ESAB Multimaster-260 User manual

Category
Welding System
Type
User manual

This manual is also suitable for

Multimaster 260
Signature Series
0558005188 08/2007
Instruction Manual
MIG/TIG/STICK WELDING PACKAGE
2
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
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.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation 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 be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3
TABLE OF CONTENTS
1.0 Safety Precautions ....................................................................................5
1.1 Safety - English ..................................................................................5
1.2 Safety - Spanish .................................................................................9
1.3 Safety - French .................................................................................13
2.0 Description ..........................................................................................17
2.1 General ........................................................................................19
2.2 Receiving - Handling............................................................................19
2.3 Safety ..........................................................................................19
2.4 Power Source...................................................................................19
2.5 Wire Feeder ....................................................................................19
2.6 Controls....................................................................................... 20
2.7 Built-in Toolbox................................................................................ 20
2.8 Gun Master 250 Mig Gun....................................................................... 20
2.9 Running Gear.................................................................................. 20
3.0 Installation.......................................................................................... 23
3.1 Location....................................................................................... 23
3.2 Handle Assembly Installation....................................................................24
3.3 Electrical Input Connections ................................................................... 25
3.4 Voltage Changeover ........................................................................... 26
3.5 Secondary Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.6 “Euro” Torch Connections ...................................................................... 28
3.7 Wire Feeder Mechanism ....................................................................... 29
3.8 Connection of Shielding Gas Supply.............................................................32
4.0 Operation ...........................................................................................35
4.1 Standard Controls ..............................................................................35
4.2 Optional Controls.............................................................................. 38
4.3 Mig Welding Set-up.............................................................................41
4.4 Tig Welding Set-up .............................................................................42
4.5 Handling the Tig Torch.........................................................................44
4.6 Stick Welding Set-up........................................................................... 45
5.0 Maintenance.........................................................................................47
5.1 Maintenance and Service .......................................................................47
5.2 Inspection and Service..........................................................................47
6.0 Replacement Parts .................................................................................. 49
6.1 General ....................................................................................... 49
6.2 Ordering ...................................................................................... 49
Section / Title Page
4
TABLE OF CONTENTS
5
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
1.1 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 precau-
tions 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 operating
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
SECTION 1 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
SECTION 1 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
SECTION 1 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.
17
Multimaster 260
Advanced SuperSwitch•
TM
technology makes multi-
process welding a breeze. Simplied setup makes it
easy to select Mig, Tig, or Stick
DC welding output from 15 to 300 amps; rated 260 •
amps at 50% duty cycle
Output Pre-Set Capability for Quick Set-Up•
Two Digital Meters for Easy Fine Tuning•
Heavy Duty Four Drive Roll Stand•
Convenient, Large Capacity Built-In Tool Box •
Dual “Easy-On” Cylinder Tray•
Industrial Ready-To-Weld Multi-Process Package
Ordering Information
SECTION 2 DESCRIPTION
The Multimaster 260 is a DC welding system designed for Mig (GMAW), Tig (GTAW) or Stick (SMAW) welding. 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 two gas cylinders.
The following part number and description is for the Jesse James Series Multimaster 260 package.
Part Number - 0558004425, MultiMaster 260 230V Jesse James 15’ package
The following part number and description is for the basic Jesse James Series Multimaster 260 console (no accessories).
Part Number - 0558004424, MultiMaster 260 230V Jesse James console
PACKAGE CON TENTS (Standard Accessories)
Each Jesse James Series Multimaster 260 package includes:
P/N 0558004424, MM260 230V Jesse James console•
P/N 0558001649, 250 Amp “CC” 15 x 035-045 MST Gun•
P/N 21557, R-33-FM-580 Regulator / Flowmeter•
P/N 811FTF45, 87 HP HI Dep III .035•
P/N 811005313 5 lb. Stick Electrode Assortment •
P/N 13733936, Cable Plug (1/0 - 2/0)•
P/N 882F25, AF-1 Electrode Holder•
P/N 996995, Contact Tip MT M 035 (5)•
P/N 37290, Contact Tip MT M 045 (5)•
2.0 DESCRIPTION
18
Optional Equipment
Pre/Post Flow/Spot/Burnback module ..................................... 0558002889
Inductance Control Module ......................................................... 0558002888
Remote Control Module ................................................................ 0558002605
FC-5B Foot Control - 30 ft. (9.1 m) cable................................................33646
Provides remote current control and contactor (on/o) control
Spool Gun Module ........................................................................... 0558002606
MT-250SG Spool Gun ..................................................................................36779
(Requires Spool Gun module)
ST-23A Spool Gun .........................................................................................19164
(Requires adapter 37301 and Spool Gun module)
HW-17V-2TL (w/valve) Heliarc Tig Torch Assembly ..........................35857
Tig weld without disconnecting the Mig torch. 60 deg. 12.5 ft.
