Migmaster 300i cvcc
MIG/TIG/STICK WELDING PACKAGE
P/N 34677
INSTALLATION AND OPERATION for
Be sure this information reaches the operator.
You can get extra copies through your sup-
plier.
F-15-094-A
October, 1994
F-15-094-A
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe
practices for electric welding equipment, we urge you to read our booklet, ‘‘Precautions and Safe Practices for Arc Welding,
Cutting, and Gouging,’’ Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT
attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully
understand these instructions, contact your supplier for further information.
ESAB Welding & Cutting Products
PO Box 100545
Florence SC 29501-0545
2
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the
instructions provided. This equipment must be checked periodically. Defective equipment should not be used.
Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such
repair or replacement become necessary, the manufacturer recommends that a telephone or written request
for service advice be made to the Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a
service facility designated by the manufacturer.
3
TABLE OF CONTENTS
SECTION NO. PAGE NO.
SECTION 1 - GENERAL SAFETY RULES FOR WELDING AND CUTTING ........................... 2
GENERAL PRECAUTIONS ....................................................................................................... 2
ADDITIONAL SAFETY INFORMATION .................................................................................... 4
PRECAUTION SYMBOL DEFINITIONS .................................................................................... 5
SECTION II - INTRODUCTION
2.1 GENERAL ..................................................................................................................... 6
2.2 RECEIVING-HANDLING ............................................................................................... 6
2.3 DUTY CYCLE................................................................................................................ 6
2.4 DESCRIPTION .............................................................................................................. 6
2.5 OPTIONAL EQUIPMENT .............................................................................................. 7
2.6 SAFETY ........................................................................................................................ 8
SECTION III - INSTALLATION
3.1 LOCATION .................................................................................................................... 9
3.2 REAR WHEEL ASSEMBLY .......................................................................................... 9
3.3 PRIMARY (INPUT) ELECTRICAL CONNECTIONS ...................................................... 9
3.4 SECONDARY (OUTPUT) WELDING CONNECTIONS ................................................ 10
3.5 TORCH CONNECTIONS .............................................................................................. 10
3.6 WIRE FEEDER MECHANISM....................................................................................... 10
3.7 CONNECTION OF SHIELDING GAS SUPPLY ............................................................. 11
3.8 WELDING CABLE CONNECTIONS ............................................................................. 13
SECTION IV - OPERATION
4.1 CONTROLS .................................................................................................................. 13
4.2 OPERATING PROCEDURES ....................................................................................... 14
4.3 WELDING SETUP ....................................................................................................... 15
SECTION V - MAINTENANCE
5.1 INSPECTION AND SERVICE ....................................................................................... 28
4
SAFETY PRECAUTIONS
(TBS)
5
(TBS)
6
II. INTRODUCTION
2.1 GENERAL
This manual has been prepared for experienced weld-
ers. Do NOT permit untrained persons to install, oper-
ate or maintain this equipment. Do NOT attempt to
install or operate this equipment until you have read and
fully understand these instructions.
This manual is intended for use in familiarizing person-
nel with the design and operation of this equipment. All
information presented here should be read carefully
before installing and using this equipment.
2.2 RECEIVING-HANDLING
Upon receipt of this equipment, clean all packing mate-
rial from around the unit and immediately inspect for
any damage that may have occurred during shipment.
Any claims for loss or damage occurring in transit must
be filed with the carrier. The carrier will furnish a copy
of the bill of lading and the freight bill on request, if the
need to file a damage claim arises.
When requesting information regarding this equip-
ment, make sure that you include product name, part
number, and serial number.
2.3 DUTY CYCLE
The duty cycle of the equipment is the percentage of a
10 minute period which it can operate safely at a given
output current. The Migmaster 300i is rated at 300
amps at 40% duty cycle and 250 amps at 60% duty
cycle..
2.4 DESCRIPTION
The Migmaster 300i is a DC welding system designed
for Mig Welding(GMAW), Tig(GTAW) or Stick(SMAW).
In the Mig mode this unit is capable of operating with
short arc or spray arc transfer and handles both solid
wires and tubular cored wires. This unit is suitable for
carbon steel, stainless steel, aluminum and many other
alloys. It provides a power source with built in wire
feeder and undercarriage with provisions for one gas
cylinder.
