ESAB 200 MIG User manual

200 MIG, 230 MIG and 280 MIG

Power Sources

Form No: 0558007453 03 / 2007

Instruction Manual

Installation, Operation and Service

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera-

tion and safe practices for arc welding and cutting 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. Be sure to read the Safety Precautions before installing 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 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. Malfunctioning or poorly

maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contami-

nated should be replaced immediately. Should such repair or replacement become necessary, the manu-

facturer 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 manu-

facturer. 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.

CAUTION

TABLE OF CONTENTS

1 DIRECTIVE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Placing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Assembly of components 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Electrical installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Mains power supply 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Connection and control devices 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Functions explanation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 MIG process set--up guide 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 MAINTENANCE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Inspection and cleaning 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 FAULT TRACING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 ORDERING OF SPARE PARTS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEAR COMPONENTS 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

5

17

19

21

22

23

25

26

31

33

35

37

42

43

1

2

3

4

5

6

7

4

DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding

power source Migmaster 173/203/253 from serial number 421/402/429 complies with standard IEC/

EN 60974--1, in accordance with the requirements of directive (73/23/EEC) and addendum

(93/68/EEC) and with standard EN 60974--10 in accordance with the requirements of directive

(89/336/EEC) and addendum (93/68/EEC).

--------------------------------------------------------------------------------------------------------------------------------------

Henry Selenius

Vice President

ESAB Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 16.11.2004

5

SAFETY PRECAUTIONS

Safety Precautions

Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

procedures, be sure to read and follow the safety

precautions listed below as well as all other manuals,

material safety data sheets, labels, etc. Failure to observe

Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation

and can injure skin and eyes. Hot metal can cause

burns. Training in the proper use of the processes

and equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any

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

goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operat-

ing or observing operations. Warn bystanders not

to watch the arc and not to expose themselves to

the rays of the electric-arc or hot metal.

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.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

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.

2. Hot sparks or hot metal can fall through cracks or

crevices in oors or wall openings and cause a hid-

den smoldering re or res on the oor below. Make

certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the

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

create a re hazard.

6. After completing operations, inspect the work area

to make certain there are no hot sparks or hot metal

which could cause a later re. Use re watchers when

necessary.

7. For additional information, refer to NFPA Standard

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

Processes", available from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conned, or if there is

danger of falling.

6

SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to 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 fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged 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

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

3. Welders should use the following procedures to

minimize exposure 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.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

7

SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal

-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment 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 position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American 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"

8

SAFETY PRECAUTIONS

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 Held

Hazardous Substances."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

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17

1.0 INTRODUCTION

200 MIG, 230 MIG and 280 MIG are step controlled power sources in a compact design, intended for

welding with solid steel, stainless steel or aluminium wire as well as ux-cored wire with or without

shielding gas.

200 MIG, 230 MIG and 280 MIG are equipped with facilities for connection of the MIG ”spool-on” gun

torch (type: MT-250SG).

Prest-O-Lite accessories for the product can be found on Page 43.

1.1 EQUIPMENT

The power source is supplied with:

Welding gun

Return cable 3m with return clamp

Shelf for gas cylinder

Instruction manual

•

SECTION 1 INTRODUCTION

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19

SECTION 2 TECHNICAL DATA

-- 6 --

MM1725e

3 INTRODUCTION

Migmaster 173/203/253 are step controlled power sources in a compact design, intended for welding

with solid steel, stainless steel or aluminium wire as well as flux--cored wire with or without shielding

gas.

Machines MM 203 / 253 are equipped with facilities for connection of the MIG ”spool--on” gun torch

(type: MT--250SG).

ESAB’s accessories for the product can be found on page 39.

3.1 Equipment

The power source is supplied with:

� Welding gun

� Return cable 3m with return clamp

� Shelf for gas cylinder

� Instruction manual

4 TECHNICAL DATA

Migmaster 173

Voltage 230V, 1∼ 50/60Hz

Permissible load at

100% duty cycle

76A

60 % duty cycle 98A

20 % duty cycle 170A

Setting range (DC) 30A/15.5V--170A/18.5V

Open circuit voltage 19.5--35.0V

Open circuit power 160W

Power factor at max load 0,90

Control voltage 42V, 50/60Hz

Wire feed speed 40--670ipm (1.0--17m/min)

