Instruction Manual

0558008552 07 / 2009

Welding Package

Migmaster 275

OPTIONAL

DIGITAL METER

MODULE

OPTIONAL

BURN BACK

diately. 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 it was 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 ser-

vice facility designated by the manufacturer.

2.1 GENERAL ........................................................................................................................................................................................................17

2.2 RECEIVING-HANDLING ..............................................................................................................................................................................17

3.3 SECONDARY OUTPUT CONNECTIONS .................................................................................................................................................24

3.4 TORCH CONNECTIONS ..............................................................................................................................................................................25

3.5 WIRE FEEDER MECHANISM ......................................................................................................................................................................25

3.6 CONNECTION OF THE SHIELD GAS .......................................................................................................................................................26

3.7 WELDING CABLE CONNECTIONS ..........................................................................................................................................................26

3.8 INSTALLING OPTIONAL BURN BACK MODULE .................................................................................................................................27

3.9 INSTALLING OPTIONAL DIGITAL METER .............................................................................................................................................27

4.1 CONTROLS .....................................................................................................................................................................................................29

4.2 PROCESS SETUP ...........................................................................................................................................................................................31

6.1 GENERAL ........................................................................................................................................................................................................43

6.2 ORDERING .....................................................................................................................................................................................................43

TABLE OF CONTENT

SECTION 1 SAFETY PRECAUTIONS

1.1 Safety - English

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes,

and a welding helmet or cap for hair protection, to

protect against arc rays and hot sparks or hot metal.

A ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated from

the front of clothing.

glasses.

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ammable covering. Combustible materials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

workpiece has been completely cleaned so that there

are no substances on the workpiece which might

produce ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

not modify it in any manner.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

6. AWS C5.6 - "Recommended Practices for Gas Metal

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

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

SECTION 2 INTRODUCTION

This manual has been prepared for use in familiarizing per-

sonnel with the safe installation, operation, maintenance,

and troubleshooting of this equipment. All information

presented here in must be given careful consideration to

assure safe operation and use of this equipment.

Upon receipt, carefully inspect for damage that may have

occurred during shipment. Claims for loss or damage that

in the box below for future reference.

Date / /

Model Name

Stock Number

Serial Number

The Migmaster 275 self contained welding system is designed

to deliver superior performance using short arc, spray arc, as

well as ux and metal cored wires ranging from .023 (.6mm),

to 1/16" (1.6mm) diameter.

to weld 0.035 / 0.045 in. steel wire.

Quick connect output receptacles provide for easy polar-

ity reversal as well connection point for an optional Spool

Gun.

The built in Spool Gun Control can be used to weld hard

and aluminum wire with an optional MT-250SG or ST-23A

spool-guns.

The built in running gear assures convienent shop mobility

and features a cylinder tray and support.

SECTION 2 INTRODUCTION

This easy-to-install, plug-in module enables the use of

an adjustable Anti-Stick feature that allows adjustment

of burnback time to prevent wire sticking at the end of

a weld. See Sec 3.8 Installation and Sec. 4.2 Operation -

Process Setup.

For Spot Welding, Spotweld Nozzle, P/N 0885001602 is

recommended.

SECTION 2 INTRODUCTION

SECTION 2 INTRODUCTION

Proper installation permits free air movement into and out

of the unit and minimizes exposure to dust, dirt, moisture,

and corrosive vapors. A minimum of 18 inches (46 cm)

unrestricted space must be maintained between the rear

panel and the nearest obstruction.

restrict air intake and cause an overheating

condition and possible failure. Warranty is

void if any type of ltering device is used.

If a forklift vehicle is used for lifting the unit, be sure that

the lift forks are long enough to extend completely under

the base.

Do not operate the machine without the running gear

installed.

A line disconnect switch must be installed in the input circuit

SECTION 3 INSTALLATION

208 66 90 6 8

230 61 80 8 8

380 37 50 10 10

380 (50Hz) 38 50 10 10

400 36 50 10 10

400 (50Hz) 36 50 10 10

Figure 3.2A illustrates wiring to a single phase system and

Figure 3.2B illustrates wiring to a three phase system.

The 208/230/380/400/460/575 primary input voltage unit is

provided with a three conductor primary input cable without

plugcap. The ground lead of this cable must be connected

to a reliable ground and the two remaining wires must be

connected to the separately fused lines of the disconnect

SECTION 3 INSTALLATION

Fig. 3.3A shows the 230v and 208v connections for the

208/230 dual voltage model. Change over is made by remov-

ing the right side panel below the wire feed compartment

and switching the primary transformer tap at the top of the

Before switching the voltage taps, verify the actual voltage

requirement as well as the current voltage connection to

be certain re-connection is necessary. If voltage tap re-

connection is necessary, the following paragraphs cover

the procedure to switch the voltage tap for either 208vac

or 230vac input.

and cut the tie-wrap to remove the insulation sleeving (on

early models this lead may have been wrapped with black

electrical tape). Open the insulating cover around the power

switch (Fig. 3.3C.) to expose the terminals and disconnect

the 230 Vac lead from the top of the switch as shown in Fig.

3.3A. Insulate the 230 Vac lead that was removed from the

power switch with sleeving or approved electrical tape

and re-position to a safe area beside the transformer (see

Fig. 3.3B), leaving a minimum of one inch clearance from

other components and the side panel.

SECTION 3 INSTALLATION

SECTION 3 INSTALLATION

SECTION 3 INSTALLATION