2.4.1 AVAILABLE PACKAGES AND
CONTENTS
Each of the following packages include the power
source, with the built-in wire feeder, factory installed
19.5''
32.25''
undercarriage and cylinder rack, MT-200cc Mig Torch
(with .035" and .045" accessories), dual groove feed
rolls (.035"/.045"), regulator and adjustable flowmeter,
6' gas hose, 10' work cable and clamp, 8' primary cable
(with plug and receptacle), Mig Welding Handbook, Tig
Welding Handbook, and set-up guide.
Description Part Number
Migmaster 300i cvcc
w/12' MT-200cc Torch 604576
Migmaster 300i cvcc
w/15' MT-200cc Torch 604577
Figure 2.3 Dimensions
2.4.2 POWER SOURCE
The power source consists of an inverter DC power
source for single phase 208 or 230 primary connection.
2.4.3 WIRE FEEDER
The wire feeder is built into the power source cabinet,
housed separately from the welding machine electrical
components. Cooling air is not drawn through the wire
feeder mechanism, reducing its exposure to dirt and
dust.
The wire feeder pushes wire at speeds up to 655 ipm
(inches per minute). The purge/inch switch mounted
inside the power source cabinet allows the operator to
advance the wire without welding voltage.
40''
7
TABLE 2.1. SPECIFICATIONS
Rated DC Output...............................................
40% duty cycle..................................................300 amps @ 32 vdc
60% duty cycle (NEMA Class I).........................250 Amps @ 34 vd
c
Output Current Range.......................................
Mig (GMAW)...............................................................35 - 300 amp
s
Tig (GTAW)................................................................10 - 300 amps
Stick (SMAW)............................................................40 - 300 amps
Output Voltage (open circuit):............................
Mig (GMAW).........................................................................40 vdc
Tig (GTAW) ..........................................................................40 vdc
Stick (SMAW)...............................70 vdc (51 vdc shown on display)
Rated Primary Input @ 300 amp rated load: ...................................208/230 vac, 72/65 amps, single phase, 50/60
Wire Feed Range: ...................................................................................................................................65 - 655 ip
m
Dimensions (with cylinder rack and
wheels):.............................................................
length......................................................................40" (1016 mm)
width....................................................................19-1/2" (495 mm)
height ..................................................................32-1/4" (819 mm)
Weight (no cylinder): ...........................................................................................................................175 lbs. (80 kg
CSA..................................................................................................................................................approval pendin
g
2.4.6 RUNNING GEAR
The Migmaster 300i is equipped with a running gear
with swiveled front wheels and a gas cylinder support.
The rear wheels are packed loose for shipping but are
easily installed, as described in Section 3.8.
2.5 OPTIONAL EQUIPMENT
2.5.1 Mig 41A Push/Pull Mig Torch Assembly; includes
liner, contact tip, feed roll and nozzle.
15 ft, .035" soft wire ...................................... 604417
25 ft, 3/64" soft wire ...................................... 604578
2.5.2 Mig 41A Push/Pull Basic Mig Torch; does not
include liner, feed roll or contact tip; order separately
(see Form F-7036).
15 ft Basic ....................................................... 20506
25 ft Basic ....................................................... 20536
2.5.3 HW-17TV-2 (w/valve) Heliarc Tig Torch; 60 deg
head, 17 ft; ................................................ 33814CS
TIG weld without disconnecting the Mig torch. Includes
HW-17TV body, handle, long cap, cable cover, contactor
switch and cable, power adaptor, and gas hose.
2.4.4 MT-200cc TORCH
This air-cooled welding torch is supplied complete and
ready to weld 0.035 in. hard wire. The torch accommo-
dates 0.045 inch wire by changing the contact tip. Other
wire sizes can be used. Refer to Table 2.2 and Table 2.3
for other wire size accessories.
2.4.5 CONTROLS
The Migmaster 300i can be used to weld hard, alumi-
num, and flux cored wire . Control of the power source
and its different applications is provided by the 2 line, 32
character display screen. The operator selects the
process desired on a three position rotary switch
located on the front panel. A detailed description of the
power source controls is included in Section III (Opera-
tion) of this manual.
