ESAB MigMaster 210 User manual

Brand: ESAB

Model: MigMaster 210

Category: Welding System

Type: User manual

MigMaster 210

F15-690 062002

Instruction Manual

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, con-

tact 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, main-

tained 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 contaminated should be re-

placed 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 manufacturer. The user of this equipment shall have the sole responsi-

bility 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.

Safety Precautions 2-6

Introduction 7

Technical Data 7

Installation 8-9

Seam Welding 10

Spot Welding 10

Welding Process 11

Changing Setup for Different Materials 11

Common Welding Faults 12

Assembly Diagram 13

Dimension Diagram 13

Recommended Welding Parameters 14

Electrical Diagram 15

Spare Parts Lists 16-23

MigMaster

210

ONTENTS

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary information from the references listed in

Additional Safety Information section. 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. There-

fore:

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 fitted with the correct filter 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 flameproof gauntlet type gloves, heavy long-

sleeve shirt, cuffless 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 flame-

proof apron may also be desirable as protection against

radiated heat and sparks.

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

trouser cuffs, 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-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and

can fly far. Bystanders should also wear

goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot

slag or sparks can also cause fires and

explosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable 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 floors or wall openings and cause a hidden

smoldering fire or fires on the floor 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 pro-

duce flammable or toxic vapors. Do not do hot work on

closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

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

SAFETY PRECAUTIONS

10/98

portable fire extinguisher. Be sure you are trained in its

use.

5. Do not use equipment beyond its ratings. For example,

overloaded welding cable can overheat and create a fire

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 fire. Use fire watchers when neces-

sary.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Pro-

cesses", available from the National Fire

Protection 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

confined, or if there is danger of falling.

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

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 dam-

aged 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 off the power before removing your gloves.

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

for specific grounding recommenda-

tions. Do not mistake the work lead for

a ground cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent flowing through any conductor

causes localized Electric and Mag-

netic Fields (EMF). Welding and cutting current creates

EMF around welding cables and welding machines. There-

fore:

1. Welders having pacemakers should consult their physi-

cian before welding. EMF may interfere with some pace-

makers.

2. Exposure to EMF may have other health effects 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 confined 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, stainless steel,

copper, zinc, lead, beryllium, or cadmium unless posi-

tive 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 irritation

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 discomfort persists.

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

for specific ventilation recommendations.

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 violently

release gas. Sudden rupture of cylin-

der, 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 fittings in good condition. Follow

manufacturer's operating instructions for mounting regu-

lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain

or strap to suitable hand trucks, undercarriages, benches,

walls, post, or racks. Never secure cylinders to work

tables or fixtures 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 flames.

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 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, troubleshooting, and maintenance work. Do not

perform any electrical work unless you are qualified 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 elec-

tric arc welding and cutting equipment, 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"

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 through-

out this manual: Means Attention! Be Alert!

Your safety is involved.

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.

SP98-10

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Introduction

Semi-automatic welding (MIG/MAG)

MIG is the abbreviation for METAL INERT GAS and

concerns welding with an inactive shielding gas, gene-

rally Argon or a mixture of gases (MIXED-GAS).

MAG means METAL ACTIVE GAS and it concerns welding

with an active shielding gas, generally carbon dioxide

(CO

The MigMaster 210 is an advanced, compact, step

switched welding power sources designed for professional

welders and suitably qualified trades people. The unit is

intended for Mig/Mag welding utilizing solid wire with a

shielding gas. They can also be used with gasless welding

wires using reverse polarity feature.

Ideal for welding on thin sheet metal through to medium

fabrication tasks. The MigMaster 210 satisfies the need

of high capacity for repair and maintenance welding. This

unit has been designed, tested and manufactured for

industrial use, using quality components, to provide a long

service life.

Features include a rugged all steel construction, with

wheels for ease of handling, handy rubber matted top for

tool storage, and a powerful integrated feed system. The

machine is fan-cooled, thermostatically protected, and

includes seam, spot and stitch welding.

The MigMaster 210 has space for a standard 12- inch

spool (33 lbs.).

The MigMaster 210 is a Single Phase 200/230v 60Hz machine.

Optional Accessories

• Wire Feed Rollers of various sizes

• Shielding Gas supply

•Tips

• Nozzles

• Spool Gun Option .......................... P/N 0558002850

Consumable Items

From time to time depending on usage the following items

may need to be replaced due to normal wear and tear.

• Replacement wear parts for the Mig gun such as

contact tips, gas nozzles, wire liners, etc.

