ESAB Migmaster 215 Pro User manual

Brand: ESAB

Model: Migmaster 215 Pro

Category: Welding System

Type: User manual

ESAB Migmaster 215 Pro is a welding power source designed for a variety of welding tasks for both professionals and hobbyists. This powerful and versatile machine is suitable for welding different materials including steel, stainless steel, aluminum, and flux-cored wire. With its compact design and intuitive controls, the Migmaster 215 Pro is easy to use and allows for precise welding. It features adjustable voltage and wire feed speed, enabling you to customize the welding parameters based on the thickness and type of material being welded.

0349 300 092 Valid for serial no. 012, 014--xxx--xxxx100621

Migmaster 215 Pro

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TOCe

READ THIS FIRST 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TECHNICAL DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM, Migmaster 215 Pro 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Migmaster 215 Pro, 208/230V 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Migmaster 215 Pro, 208/230V 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Migmaster 215 Pro, 208/230/460/575V 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Migmaster 215 Pro, 208/230/460/575V 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 Control board 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:1 Power supply 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:2 Start / Stop 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:3 Spot welding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:4 Wire feed speed, creep start 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:5 Motor control 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:6 Burnback time, contactor, gas valve 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:7 Thermal overload cutout 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 -- Migmasterr 215 Pro component positions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AR Control board 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AR component positions 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AR diagram 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2 Digital instrument 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2:1 Calibration and voltage correction 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is ESD? 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermal switch (thermostat) replacement procedure 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mains power supply 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection and control devices 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching--on and overheating protection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the wire feed pressure 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and cleaning 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT TRACING 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING OF SPARE PARTS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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READ THIS FIRST

Maintenance and repair work should be performed by an experienced person, and

electrical work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault--tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit

board is divided into numbered blocks, which are described individually in more detail in

the description of operation. All component names in the wiring diagram are listed in the

component description.

This manual contains details of all design changes that have been made up to and

including June 2010.

The Migmaster 215 Pro is designed and tested in accordance with international and

European standard IEC/EN 60974--1 and EN 60974--10.

On completion of service or repair work, it is the responsibility of the person(s) etc.

performing the work to ensure that the product does not depart from the requirements

of the above standard.

INTRODUCTION

Migmaster 215 Pro is step controlled power source in a compact design, intended

for welding with solid steel, stainless steel or aluminium wire as well as tubular wire

with or without shielding gas.

The possibility of welding with homogeneous wire/shielding gas and welding with

gasless tubular wire is obtained by switching the + and -- connections on the

machine front.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical equipment

that has reached the end of its life must be collected separately and returned to an

environmentally compatible recycling facility. As the owner of the equipment, you should

get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human health!

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TECHNICAL DATA

Migmaster 215 Pro Migmaster 215 Pro

Voltage 208/230V, 1∼ 50/60Hz 208/230/460/575V, 1∼ 50/60Hz

Permissible load at

100% duty cycle 110A 110A

60 % duty cycle 160A 160A

25 % duty cycle 250A 250A

Setting range (DC) 40A/16.0V--250A/23V 40A/16.0V--250A/23V

Open circuit voltage 19.5--42V 19.5--42V

Open circuit power 200W 320W

Power factor at max load 0.92 0.92

Control voltage 42V, 50/60Hz 42V, 50/60Hz

Wire feed speed 55--748ipm (1.4--19m/min) 55--748ipm (1.4--19m/min)

Burnback time 0--0.25s 0--0.25s

Spot welding 0.2--2.5s 0.2--2.5s

Welding gun connection EURO EURO

Wire dimension range

FCW

.023--.045” (0.6--1.1mm)

.035--3/64” (0.9--1.2mm)

.030--.045” (0.8--1.1mm)

.023--.045” (0.6--1.1mm)

.035--3/64” (0.9--1.2mm)

.035--.045” (0.9--1.1mm)

Max diameter/weight

of wire bobin

12” (300mm)/33lb (15kg) 12” (300mm)/33lb (15kg)

Dimensions lxwxh 33,8x16,5x28,7”

(860x420x730mm)

33x17x32,7”

(840x430x830mm)

Weight 220lb (100kg) 304lb (138kg)

Operating temperature 14÷104F (--10 ÷ +40

C) 14÷104F (--10 ÷ +40

Enclosure class IP 23 IP 23

Application classifica-

tion

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain load without overloading.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

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WIRING DIAGRAM, Migmaster 215 Pro

Component description

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

S Observe precautions for handling electrostatic

sensitive devices.

S Use proper static--proof bags and boxes.

ESD

AP1

Circuit board

AP2

Digital instrument

C1, C2, CVS

Capacitor 0,1uF/250V

EV1

Fan

KM1

Contactor 42V, 50--60Hz

Inductor

L2, L3

Ferrite core

LF1

Lamp, white, On/Off

Feed unit motor

QF1

Switch, ON/OFF

QF2

Switch, welding voltage selector

QF3

Switch, welding voltage selector

Resistor 15Ω/20W

RVS

Resistor

RP1

Potentiometer, wire feed speed

RP2

Potentiometer with switch, spot welding

Shunt

Resistor

ST1

Thermal oveload cutout, operates at 130

C. The cutout is mounted at the main

transformer TM1.