8
Wire
Size & Type
Standard Duty Contact Tips* Liners
Short Medium Long 10' 12' 15'
Hard Wires &
Cored Wires
-- 20543 999742 999743** -- --
.023" (.6mm)
.030" (.8mm) -- 20544 996994 948850 17717 --
.035"(.9mm) -- 996995 996996 2075237 17718 2075238
.045"(1.2mm) 999578 996999 996998 2075237 17718 2075238
.052"(1.4mm) 948340 2075349 -- 2075239 17719 2075240
1/16"(1.6mm) 948341 996997 -- 2075239 17719 2075240
Soft Wires
(aluminum)
-- 996995 996996 948862 -- --.035"(.9mm)
3/64" 999578 996999 996998 948863 -- --
* Short contact tips are generally recommended to give proper wire stick out for flux cored wire welding.
Medium contact tips are generally recommended to give proper wire stick out for spray arc Mig welding.
Long contact tips are generally recommended to give good visibility and proper wire stick out for short
arc Mig welding.
** Requires support liner for .023" wire. Order P/N 999797.
*Requires support tube. Order P/N 21169
Nozzle
Desc. I.D.
Standard
Duty
Heavy
Duty
#6 Tapered 3/8" 998895 -
#8 1/2" 998893 999471
#10 5/8" 998894 999472
#12 3/4" - 999473
#12 Spot 3/4" 17316 999625
2.5.4 HW-17cc Heliarc Tig Torch;
60 deg head, 12-1/2 ft. ........................... 16X48cc
Torch plugs into same front panel connector as the MT-
200cc; convert from Mig to Tig quickly and have gas
control through the power source. Includes body,
handle, long cap, cable cover, contactor switch and
cable “cc” connector.
2.5.5 HC-6 Hand Control; 25 ft. ..................... 21225
Attach to welding torch for remote hand control of
output and trim functions.
2.5.6 FC-6 Foot Control; 25 ft. ....................... 33517
Remote foot control of output and trim functions.
2.5.7 Stick Electrode Holder Assembly .......... 21226
Assembly includes holder, cable and twist lock connec-
tor, 15 ft.
2.5.8 Hub Adaptor .......................................... 17511
Required for 8-in. spools
Table 2.4 Slide-on Nozzles
(MT-200cc & MIG-41A)
*Uses Nozzles Adapter P/N 999452.
2.6 SAFETY
The safety section at the front of this manual should be
read completely before attempting to install and oper-
ate this equipment. Both equipment and personnel
hazards are reduced if proper safety precautions are
taken. If you are unsure of yourself in any situation, ask
your supervisor or other experienced personnel for
help.
Wire
Size & Type
Guide
Tube
Feed
Roll
Hard Wires -
"V" Groove
21163 21155
.023"(.6mm)
.030"(.8mm) 21164 21155
.035"(.9mm) 21165 21156
.045"(1.2mm) 21165 21156
Cored Wires -
Serrated
21164 21160.030"(.8mm)
.035"(.9mm) 21165 21160
.045"(1.2mm) 21165 21161
.052"(1.4mm) 21166 21161
1/16"(1.6mm) 21166 21161
Soft Wires
(aluminum)-
"U" Groove
21167" 21158
.035"(.9mm)
3/64"(1.2mm) 21168* 21158
Table 2.3 Guide Tubes and Feed Rolls
Table 2.2 Contact Tips and Liners
9
Before making electrical input connections to the
welding machine, “Machinery Lockout Procedures”
should be employed. If the connections are to be
made from a line disconnect switch, the switch
should be padlocked in the off position. If the
connection is to be made from a fusebox, remove
the fuses and padlock the cover closed. If no
locking facilities are available, attach a red tag to
warn others not to energize the circuit.
3.3.1 Input Electrical Requirements
The primary input voltage requirements are shown on
the power source nameplate. The power source is
designed to be operated from 208/230 single phase 50/
60 Hz.
Figure 3.1 Primary Connections
3.3.2 Input Conductor Connections
The input power cord is provided with an attachment
plug. The plug will mate with a 250 Volt, 50 Amp
receptacle conforming to NEMA 6-50R configuration.
The receptacle should be wired to a separately fused
disconnect or circuit breaker. This disconnect or breaker
can be wired to a single phase system or to two
conductors of a three phase system. A third conductor
for grounding should also be connected between the
disconnect and the receptacle.
The terminal labeled GRD is connected to the power
source chassis and is for ground purposes only. It
must be connected to a good electrical ground. Do
not connect a conductor from the terminal labeled
GRD to any one of the L1, L2 terminals as this will
result in an electrically hot machine chassis.