• Wire feed guides

• Wire feed rolls

Complete Assemblies (CC Style)

0558001643 Gun Master 250cc 10 ft X 023

0558001644 Gun Master 250cc 10 ft X 035-045

0558001645 Gun Master 250cc 12 ft X 035-045

0558001649 Gun Master 250cc 15 ft X 035-045

Torch Options & Accessories

Liner Selection

Steel & Flux Core

0558001675 .023 X 10,12,15' Liner

37031 .030 X 10,12,15' Liner

37032 .035/.045 X 10,12,15' Liner

NOTE: All Liners are 15’ and can be trimmed to fit.

The MigMaster 210 complies with international standards SS

483 01 11, ISO R700, NF A 85 013 and VDE 0542.

IP - The code describes the degree of protection provided by the

casing, against the penetration of fixed objects and water.

Equipment mark IP 21 is designed for indoor use.

Technical Data

Standard Duty Tips

20543 023 Standard Duty Tip

20544 030 Standard Duty Tip

996995 035 Standard Duty Tip

TORCH TIPS

MigMaster 210

Main supply 1-phase

Frequency (Hz) 60

Voltage (V) 208/230

Fuse slow (A) 16

Permissible Loading @ :

20% 210A / 24.5V

60% 120A/ 20V

100% 90A / 19V

Open circuit voltage (V) 18-37

Voltage steps 10

Inductance outlet 2

Wire feed speed (ipm) 40-680

Welding time :

Spot time (sec) 0.2-2

Interval time (sec) 0.2-2

Efficiency h 0.69

Power factor l 0.87

Operating voltage (V AC) 42

Class of enclosures IP 21

Weight (lbs.) 146

Dimensions (LxWxH) 33 x 14.8 x 29 inches

Nozzles

Standard Duty

0558001610 3/8" Standard

0558001609 3/8" Standard

0558001612 1/2" Standard

0558001611 1/2" Standard

0558001613 1/2" Standard

0558001614 5/8" Standard

0558001615 5/8" Standard

Spot

0558001602 Spot Nozzle

Std. Duty Tip/Noz. Adapter

0558001608

1/8" Recess

Flush

1/8" Recess

Flush

1/8" Stick Out

Flush

1/8" Stick Out

Brass

Installation

Recommended Wire Sizes (inches)

MigMaster 210

Mild Steel .023 -.035

Stainless Steel .030 - .035

Cored (gasless) .035

Unpacking

After unpacking, fit the wheels and gas bottle rack according to

the guide shown on page 13. Remove any covers over the

machine to ensure adequate cooling.

Electrical Connections

First make sure that the power supply is appropriately

fused (see Technical Data on page 8). Check that the

unit is connected for the appropriate main voltage. As

standard, the MigMaster 210 is connected for 230v-1

phase supply. Reconnecting should be done according

to the wiring diagrams on page 15. When connecting the

power plug, it is absolutely essential that the green/yellow

wire of the primary cable is connected to the earth screw

of the plug. The remaining two wires, live and neutral,

should be connected to the remaining two terminals in

the correct order.

Electrical connections should be made by a fully

qualified person.

Return Welding Cable And Clamp

The return cable should be firmly connected to the required

outlet terminal on the front of the machine. The clamp

should be clamped securely to the workpiece. Ensure all

connections are clean and tight to avoid welding defects.

Connecting The Welding Gun (See Fig. 1, pg.9)

The gun is connected to the Euro connector on the front

of the machine. Carefully align gas connection tube and

trigger connection pins with Euro adaptor on Mig gun.

Push in and tighten the lock nut. Be careful to line up gun

fittings correctly before tightening to avoid damaging

trigger pins and gas connection. Ensure that the Mig gun

is fitted with a wire conduit and contact tip suitable for the

size and type of wire being used. Refer to the Gun Manual

for spare parts

Feed Rolls

Make sure that the correct feed roll and grooves are used

for the dimension and type of wire being used. Each feed

roll has grooves for two dimensions of filler wire. The

feed roll

must be fitted with its size marking facing you.

The feed roll can be changed or replaced by removing the

screw in the centre of the hub.

“V’” groove rolls as supplied as standard for solid wire,

and serrated rolls for use with cored wire to ensure positive

feeding.

Welding Wire

Select a welding wire of the appropriate type and

size for the job at hand. See ESAB’s consumable

catalogue, available from your nearest ESAB Dis-

tributor, for a range of quality welding filler materials

and their recommended welding parameters.

Fit the reel on to the hub so that the wire runs off at the

bottom into the wire guide. Two catches on the hub hold

the reel in place. It is in the lock position when the arrows

on the hub align with the arrows on the two catches (see

Fig. 2). To disengage the locking mechanism, twist the

center knob to the left (see Fig. 3). On a new reel, the

outer end of the wire is inserted through a hole and bent

over.