TC1

Control transformer

TC3

Transformer for digital instrument

TM1

Main transformer

Diode bridge

LED yellow indication, thermal overload

XTP

Main welding current contact, single -- pole

XTM

Terminal block

YV1

Gas valve

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Migmaster 215 Pro, 208/230V

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Migmaster 215 Pro, 208/230V

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Migmaster 215 Pro, 208/230/460/575V

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Migmaster 215 Pro, 208/230/460/575V

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DESCRIPTION OF OPERATION

AP1 Control board

AP1:1 Power supply

The circuit board uses one supply voltage: 27VAC -- rectified by V18 for power

supply to the wire feed motor and electronic circuitry.

Power supply to the electronic circuitry

The +35VS power supply from diode V9 through R31 -- is regulated to 15V by

voltage regulator A2.

+35V/+35VS power supply

+35V -- is used for motor control, relay K1 (on PCB) and ”ON” indication

(optional, LED -- on the front panel)

+35VS -- is used for powering of auxiliary control circuits (see next sections).

Above voltages may vary (with load/mains voltage deviation) from --15% to +10%.

AP1:2 Start / Stop

Closing trigger contact on the welding torch starts the welding process.

The PCB provides only two--stroke control mode.

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T 1

Gas valve

trigger switch

Wire feed

Contactor

T1 = Burn--back time

T 1

Start-- stop sequence.

AP1:3 Spot welding

The spot welding is active when the switch in potentiometer RP2 is closed

(turning clockwise). Spot welding time is adjustable between ca 0,5 and 3,5

seconds.

If the welding torch trigger is released during a spot welding, the welding

sequences will be interrupted. If the trigger is pressed for longer than the spot

weld time, welding stops after spot weld time elapses. In order to restart, the

trigger must be released and then pressed again.

AP1:4 Wire feed speed, creep start

The wire feed speed adjustment range is 1,5 -- 19 m/min (60 -- 748 ipm).

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The +5,1V reference voltage (±1%) is derived from the IC -- A4 (PWM

generator).

The creep start function enables the start of welding at reduced wire speed

and after ca 0,5 sec speed increases automatically to the value set with RP1.

Initial wire speed -- ”creep speed” (85% or 100% of the preset work speed) is

selected with the switch S1 on the PCB -- accessible from the wire drive

compartment.

AP1:5 Motor control

The motor is powered by the smoothed +35 V supply. Pulse width modulation

of the transistor V11 controls the motor voltage. The pulse frequency is about

16 kHz, and maximum conduction time of the pulses is about 95% of the pulse

cycle time. During the Off period of the pulse cycle, the motor current

freewheels through diode V12.

At 24V motor supply voltage, the wire feed roller speed is 160 rpm ±5%. At a

roller speed of 200rpm, the wire feed speed is 19 m/min ±5%.

Speed control

The gate pulses to transistor V11 are generated by a PWM circuit (IC A4),

which compares speed reference with signal proportional to the motor voltage.

Current limit

The current limit is set at ca 6,0 A. The motor current is measured by resistor

R42 which produces a voltage drop proportional to the current (1A = 100mV).

The current limit restricts the conduction time of the gate pulses to transistor

V11.

I x R Compensation

The network R38, R44, R45 allows to compensate the voltage drop on the

motor armature resistance in order to improve wire transportation (especially at

low speed settings).

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AP1:6 Burnback time, contactor, gas valve

Burnback time

The burn--back time is the time from when motor braking starts until the main

contactor opens. When welding stops, capacitor C7 is discharged through

potentiometer R27 and resistor R28. The time can be adjusted from 0,03 to 0,5

seconds.

Contactor and Gas valve

Contactor and gas valve are switched--on by the relay K1, which is controled

by transistor V3. Resistors R18 and R19 reduce the voltage on the coil of K1

(rated value -- 24V DC).

AP1:7 Thermal overload cutout

The thermal overload cutout ST1 is mounted on the cooling fins of the diode

bridge, and operates at a temperature of 130 °C. When ST1 operates (contact

opens), ”ALARM” signal goes high (11,5 -- 15V), the output signals from the

PCB are disabled and the orange LED VH indicates the overload.

When the equipment cools down, ST1 resets automatically. The LED VL (white

or green) indicates energising of the welding machine, it is ON independently

of the overload signalling.

Note: LED VL is only installed optionally if there is no external ON--lamp (refer

to the Electrical diagram -- lamp LF1).

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AP1 -- Migmasterr

r 215 Pro component positions

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AR Control board

AR component positions

AR diagram

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AP2 Digital instrument

AP2:1 Calibration and voltage correction

The meter has a possibility of the voltage and current calibration, as well as a

possibility of the current--dependant voltage correction, to show a voltage

approximately equal to the actual arc voltage.

