ESAB Multimaster-260 User manual

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.

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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 machine’s 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

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

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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

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