III. INSTALLATION
3.1 LOCATION
Several factors should be considered when selecting
an installation site. Adequate ventilation is necessary
to provide cooling, and the amount of dirt and dust to
which the machine is exposed should be minimized.
There should be at least 18 inches of unrestricted
space between the machine’s side and rear panels and
the nearest obstruction to provide freedom of air move-
ment through the power source.
The installation site should permit easy removal of the
machine outer enclosure for maintenance. Installing or
placing any type of filtering device will restrict the
volume of intake air, thus subjecting the power source
internal components to overheating. Warranty is void
if any type of filtering device is used.
Do not operate the machine without the running
gear installed.
3.2 ASSEMBLE REAR WHEELS
The units’ running gear is factory assembled except for
the rear wheels which are packed loose and in the
shipping carton. The rear gear consists of 2-wheels, 4
washers, 2-cotter pins, and an axle. To install the gear,
do the following:
A. Insert the axle through the holes provided at
the rear of the gear.
B. Place a washer onto each end of the axle, then
slip on the wheels, then add another washer to
the outside of each wheel, and secure the
whole assembly by inserting a pin in each end
of the axle.
C. Remove the existing shipping supports by un-
screwing from chassis. (Wooden lifting lever
provided.)
3.3 ELECTRICAL INPUT CONNECTIONS
In order to provide a safe and convenient means to
completely remove all electrical power from the ma-
chine, it is highly recommended that a line disconnect
switch be installed in the input circuit to the machine.
10
Figure 3.2 Voltage Changeover Terminal Board
3.4 SECONDARY OUTPUT CONNECTIONS
The Migmaster 300i Welding System is completely
self-contained so that the front panel torch fittings are
internally connected to the welding polarity (DC reverse
or DC straight) via the secondary output terminals. The
machine comes set up for DCRP welding.
3.5 TORCH CONNECTIONS
The MT-200cc torch is supplied as standard equip-
ment. Line up the matching holes, push on and tighten
the locking collar. As shipped from the factory, the
common connector type torches are set-up for DCRP
welding polarity.
3.6 WIRE FEEDER MECHANISM
3.6.1 DRIVE ROLLS
The drive roll has two grooves: the small groove feeds
0.035 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 correctly positioned, per-
form the following:
A. Release the pressure drive roll lever and lift the
assembly upward.
B. Remove the two (2) screws holding the drive
roll to the gear.
Figure 3.3 Front Panel Connections
c. Reverse the drive roll on the drive roll shaft.
d. Replace the screws and tighten.
e. Secure the pressure drive roll assembly.
3.6.2 WELDING WIRE SPOOL
As with any work area, make sure safety glasses
with side shields are worn when handling or chang-
ing wire or clipping wire off at the spool or at the end
of the torch. Hold onto the wire coming off the
spool with one hand before clipping. Serious eye
injury can result due to the resilience of the wire
which can quickly unravel, or a cut wire end which
may shoot across the room.
Install a spool of welding wire on the hub as follows:
11
A. Unscrew spool nut from hub.
B. Place wire spool on hub to rotate clockwise as
wire is unwound; hub pin must engage hole in
spool.
C. Replace nut.
3.6.3 THREADING WELDING WIRE
A.Turn off power switch.
When the power switch is on, and gun trigger is
depressed, the electrode wire becomes electrically
hot, and the wire drive rolls will run.
B. Release pressure drive roll assembly and lift
upward. Check that proper wire diameter
groove is in the inner position.
Before threading welding wire through liner, make
sure chisel point and burrs have been removed
from wire end to prevent wire from jamming in gun
or liner.
C. Feed the wire from the spool through the inlet
guide, across the drive roll groove and into gun
outlet guide.
Make sure that the proper “outlet guide tube” is inserted
into the front-panel gun fitting for the size and type of
wire being used, see Table 2.3 for wire feed accesso-
ries.
To ensure proper wire feeding, it is important that the
wire be kept clean and that the drive rolls be periodically
cleaned of any chips or scale that might be carried into
the gun liner and cause sticking.
D. Lower pressure roll assembly and secure.
Check that the gears mesh. Feed wire through
to gun tip using the inch/purge switch.
3.6.4 SPOOL BRAKE DRAG ADJUSTMENT
Spool brake disc friction should provide enough drag to
keep the wire spool or core from spinning freely after
wire feed stops. If adjustment is required, turn adjusting
screw clockwise to increase drag, counterclockwise to
decrease it. Drag should be just low enough to limit wire
overrun.