HW-17 Torch Accessory Kit ..................................................................... 999126
Work Cable & Clamp .....................................................................................35881
Digital Meter
Volts, Amps, and Wire feed speed
Voltage/Current
Control
Process Selector
Voltage Preset
Status Indicators
Wire Feed Speed
Control
Remote Control Option
“Spool-on-Gun Option
Electrode Holder Assembly - 175 amp (15 ft.) ......................0558001786
Includes holder, cable and quick connector
Electrode Holder Assembly - 300 Amp (15 ft.) ...................................21226
Includes holder, cable and quick connector
Tee Connector (1 male/ 2 female) ................................................... 13792804
Primary Extension Cord (25 ft.) .................................................................37833
TIG Welding Handbook ............................................................................ 781F29
MIG Welding Handbook ........................................................................... 791F18
SECTION 2 DESCRIPTION
Specifications
Rated DCCV or DCCC Output (10 min base)
50% duty cycle (NEMA Class I) ..................................260 amps @ 27 vdc
Output Current Range
Mig (GMAW) ................................................................................. 35-300 amps
Tig (GTAW) ....................................................................................10-300 amps
Stick (SMAW)................................................................................40-300 amps
Open Circuit Voltage
Mig (MGAW)...........................................................................................39.0 vdc
Tig (TGAW).................................................................................................20 vdc
Stick (SMAW).............................................................................................70 vdc
Primary Input Voltage & Current @ 260 amp rated load
208/230 vac, 60 Hz, 1 ph ............................................................57/52 amps
Wire Feed Range ..............................................65-675 ipm (1.6 - 17.3 m/min)
Net Weight ................................................................................250 lbs. (112.5 kg)
Shipping Weight .....................................................................290 lbs. (130.5 kg)
W x L x H ................... 25.3 in. (64 cm) x 39.5 in. (100 cm) x 33.5 in. (85 cm)
19
SECTION 2 DESCRIPTION
2.1 GENERAL
This manual has been prepared for experienced welders. 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.
This manual is intended for use in familiarizing person nel with the design and operation of this equipment. All informa-
tion presented here should be read careful ly before installing and using this equipment.
2.2 RECEIVING-HANDLING
Upon receipt of this equipment, clean all packing material 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 led with the carrier.
The carrier will furnish a copy of the bill of lading and the freight bill on request, if the need to le a damage claim arises.
When requesting information regarding this equipment, make sure that you include product name, part num ber, and
serial number.
2.3 SAFETY
The safety section at the front of this manual should be read completely before attempting to install and operate this
equipment. Both equipment and person nel hazards are reduced if proper safety precautions are taken. If you are unsure
of yourself in any situa tion, ask your supervisor or other experi enced person nel for help.
Means immediate hazards which, if not
avoided, will result in immediate, 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.
2.4 POWER SOURCE
The power source is a secondary chopper DC output designed for single phase primary connec tions. An ouput controlled
fan provides proper cooling during normal welding operations and shuts o four minutes after welding stops. The fan will
automatically re-start when welding resumes and proper machine temperatures will be maintained.
2.5 WIRE FEEDER
The four (4) roll drive wire feeder is built into the power source cabinet, housed separately from the welding machine electri-
cal components. Cooling air is not drawn through the wire feeder compartment or electronic controls reducing exposure
to dirt and dust which improves product performance and reliability.
The wire feeder pushes wire at speeds from 65 to 675 ipm (inches per minute).
20
2.6 CONTROLS
The Multimaster 260 can be used to weld solid and ux cored wires. The operator selects the process desired on a three
position switch located on the front panel. A detailed description of the power source controls is included in Section 4
(Operation) of this manual.
2.7 BUILT-IN TOOL BOX
The Multimaster 260 is designed with a lockable storage space on the left side of the machine for welding accessories such
as contact tips, gas nozzles, small grinder, spare parts, welding hood and protective clothing. (Figure 1B)
2.8 GUN MASTER 250 MIG GUN
This air-cooled welding gun is supplied complete and ready to weld .035 in. hard wire. The gun accommodates .045 inch wire
by changing the contact tip. Other wire sizes can be used. Refer to Section 6, for other wire size and alloy accessories.
2.9 RUNNING GEAR
The Multimaster 260 is equipped with running gear with swivel front wheels and a dual gas cylinder support.
SECTION 2 DESCRIPTION
21
15’ Gun Master
250 Mig Gun
HW-17 Tig Torch
(Optional)
Stick Electrode
Holder
(Optional)
15’ Work Cable
and Clamp
Choice of Argon or CO
2
Regulator/
Flowmeter
Simple To Use Weld
Controls
Figure 1A - Components
Welding Gloves
(not shown,
optional)
Eyetech Automatic
Helmet
(Optional)
Factory Installed
Two Cylinder Easy
Load Running Gear
Large, Easy To Read
Digital Displays for Wire
Speed, Amps and Volts
6’ Gas Hose
Simple and quick
polarity change-over
Cylinder Safety
Chain
SECTION 2 DESCRIPTION
22
Tool Box with Small
Parts Tray
Voltage Switch
Compartment
4 Roll
Drive Stand
2 Cylinder
Low Mount Tray
Wheel Kit
Installed
Handle
Hinged Wire
Compartment Door
Adaptable
Spindle Assembly
Inductance Burnback
Preow/postow
Spot (Options)
Figure 1B - Components
SECTION 2 DESCRIPTION
23
SECTION 3 INSTALLATION
3.0 INSTALLATION
3.1 LOCATION
Several factors should be considered when selecting an installation site. Adequate ventilation is necessary to provide cool-
ing, 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 movement through the power source.