As with any work area, make sure safety glasses

with side shields are worn when handling or

changing wire or clipping wire off at the spool or

at the end of the torch. Hold onto the wire coming

off the spool with one hand before clipping.

Serious eye injury can result due to the springi-

ness of the wire which can quickly unravel, or a

cut wire end which may shoot across the room.

When loosening the wire from the hole, take care to hold

the coil so that it does not spring out and unravel. Cut off

the bent end of the wire, straighten the tip and then file off

any sharp edges so that the wire can run easily through

the soft wire guide of the welding conduit without

Fig. 1 - Mounted Welding Wire Reel

Fig. 2 - Locked

Fig. 3 - Unlocked

damaging it. These precautions are very necessary. A

sharp wire tip can quite easily pierce both the wire guide

and the wall of the welding conduit and thus seriously

impair the function of the gun.

Feed the wire into the protruding wire guide on the inlet

side of the feed unit and then by hand feed the wire up to

the roll. Before the wire is fed further into the guide nozzle

of the feed unit, the pressure arm and roller must be lifted

up.

Keep your fingers clear of the drive rolls;

they will start turning when the torch trigger

is pressed.

The wire can now be fed in by hand through the guide

nozzle and into the welding conduit and the pressure roll

can be lowered again. The contact pressure of the feed

roll is adjusted at the factory, but if necessary it can be

modified by means of the screw on the pressure arm. A

rule of thumb for this type of secondary adjustment is that

the pressure must not be harder than makes it possible to

stop the forward travel of the wire through the Mig gun by

pressing the contact nozzle against a piece of wood or

equivalent so that the rollers of the feed unit slip. If the

pressure is too high when welding, the result may be that

the wire will build up and jam in the outlet nozzle of the

feed unit should the tip of the wire stick. This is

troublesome to straighten out and, with correct settings,

also unnecessary.

Mild Steel

Stainless

(Argon + CO

) (Argon + CO

+ Oxygen)

(Argon + CO

+ Oxygen) (Argon + Oxygen)

Fig. 4 - Feed Roll With Wire Inserted

Another drawback of excessive feed pressure is that the

welding wire can be rolled flat which causes unnecessary

wear on the wire guide and that contact in the gun will be

jeopardized.

Set the voltage selector switch on front of machine to po-

sition 1. The wire feed can be turned to one of the center

settings. Straighten out the gun hose. Wire is fed forward

either by pressing the inch button on the wire feed unit

(cold wirefeed), or by pressing the gun trigger.

Take care

when the wire emerges from the gun since the point can

cause injury.

Gas Selection

Select the appropriate shielding gas for the type of mate-

rial to be welded and filler metal being used. The shielding

gas is used to protect the molten weld pool from being

contaminated by the surrounding air. The shielding gas

also contributes to arc stability, weld strength and

appearance so care should be taken to ensure that the

correct gas type/mixture is selected for the metal being

welded. Contact your local ESAB distributor or gas

supplier for recommendations.

Typical Gas Selections

Recommended Output Inductance Tap Connections for Short-Arc Welding

Notes: The above chart shows the recommended output inductance tap connection for Mig Short Circuiting Transfer.

For Mig Spray Arc Transfer (stainless or carbon steel) - use low tap

For Flux Cored Wire (all types) - use low tap

NR - Not Recommended

* The best connection (high tap or low tap) depends on the specific welding application and personal preference.

Stainless Steel

Solid Wires Carbon Steels Solid Wires

Helium/Argon Based

Shielded Gases Argon Based Shielding Gases CO

Shielding Gas

Welding .023" .030" .035" .045"

Current All Wire Diameters (0.6mm) (0.8mm) (0.9mm) (1.2mm) All Wire Diameters

≤ ≤

≤ 100 amps high tap high tap high tap high tap high tap low tap

125 amps high tap high or low* high or low* high or low* high or low* low tap

150 amps high tap N R low tap low tap low tap low tap

≥≥

≥ 200 amps high tap N R N R low tap low tap low tap

Figure 1 - Output Connections and Guidelines

Lift the gas cylinder carefully onto the tray at the rear of

machine. Fasten the cylinder securely using the supplied

chain. Attach gas hose to a gas regulator on gas cylinder.

For normal operation using the GunMaster 250, gas flow

should be set to approximately 21 - 25 cfh. Avoid excessive

gas flow as this can lead to weld defects. (Gas is not

required when using self shielded/gasless wires)

Gas flow can be checked without welding by setting the

voltage selector switch on the front of the machine in the

upright position pointing to the gas flow symbol. In this

position gas flow can be checked and the welding lines

purged without wire feeding or welding voltage being pre-

sent.