Figure 3.4 Wire Feeder Mechanism
3.7 CONNECTION OF SHIELDING GAS
SUPPLY
The R-50-FM-580 regulator is an adjustable regulator
designed for use with Argon, Helium, Nitrogen, and C-
25 (75% argon/25% CO2) gas service. The following
chart provides the recommended flow ranges for the R-
50-FM-500 regulator.
Argon 10-40 CFH
Helium 25-125 CFH
Nitrogen 10-50 CFH
C-25 10-40 CFH
TO SET UP THE GAS SHIELDING SUPPLY:
A. With the cylinder cap in place, CAREFULLY
slide the cylinder of gas onto the Migmaster
300i cylinder rack.
B. Secure the cylinder to the unit, using the chain
provided.
C. Unscrew the cylinder cap.
12
Never stand directly in front of or behind the regu-
lator when opening the cylinder valve. Always
stand to one side.
E. Open the cylinder valve SLOWLY a fraction of
a turn. This will prevent damage to gauge and
critical components in the regulator. When the
gauge needle stops moving, then open the
cylinder valve fully.
TO REGULATE FLOW:
Flow is controlled by adjusting the flowmeter valve until
desired flow is indicated by the ball float in the flowmeter
tube. Always take the reading across the TOP of the
ball.
Using a leak test solution, such as P/N 998771 (8 oz.
ctr) or soapy water, test for leakage about the cylinder
valve stem, the regulator inlet connection, and the hose
connections at the regulator and at the Migmaster 300i
for leakage. Correct any leaks before starting work.
TO STOP WORK:
If work is to be stopped for a half-hour or more, the
regulator is to be removed from the cylinder, shut down
the regulator as follows:
A. Close the cylinder valve.
B. Release gas from the regulator by closing the
torch trigger lever.
C. When pressure gauge drops to zero, the regu-
lator is depressurized and shut down.
Each regulator is equipped with a porous metal inlet
filter, P/N 71233, pressed into the regulator input
nipple. No regulator should be connected to a cylinder
or station valve unless it contains this filter. You can
replace the filter if necessary. Refer to the regulator
instruction literature for details.
Regulators in need of repair should be returned to your
welding equipment distributor or to an authorized
remanufacturing center.
For a detailed description of the regulator, refer to the
R-50-FM-580 Regulator-Flowmeter Instruction Manual,
F-14-238.
TO CONNECT:
Do not clamp regulator cap in a vise or grip it with
a pair of pliers. Distortion of cap can jam the
internal parts and cause excessively high delivery
pressure as well as weaken the threaded joint to the
regulator body. This may cause cap to fly off and
possibly injure personnel in area.
A. Open the cylinder valve slightly, for an instant,
to blow out any dust or dirt that may have
collected in the valve outlet. BE SURE to keep
your face away from the valve outlet to protect
your eyes.
B. Attach the regulator to the cylinder valve. Align
the regulator so that the flowmeter is vertical
and then tighten the connection nut with a
1-1/8 in. open end or adjustable wrench. (To
prevent damaging the O-ring seals and plastic
tube, do not use the flowmeter tube as a
'handle' when attaching the regulator.)
Figure 3.5 R-50 Regulator
C. Make sure that the flow control valve on the
flowmeter is closed.
D. Attach the gas hose from the rear of the Mig-
master 300i to the regulator outlet connection.
13
If welding is performed in a confined area, shield-
ing gas flow can displace oxygen, thereby endan-
gering personnel entering the area.
3.8 WELDING CABLE CONNECTIONS
Connect the work clamp solidly to the workpiece or
work table. Clamp onto a bare metal area.
A good electrical connection to the work is essen-
tial for proper welding operation and for prevention
of electric shock.
+
—
Migmaster 300i
REAR VIEW
FRONT VIEW
Figure 3.6 Controls and Welding Cable Connections
Welding cables should be kept as short as possible and
be of adequate current carrying capacity. Resistance
of the welding cables and connections causes a voltage
drop which is added to the voltage drop of the arc.
Excessive cable resistance may result in a reduction of
the maximum usable current output of the equipment.
The proper operation of this equipment is to a large
extent dependent on the use of welding cables and
connections which are in good condition and of ad-
equate size.