Burnback time 0.02--0.25s

Spot welding 0.2--2.5s

Welding gun connection EURO

Wire dimension range

Fe

Al

FCW

.023--.030” (0.6--0.8mm)

.035--.040” (0.9--1.0mm)

.030” (0.8mm)

Max diameter/weight

of wire bobin

12” (300mm)/33lb (15kg)

Dimensions lxwxh 33x16x28” (860x420x730mm)

Weight 130lb (59kg)

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

o

C)

Enclosure class IP 23

Application classifica-

tion

GB

2.0 TECHNICAL DATA

200 MIG

20

SECTION 2 TECHNICAL DATA

-- 7 --

MM1725e

Migmaster 203 Migmaster 253

Voltage 230V, 1∼ 50/60Hz 230V, 1∼ 50/60Hz

Permissible load at

100% duty cycle

90A 110A

60 % duty cycle 115A 140A

20 % duty cycle 200A 250A

Setting range (DC) 30A/15.5V--200A/22V 40A/16.0V--250A/23V

Open circuit voltage 18--38V 19.5--43V

Open circuit power 140W 200W

Power factor at max load 0.83 0.92

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

Wire feed speed 40--670ipm (1.0--17m/min) 75--748ipm (1.9--19m/min)

Burnback time 0.02--0.25s 0--0.25s

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

Welding gun connection EURO EURO

Wire dimension range

Fe

Al

FCW

.023--.045” (0.6--1.1mm)

.035--.040” (0.9--1.0mm)

.030--.045” (0.8--1.1mm)

.023--.045” (0.6--1.1mm)

.040--3/64” (1.0--1.2mm)

.030--.045” (0.8--1.1mm)

Max diameter/weight

of wire bobin

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

Dimensions lxwxh 33x16x28” (860x420x730mm) 33x16x28” (860x420x730mm)

Weight 150lb (68kg) 216lb (98kg)

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

o

C) 14÷104F (--10 ÷ +40

o

C)

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.

GB

2.0 TECHNICAL DATA CON'T.

230 MIG 280 MIG

21

SECTION 3 INSTALLATION

3.0 INSTALLATION

3.1 PLACING

3.2 ASSEMBLY OF COMPONENTS

The installation must be performed by a professional.

Position the welding power source such a way that its cooling air inlets and outlets are not obstructed.

NOTE:

For packing and shipment of the machine the wheels are detached from the unit. Before use

attach the wheels per illustrations below.

-- 8 --

MM1725e

5 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.

5.1 Placing

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

not obstructed.

5.2 Assembly of components

For packing and shipment of the machine the wheels are detached from the unit.

Before use attach the wheels according to instruction.

WARNING!

1.

3.

2.

GB

NOTE:

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.

22

SECTION 3 INSTALLATION

3.3 ELECTRICAL INSTALLATION

Mains voltage

The single voltage machines are factory-congured for 230V, the multi voltage machines are factory

congured for highest rated voltage and are tted with appropriate marking tape on the mains cable.

Mains voltage selection

Machines 230 MIG and 280 MIG can be supplied from 230V or 208V mains (1 ph.).

Factory conguration is for 230V. In order to adapt the machine for 208V following must be carried

out (refer to the diagrams on page 38 and 39):

reconnect the primary winding of the TM1 at the auxiliary terminal block XTM, as indicated with

dashed lines (208V taps),

reconnect the wire No 10:

280 MIG - from terminal 7 onto 5 on the control transformer TC1,

230 MIG - from terminal 6 onto 4 on the control transformer TC1.

•

Welding voltage polarity

Welding voltage polarity may be changed as shown below.

200 MIG

23

SECTION 3 INSTALLATION

3.3 ELECTRICAL INSTALLATION CON'T.

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.

3.4 MAINS POWER SUPPLY

-- 10 --

MM1725e

Migmaster 203/253

5.4 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 173 Migmaster 203 Migmaster 253

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

Current A

at 100% duty cycle

10.5 15.5/14.0 18.6/16.8

at 60% duty cycle 14.5 20.5/18.5 25.9/23.4

at 20% duty cycle 28.0 41.0/37.0 53.1/48.0

Cable area AWG 3 x 10 3 x 10 3 x 10

Fuse slow A 16 25 35

GB

200 MIG 280 MIG230 MIG

230 MIG, 280 MIG

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25

SECTION 4 OPERATION

4.0 OPERATION

General safety regulations for the handling of the equipment can be found on

Page 5. Read thoroughly before you start using the equipment!

