001
69 Cable set 0367543883
70 Gun connection 0368754001
Description Part No.
MigMaster 210 Spare Parts (Figure 8)
Figure 8 - MigMaster 210 Wire Feeder Assembly
Welding clamp 82F31
Work Assembly 32995
MigMaster 210 Spare Parts (Items Not Illustrated)
Option: Primary Extension Cord 37833
Option: V Feed Roll 023/030/035 SS 0367556001
Option: Serrated Feed Roll 030/035 Cored 0558002433
26
27
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
Central Distribution Center Telephone: (800)783-5360 / Fax: (800) 783-5362
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
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
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
G. WELDING PROCESS ASSISTANCE:Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
ESAB Welding & Cutting Products, Florence, SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES
F15-690 6/2002