IV. OPERATION
4.1 CONTROLS
4.1.1 POWER ON/OFF SWITCH
The rotary power switch is located on the back panel in
the upper right hand corner. This switch also turns on
the fan. The twelve o’clock position is the “off” position,
the “on” is one quarter turn clockwise.
14
Figure 4.1 Control Display Screen
4.1.4 SECONDARY WELDING CONNEC-
TIONS
The secondary output welding terminals, POS (+) and
NEG (-) are located on the lower front panel, directly
beneath the common connector (see figure 3.3).
4.1.5 WIRE FEED SPEED CONTROL
Wire feed speed is controlled automatically. It can be
adjusted using the arrow keys or from a remote control
while welding (fine tuning the arc).
4.1.6 MIG-41A PUSH-PULL GUN
The MIG-41A push-pull gun combines with the Mig-
master 300i to create a high performance push-pull
system. The MIG-41A synchronizes with the wire
feeder, providing an ideal means for feeding small
diameter wires or soft wires long distance.
The MIG-41A connects to the front panel of the Mig-
master 300i. The inlet connector of the MIG-41A is
inserted into the common connector and the power lead
plugs into the MIG-41A connector in the center of the
front panel.
For a detailed description of the MIG-41A, refer to the
MIG-41A Push-Pull Gun Instruction manual, F-14-497.
4.2 OPERATING PROCEDURES
4.2.1 OPERATING SAFETY PRECAU-
TIONS
Comply with all ventilation, fire and other safety
requirements for arc welding as established in the
SAFETY Section at the front of this manual.
Also remember the following:
A. Because of the radiant energy of the welding
arc and the possibility of drawing an arc before
the helmet is lowered over the face, the opera-
tor should wear flash goggles with filter lenses
under his helmet. The helmet filter plate should
be shade number 11 (nonferrous) or 12 (fer-
rous). All those viewing the arc should use
helmets with filter plates, as well as flash
goggles. Nearby personnel should wear flash
goggles.
B. The radiant energy of the arc can decompose
chlorinated solvent vapors, such as trichloro-
ethylene and perchlorethylene to form phos-
gene, even when these vapors are present in
low concentrations. DO NOT weld where
chlorinated solvents are present in at-
mospheres in or around the arc.
C. DO NOT touch the electrode, nozzle or metal
parts in contact with them when power is on; all
4.1.2 PROCESS SELECTOR SWITCH
The three position process selector switch is on the
upper right front panel. The processor selector switch
provides the visual indication of which process (Mig, Tig
or stick) has been selected.
4.1.3 CONTROL DISPLAY SCREEN
(Figure 4.1)
Welding set-up options are controlled and monitored by
use of the Display Window and the control pushbuttons.
The screen displays the settings required for the de-
sired welding process as determined by the position of
the Process Selector Switch. The Scroll Key is used to
select functions as required to select wire speed, volt-
age, trigger type, etc. The arrow keys are used to select
options. For example, the operator would use the keys
in order to select plate size. The scroll key is depressed
several times, until SEL PLATE SIZE is displayed. The
arrow keys are then depressed until the desired plate
size appears in the display.
15
are electrically energized (HOT) and can cause
a potentially fatal shock. DO NOT allow elec-
trode to touch grounded metal, it will create an
arc flash that can injure eyes. It may also start
a fire or cause other damage.
D. When working in a confined space, be sure it
is safe to enter. The confined space should be
tested for adequate oxygen (at least 19%) with
an approved oxygen measuring instrument.
The space should not contain toxic concentra-
tions of fumes or gases. It this cannot be
determined, the operator should wear an ap-
proved air supplied breathing apparatus. DO
NOT bring gas cylinders into confined spaces.
When leaving a confined space, shut off gas
supply at the source to prevent gas from leak-
ing into the confined space.
E. Never operate the equipment at currents greater
than the rated ampere capacity; overheating
will result.
F. Never operate equipment in a damp or wet
area without suitable insulation for protection
against shock. Keep hands, feet and clothing
dry at all times.
G. Whenever the equipment is left unattended,
turn all control and power supply switches and
gas supplies off and open the main line switch.
H. Wear dark substantial clothing to protect ex-
posed skin from arcburn, sparks and flying hot
metal.
I. Turn off welding power before adjusting or
replacing electrodes.
4.2.2 PRE-WELD REQUIREMENTS
Before welding commences, with all power OFF, check
the following:
A. All safety requirements have been read and
understood.