ROTATING PARTS CAN CAUSE INJURY, TAKE GREAT

CARE.

TIPPING RISK!  THERE IS A RISK OF TIPPING WHILE

TRANSPORTING AND OPERATING IF THE WELDING

MACHINE LEANS MORE THAN 10

. IN THAT CASE

APPROPRIATE SECURING HAS TO BE PROVIDED!

CAUTION

-- 11 --

MM1725e

6 OPERATION

General safety regulations for the handling of the equipment can be found on

page 4. 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

o

. In that case appropriate securing has to be provided !

6.1 Connection and control devices

1 Mains supply switch with indicating lamp 6 Knob for spot welding -- ON/OFF and time

setting

2 Orange indicating lamp, overheating 7 Knob for wire speed setting

3 Welding voltage switch

Migmaster 173: 8 steps

Migmaster 203: 12 steps

Migmaster 253: 12 steps

8 Digital instrument -- V/A,

(option,see page 39)

4 EURO -- connector for welding gun 9 Connector for ”spool--on gun” (wire control)

5 Return cable with clamp, fixed 10 Knob for burn--back time setting.

In M 253 located in wire feeder compartment,

in M 170/200 located on control board.

5a Connector [--] for welding gun or return

cable (welding polarity change--over)

11 ”Electrode” cable with plug, connected to the

welding gun connector (welding polarity

change--over)

5b Connector [+] for welding gun or return cable (welding polarity change--over)

GB

-- 11 --

MM1725e

6 OPERATION

General safety regulations for the handling of the equipment can be found on

page 4. 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

o

. In that case appropriate securing has to be provided !

6.1 Connection and control devices

1 Mains supply switch with indicating lamp 6 Knob for spot welding -- ON/OFF and time

setting

2 Orange indicating lamp, overheating 7 Knob for wire speed setting

3 Welding voltage switch

Migmaster 173: 8 steps

Migmaster 203: 12 steps

Migmaster 253: 12 steps

8 Digital instrument -- V/A,

(option,see page 39)

4 EURO -- connector for welding gun 9 Connector for ”spool--on gun” (wire control)

5 Return cable with clamp, fixed 10 Knob for burn--back time setting.

In M 253 located in wire feeder compartment,

in M 170/200 located on control board.

5a Connector [--] for welding gun or return

cable (welding polarity change--over)

11 ”Electrode” cable with plug, connected to the

welding gun connector (welding polarity

change--over)

5b Connector [+] for welding gun or return cable (welding polarity change--over)

GB

4.1 CONNECTION AND CONTROL DEVICES

200 MIG: 8 steps

230 MIG: 12 steps

280 MIG: 12 steps

In 280 MIG located in wire feeder compartment,

in 200/230 MIG located on control board.

26

SECTION 4 OPERATION

4.2 FUNCTIONS EXPLANATION

4.2.1 SWITCHINGON AND OVERHEATING PROTECTION

4.2.2 OPERATION

4.3 MIG PROCESS SETUP GUIDE

When machine is switched on with the illuminated switch [1], its lamp is on. If the machine is not over-

heated (lamp [2] is o) it is ready to work. If the internal temperature during welding becomes too high,

the welding is interrupted and disabled. This state is indicated by permanent lighting of the orange

indicating lamp [2] on the front of the unit. It resets automatically when the temperature falls down.

Operator can manually select and set welding parameters as follows:

required welding voltage ( and thus welding current) with knob [3]

appropriate wire feed speed with knob [7]

burn-back time: for 280 MIG with potentiometer [10] located in the wire feeder compartment, for

200/230 MIG with trim potentiometer located on the control board inside the machine

spot welding, activated by turning the knob [6] clockwise, spot welding time increases while turning

the knob [6] clockwise; set knob [6] in the left utmost position in order to return to the continuous

welding.

If the welding gun is used, welding process starts after its trigger is pressed and the wire speed is con-

trolled with potentiometer [7] on the front panel.

If the spool-on gun is used, welding process starts after its trigger is pressed, the spool-on gun motor

starts and wire speed is controlled with the potentiometer in the spool-on gun grip.

Note: For spool-on gun current cable connection it is necessary to use the OKC ”T” adapter (see Acces-

sories on Page 43).