Since all meters are factory calibrated it is recommended to carry out a second

calibration only if it’s needed. In most applications a zero voltage correction (no

correction) is factory adjusted.

For the calibration an accurate reference meter and a resistance load are required.

The resistance load should force at least 100A current flow.

For calibration following actions should be done:

1 Switch the machine on and load it. The meter should indicate voltage and

current presence.

2 Press simultaneously both pushbuttons placed on the meter PC board. In

sequence, symbols of the calibration modes appear: ”U” -- voltage calibration,

”I” -- current calibration, ”dU” -- voltage correction. Release the buttons as the

required mode appears.

3 Adjust the voltage or the current value equal to the value displayed on the

reference meter by means of the pushbuttons: S1 ”+”, S2 ”--”.

Voltage calibration mode

The reference meter should be connected to the same potentials as a calibrated

meter. Exclusively in this mode a voltage without correction is shown on display.

Voltage correction mode

The reference meter should be connected to the end of mass cable and to the

torch current tip, which are connected to the external load. In this mode, as well as

during the regular work, the meter shows a voltage taking in account voltage drops

on cables and welding torch. An adjustment of the voltage correction should be

carried out only in assumption of the proper voltage calibration and in the presence

of load current above 100A.

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SERVICE INSTRUCTIONS

What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESD stands for

Electrostatic Discharge.

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to people.

ESD damage occurs when an ungrounded person or object with a static charge comes into

contact with a component or assembly that is grounded. A rapid discharge can occur,

causing damage. This damage can take the form of immediate failure, but it is more likely

that system performance will be affected and the component will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from building

up on you or on anything at your work station, then there cannot be any static discharges.

Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static

charge, so you should not bring unnecessary nonconductive items into the work area.

It is obviously difficult to avoid all such items, so various means are used to drain off any

static discharge from persons to prevent the risk of ESD damage. This is done by simple

devices: wrist straps, connected to ground, and conductive shoes.

Work surfaces, carts and containers must be conductive and grounded, use only antistatic

packaging materials. Overall, handling of ESD--sensitive devices should be minimized to

prevent damage.

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

S Observe precautions for handling electrostatic

sensitive devices.

S Use proper static--proof bags and boxes.

ESD

Thermal switch (thermostat) replacement procedure

1. Spare thermostat must be the same type as replaced one.

2. Spare thermostat should be mounted within radius of 10mm or less from broken

thermostat. If it’s possible and safe for transformer winding, broken thermostat may be

removed. Then the spare thermostat is to be mounted right in place of broken one.

3. Spare thermostat should adjoin protected winding as tight as possible.

4. Spare thermostat must be secured with silicone glue of working temperature of 200

or higher.

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INSTRUCTIONS

This chapter is an extract from the instructions for Migmaster 215 Pro.

SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well--acquainted with the operation of the welding

equipment. Incorrect operation of the equipment may lead to hazardous situations which can result

in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no--one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from draughts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during operation.

WARNING!

Read and understand the instruction manual

before installing or operating.

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INSTALLATION

The installation must be executed by a professional.

WARNING!

This product is intended for industrial use. In a domestic environment this product may cause radio

interference. It is the user’s responsibility to take adequate precautions.

Placing

Position the welding power source such way that its cooling air inlets and outlets are

not obstructed.

Electrical installation

Mains voltage

The 208/230V voltage machines are factory--configured for 230V and are fitted with

appropriate marking tape on the mains cable, the multi voltage machines are factory

configured for highest rated voltage and are not equipped with mains cable.

Welding voltage polarity

Welding voltage polarity may be changed as shown below.

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Mains power supply

Check that the unit is connected to the correct mains power supply voltage, and that

it is protected by the correct fuse size. A protective earth connection must be made,

in accordance with regulations.

Rating plate with supply connection data

Migmaster 215 Pro Migmaster 215 Pro

Voltage V 208/230V, 1∼ 50/60Hz 208/230/460/575V, 1∼ 50/60Hz

Current A

at 100% duty cycle 19/17 19/17/9/7

at 60% duty cycle 30/27 30.5/27.5/14/11

at 20% duty cycle 56/50 58/53/26/21

Cable area AWG 3 x 10 3 x 10

Fuse slow A 35 35/35/20/16

OPERATION

General safety regulations for the handling of the equipment appear from page

18. Read through before you start using the equipment!

WARNING!

Rotating parts can cause injury, take great care.

WARNING -- TIPPING RISK!

There is a risk of tipping while transportation and operation, if the welding machine leans

more than 10

. In that case appropriate securing has to be provided !

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ESAB Migmaster 215 Pro User manual

Brand: ESAB

Model: Migmaster 215 Pro

Category: Welding System

Type: User manual

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ESAB Migmaster 215 Pro User manual

ESAB Migmaster 215 Pro User manual

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