B. All hoses and cables are in good condition,
safely insulated and securely connected.
C. Turn on gas supply by slowly opening cylinder
valve to full ON.
D. Spool of correct size wire is locked in place,
brake tension is set, and wire is properly
threaded through the inlet guide to the gun tip.
E. The wire feeding compartment cover is closed
and secure.
F. Metal to be welded is properly prepared.
4.3 SET UP FOR WELDING
Work safely and follow all safety precautions listed in
the Instruction Manual.
4.3.1 MIG WELDING: GUIDED SET-UP
MODE
The Guided Set-up mode is the quickest and simplest
way of using the Migmaster 300i. Welding conditions
for a wide variety of material types, and shielding gases
have been pre-set at the factory. All that is required to
get excellent welding performance is to answer a few
questions on the front control panel.
Table 4-1 contains the actions required to set-up the
Migmaster 300i cvcc using the Guided-Set-up mode for
Mig welding.
TO FINE TUNE ARC: Press or to increase
or decrease voltage or wire feed speed for the desired
arc characteristics. These changes can be made while
welding. Make small changes when fine tuning the arc.
Too large a change will make the arc unstable.
To return to beginning of the list: momentarily press
torch trigger or turn process selector switch to Tig and
then back to Mig.
To reset to factory default settings: turn power off.
Press center scroll key and left arrow key. While press-
ing both keys, turn the power on.
4.3.2 MIG WELDING: MANUAL SETUP
MODE
A manual set up mode is selectable if you want to use
conditions that are not pre-set or if you want to set up for
a special application or condition. In the manual mode
you can manually set wire feed speed, voltage and
power supply inductance. Table 4-2 contains the
actions required to set-up the Migmaster 300i cvcc
using the manual set-up mode for Mig Welding.
16
4.3.3 MIG WELDING: SET-UP OPTIONS
There are a variety of set-up options that are available
for Mig welding. Selecting the appropriate option can
improve productivity, convenience or operator comfort.
Table 4-3 contains a list of the various options that are
available for Mig welding.
4.3.4 TIG WELDING SET-UP
Table 4-4 contains the operator actions required to set-
up the Migmaster 300i cvcc for Tig welding.
4.3.5 STICK WELDING SET-UP
Table 4-5 contains the operator actions required to set-
up the Migmaster 300i cvcc for Stick welding.
4.3.6 DESCRIPTION OF TRIGGER TYPE
OPTIONS
A. Continuous - This is the most commonly used
trigger option. When the torch trigger is de-
pressed, welding begins. When the torch
trigger is released, welding stops. The weld is
continuous as long as the torch trigger is de-
pressed.
B. Trigger Lock - Using this mode, the welding
process begins when the torch trigger is de-
pressed. Once the welding process has started,
the torch trigger may be released without af-
fecting the welding process. To stop the weld-
ing operation, the torch trigger must be de-
pressed a second time. This allows a continu-
ous weld without having to continuously de-
press the torch trigger.
C. Spot Weld - Spot welding provides a timed
weld. When this trigger type is selected an
option is added to the setting list. This option
sets the time for the spot weld duration. If the
scroll key is pressed after spot weld is se-
lected, the option "SET SPOT TIME" is dis-
played for changing the spot time duration.
Once the torch switch is pressed the option
with the spot time is moved up in the list to be
quickly accessible to trim the parameter for the
spot welding operation.
D. Stitch Welding - Stitch weld provides for the
automatic switching between welding "on" and
welding "off" while the torch trigger is pressed.
The "on/off" time for the weld is set separately.
When stitch weld is selected two options are
added to the list. "SET ON TIME" and "SET
OFF TIME". The options are handled the same
as the spot weld options described above.
E. Dual Schedule - This selection is only available
when the active list #1 is selected. When
selected, it provides the option to switch be-
tween two welding parameters during welding.
Switching is done using a short release of the
torch trigger. The first welding parameter
(voltage and wire feed speed) is from list #1.
The welding parameter switched to (voltage
and wire feed speed) are from list #2. A short
release of the torch trigger returns the param-
eters from list #1.
The bottom row of the display will not change
to show the set value from list #2 during weld-
ing using second parameters. The measured
voltage and current will show the second weld-
ing parameters.
The two welding conditions must be set up in
list #1 and list #2 before dual schedule selec-
tion is made.