Machines optionally may be tted with V/A digital instrument [8] (with ”hold” function i.e. memorizing

of the last values of welding voltage and current, see Page 43).

•

In the following tables, separately for each machine, recommended welding settings are shown, de-

pending on the joint type, workpiece thickness and ller wire diameter.

To set machine for welding:

nd the plate thickness (T) and type of joint,

nd the diameter (d) of the ller wire,

in the column corresponding to the appropriate material and shielding gas nd the suggested arc

voltage and wire feed setting; if spot welding nd recommended time setting,

set arc voltage selector [3], wire feed potentiometer [7], and (if necessary) the spot welding time [6]

according to values found in table.

NOTE: The given recommendations only serve as rough guide for the operator, optimal set-ups may dif-

fer from the ones in tables. It depends on mains voltage deviation, precision of the wire speed setting,

applied welding techniques, welding position, etc.

If needed, some corrections of the arc voltage and wire speed may be tried out for satisfactory results.

•

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31

SECTION 5 MAINTENANCE

5.0 MAINTENANCE

5.1 INSPECTION AND CLEANING

Regular maintenance is important for safe, reliable operation.

NOTE:

Warranty from the supplier is void if the customer attempts any type repair work on the prod-

uct during the warranty period.

Check regularly that the power source is free from dirt.

The power source should be regularly blown clean using dry compressed air at reduced pressure. More

frequently in dirty environments. Otherwise the air inlet/outlet may become blocked and cause over-

heating.

Welding gun

Cleaning and replacement of the welding gun’s wear parts should take place at regular intervals in

order to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the contact

tip.

•

-- 16 --

MM1725e

7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any

faults.

7.1 Inspection and cleaning

Check regularly that the power source is free from dirt.

The power source should be regularly blown clean using dry compressed air at reduced

pressure. More frequently in dirty environments. Otherwise the air inlet/outlet may be-

come blocked and cause overheating.

Welding gun

� Cleaning and replacement of the welding gun’s wear parts should take place at

regular intervals in order to achieve trouble--free wire feed. Blow the wire guide

clean regularly and clean the contact tip.

The brake hub

The hub is adjusted when delivered, if

readjustment is required, follow the instructions

below. Adjust the brake hub so that wire is slightly

slack when wire feed stops.

� Adjusting the braking torque:

� Turn the red handle to the locked position.

� Insert a screwdriver into the springs in the hub.

Turn the springs clockwise to reduce the braking torque

Turn the springs anticlockwise to increase the braking torque. NB: Turn both

springs through the same amount.

GB

The brake hub

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33

SECTION 6 FAULT TRACING

-- 17 --

MM1725e

8 FAULT TRACING

Try these recommended checks and inspections before sending for an authorised service technican.

Type of fault

Actions

No arc � Check that the mains power supply switch is turned on.

� Check that the welding current supply and return cables are

correctly connected.

� Check that correct current value is set.

Welding current is interrupted

during welding

� Check whether the thermal overload trip has operated

(indicated by the orange lamp on the front).

� Check the main power supply fuses.

Thermal overload trips

operate frequently

� Check to see whether the air inlets/outlets are clogged.

� Make sure that you are not exceeding the rated data for the

power source (i.e. that the unit is not being overloaded).

Poor welding performance � Check that the welding current supply and return cables are

correctly connected.

� Check that the correct current value is set.

� Check that the correct welding wires are being used.

� Check the main power supply fuses.

� Check the wire feed unit -- if proper rolls are applied and

properly set the pressure of the wire feeder’s pressure rollers

9 ORDERING OF SPARE PARTS

Migmaster 173/203/253 is designed and tested in accordance with the international and

European standards IEC/EN 60974--1 and EN 60974--10. It is the obligation of the servi-

ce unit which has carried out the service or repair work to make sure that the product

still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

GB

34

SECTION 6 FAULT TRACING

35

SECTION 7 ORDERING OF SPARE PARTS

NOTE:

200/230/280 MIG is designed and tested in accordance with the international and Euro-

pean standards IEC/EN 60974-1 and EN 60974-10. It is the obligation of the service unit

which has carried out the service or repair work to make sure that the product still con-

forms to the said standard.

Spare parts may be ordered through your nearest Prest-O-Lite dealer, see the last page of this publica-

tion.

7.0 ORDERING OF SPARE PARTS

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