The installation site should permit easy removal of the machines outer enclosure for maintenance. Installing or placing any
type of ltering device will restrict the volume of intake air, thus subjecting the internal components to overheating. War-
ranty is void if any type of ltering device is used.
Figure 2 - Dimensions
32”
42”
20”
24
3.2 HANDLE ASSEMBLY INSTALLATION
The Multimaster 260 is factory assembled except for the front handle assembly which is mounted to the machine upside
down for shipping purposes. The handle assembly consists of two brackets and a cross bar. To install the handle in its proper
position, do the following:
A. Remove the two sheet metal screws from the brackets on each side of the front handle assembly. See Figure 3A.
B. Remove front handle assembly and reverse sides with the mounting brackets. This will put the handle assembly in the
proper orientation. Reattach brackets using the sheet metal screws removed in Step A. See Figure 3B.
SECTION 3 INSTALLATION
Figure 3B - Handle Assembly Installation
Figure 3A - Handle Assembly Removal
Sheet metal Screws
Sheet metal
Screws
Handle Bracket
Handle Bracket
25
3.3 ELECTRICAL INPUT CONNECTIONS
In order to provide a safe and convenient means to completely remove all electrical power from the machine, it is highly
recommended that a line disconnect switch be installed in the input circuit of the machine.
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 vac single phase 50/60 Hz.
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 o 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.
Typical Installation - User
Supplied Power Discon-
nect Box, Receptacle and
Plug
SECTION 3 INSTALLATION
WARNING
Primary
Input
Volts
Full
Load
Line
Amperes
Fuse
Size
Recommended
Primary
Input
Conductor
Size
Ground
Conductor
Size
208 57 90 8 8
230 52 90 8 8
460 26 30 12 12
575 20 30 12 12
Input Conductor and Fuse Size
26
SECTION 3 INSTALLATION
3.4 VOLTAGE CHANGEOVER (Figure 4)
The voltage changeover terminal board is located in the tool compartment on the left side of the machine. As shipped from
the factory, the Multimaster 260 is congured for the highest connectable voltage. If using the other input voltages, the links
on the terminal board (TB) inside the unit must be repositioned for the appropriate input voltage. See gures 4A - 4E for
60Hz input voltage congurations. To gain access to the terminal board, open the access panel on the left side. To change
voltages, perform the following:
A. Remove the left screw ONLY and swing plexiglass door upward.
B. Adjust the copper bar links to the primary voltage being used.
C. Swing clear panel down and secure with screw.
The receptacle should be wired to a separately fused disconnect or circuit breaker by an electrician. This disconnect or
breaker can be wired to a single phase system or two conductors of a three phase system. A third conductor for grounding
must be connected between the disconnect and the receptacle.
3.3.2 INPUT PLUG
The input power cord is provided with an attachment plug. The plug will mate with a 250 volt, 50 Amp receptacle con-
forming to NEMA 6-50R congura tion (208/230 vac model only).
The termi nal labeled GRD is connected to the power source chassis and is for ground
purposes only. This 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.
WARNING
Figure 4 - Voltage Changeover Terminal Board
208/230 Version Shown Installed
Clear Panel Hinges on
corner screw
Remove this
screw only
This screw must
remain in place
Do Not Remove
28
Figure 5 - Polarity Set-up
3.5 SECONDARY OUTPUT CONNEC TIONS (Figure 5)
The Multimaster 260 Welding System is completely self-contained so that the front panel gun/torch connections are in-
ternally connected to the welding polarity (DCEP or DCEN) via the secondary output terminals depending on the welding
process being used.
3.6 TORCH CONNECTIONS (Figure 6)
The torch (GUNMASTER 250), which is supplied as standard equipment with the Migmaster 250 System, is provided with a
euro-type adapter which directly connects to the torch tting mounted on the front panel. Line up matching holes, push on
and tighten locking collar. As shipped from the factory, the euro or common connector type torches are set-up for D.C.R.P.
welding polarity (see sections 3.3 or 4.1.3). To connect the spool-on-gun torch (ST-23A) see Section 4.2.2.
Figure 6 - Gun Connector
SECTION 3 INSTALLATION
29
SECTION 3 INSTALLATION
Feed Roll Release Screws
Figure 7 - Wire Feeder Mechanism
3.7 WIRE FEEDER MECHANISM
3.7.1 DRIVE ROLLS (Figure 7 and 9)
The drive roll has two grooves: the small groove feeds .035 in. diameter wire, the large groove feeds .045 in. wire. The groove
nearest the gear motor feeds the wire. If the required groove is not correctly positioned, perform the following:
A. Release the pressure drive roll lever.
B. Remove the two (2) screws holding the drive rolls to the gears.
C. Reverse the drive roll on the drive roll shaft.
D. Replace the screws and tighten.
E. Secure the pressure drive roll assembly.
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ESAB Multimaster-260 User manual

Category
Welding System
Type
User manual
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