4.4 WELDING OPERATION
Never operate the machine with any portion of the
outer enclosure removed. In addition to a hazard,
improper cooling may result in damage to the
welding transformer and the welding machine
components. Warranty is void if the machine is
operated with any portion of the outer enclosure
removed.
A. Turn Power switch (on unit) to ON position -- be
careful not to operate the torch switch.
B. Before starting the weld, the welding wire should
extend about 1/2-inch beyond the end of the
nozzle. Adjust this length by either clipping off
the end of the wire with insulated cutters or by
using the torch switch.
(cont. to page 26)
17
Table 4-1. Migmaster 300i cvcc Guided Set-up for the MIG Process
Display Action
Power on unit
Select MIG on the front panel selector switch
Set shielding gas flowmeter to 35 cfh
Press
to accept active list #1
Press to accept guided set-up mode.
Press to accept mild steel or press or to
change WIRE TYPE to desired material.
Note: Wire Type Options are listed in Table 4-3.
Press to accept .035" dia or press or to
change WIRE SIZE to desired diameter.
Note: WIRE SIZE options are listed in Table 4-3.
SEL ACTIVE LIST
< active list #1 >
SEL WIRE TYPE
< mild steel >
SEL SET-UP TYPE
< guided set-up >
SEL WIRE SIZE
< .035" dia >
Press to accept 75% Ar + 25% C02 or press
or to change GAS SHIELD to desired mixture.
Note: GAS SHIELD options are listed in Table 4-3.
SEL GAS SHIELD
< 75% aR + 25% CO2 >
18
Table 4-1 Continued
TRIM WIRE SPEED
v ^
TRIM VOLTAGE
v ^
TRIM BURNBACK
v ^
SEL START TYPE
< slow run in >
SEL TRIGGER TYPE
< continuous >
SEL PLATE SIZE
< 1/4" .250" >
Display Action
Press
to accept PLATE SIZE or press or
to change PLATE SIZE.
Note: PLATE SIZE options are listed in Table 4-3.
Press to accept TRIGGER TYPE.
Press to accept START TYPE.
Press to accept BURNBACK.
Press to accept VOLTAGE.
Press to accept WIRE SPEED.
The shaded boxes are the only selections required to be modified by the operator when using the guided set-up mode.
The non-shaded boxes provide advanced settings or other special functions and are detailed under the Migmaster 300i
manual setup procedures.
19
Power on unit.
Select MIG on the front panel selector switch.
Set shielding gas flowmeter to 35 cfh.
Press to accept displayed active list or press or to
select desired active list.
Press to change to the manual set-up mode.
Press to accept displayed wire type or press or to
change WIRE TYPE to desired material.
Note: Wire Type options are listed in Table 4-3.
Press to accept displayed WIRE SIZE diameter or press
or to change WIRE SIZE to desired diameter.
Note: Wire Size options are listed in Table 4-3.
Table 4-2. Migmaster 300i cvcc Manual Set-up for the MIG Process
Display Action
SEL WIRE SIZE
< .035" dia >
SEL SET-UP TYPE
< guided set-up >
SEL WIRE TYPE
< mild steel >
SEL ACTIVE LIST
< active list #1 >
20
Display Action
SEL GAS SHIELD
< 75% Ar + 25% CO2 >
Table 4-2 Continued
Press
to accept displayed GAS SHIELD mixture or press
or to change GAS SHIELD to desired mixture.
Note: Gas Shield options are listed in Table 4-3.
Press to accept displayed TRIGGER TYPE or press or
to change to desired TRIGGER TYPE.
Note: Trigger Type options are listed in Table 4-3.
This display will appear when stitch weld is selected as TRIGGER
TYPE.
Press
to accept displayed ON TIME.
Press to decrease ON TIME.
Press to increase ON TIME.
This display will appear when stitch weld is selected as TRIGGER
TYPE.
Press to accept displayed OFF TIME.
Press to decrease OFF TIME.
Press to increase OFF TIME.
This display will appear when spot weld is selected as TRIGGER
TYPE.
Press to accept displayed SPOT TIME.
Press to decrease SPOT TIME.
Press to increase SPOT TIME.
SEL TRIGGER TYPE
< continuous >
SET ON TIME
v 1.2 seconds ^
SET OFF TIME
v 1.2 seconds ^
SET SPOT TIME
v 1.0 seconds ^
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