Joint Preparation

The joint to be welded must be prepared. During welding,

those parts of the workpiece are heated by the arc and

melt, this molten material mixes with the weld metal of

the wire or electrode. To make sure that fusion is good

and to avoid impurities in the molten pool, it is necessary

to clean the surfaces of the joint carefully. Therefore, use

a wire brush to remove rust, paint and other forms of

contamination where welding is to be carried out. The

area to be welded must also be dry.

Fit-up between the parts to be welded together must be

adjusted so that the joint gap is uniform from end to end.

In the case of light-gauge materials, welding can either

be done from one side or both, depending on the strength

required. For heavier materials, start with a root bead

and then fill up the joint with a sufficient number of passes.

A new welding process commences when the

trigger is pulled again. Max plate thickness

when spot welding is about 14 gage. If the

plates are of different thickness, weld from

the thin side.

Interval (Stitch) Welding (- - -)

This form of welding is particularly suitable

when working with very thin or inferior plate

or when the gap size is large since it gives

a cooler weld.

The spot welding control knob is used to

set the welding time. The interval time

control knob is used to set the pause time.

Both welding time and pause time can be set

steplessly between 0.2 and 2 sec. For welding

voltage and wire feed speed settings, see the

recommendation table on page 14.

Pull the trigger to start the welding process.

When the set welding time has elapsed,

the process is automatically interrupted and

starts again after the pause time has

elapsed.

The process continues as long as the

trigger is pulled. The molten pool of metal

is cooler and the risk of burning through

is considerably reduced.

Burn-back Time

The Power Compact has adjustable

burnback time from 0-250ms. This is

preset when supplied from ESAB. The

potentiometer is located inside the

machine above the feed unit. Use a small

screwdriver and adjust carefully.

How To Select Welding Data

– Seam Welding

VOLTAGE

WIRE

FEED SPEED

Switch the power supply on by means of

the main switch. This will cause the light-

emitting diode in the switch to light up.

Set the voltage-setting switch to the correct

position1-10.(see recommendation table

on page 13).

Note!

Do not adjust the voltage control while

welding. Stop welding, click switch to

new position and begin welding again.

The recommendation table also shows

the best inductance output for

connection of the return cable.

Set the wire feed speed (current) with the

potentiometer graded 1-10.

(See recommendation table on page 14)

Note!

Wire feed speed (current) can be adjusted

while welding.

Pulling the trigger on the gun starts the welding process,

releasing the trigger stops it.

First do a sample weld on a clean piece of plate.

According to the results adjust as follows:

Caution! In most cases, the preset value should be used

SPOT WELD

TIME

STITCH WELD

TIME

BURN BACK

POT

Spot Welding (•••)

In most cases, spot welding is done from one

side to join two overlapping plates.

For spot welding purposes, the gun must

be fitted with a spot welding nozzle.

If spot welding is required, use the spot

welding control knob to set time. The spot

welding time can be set steplessly

between 0.2 and 2 sec. For welding

voltage and wire feed speed settings, see

the recommendation table on page 13.

Pull the trigger. When the set spot weld

time has elapsed, the process is

automatically interrupted without the

trigger needing to be released.

OFF

Welding Process

A factor which influences the depth

of penetration is how the welding

gun is moved during welding.

Trailing welding (welding towards

the body) increases the penetra-

tion depth.

If instead the gun is pushed away

from the body, penetration depth

is reduced.

A short arc gives a deeper

penetration.

In the case of down-welding,

penetration depth is heavily

reduced and is at a minimum

in vertical down-welding. In

up-welding penetration is

deep.

A long arc gives shallower pene-

tration. A long arc also increases

the risk of welding spatter.

Changing Set Up For Different

Materials

Stainless Steel

Stainless steel uses similar set ups as required for mild

steel. You may want to use a new steel liner to avoid

contamination from particles left behind when welding

with mild steels. The gas mixture required will be diffe-

rent and may differ according to the grade and thickness

of the stainless steel being welded. Seek advice from

your local ESAB distributor or gas supplier.

Gasless / Self shielded wires

As the name implies, no gas is required for these wires.

Mainly only used when welding outdoors where wind may

affect shielding gas coverage.

Gasless wires and some cored wires require that the

welding polarity be changed to reverse polarity.

With the reverse polarity feature, change the short lead

coming out the front of the machine from the ‘positive’

gun terminal to one of the two ‘negative’ terminals (A or

B). The return cable should now be connected to the

positive gun terminal.

(See illustration on page 9).

Overload

The machines are fitted with thermostats which shut down

the unit should it become overheated. The LED on the

front panel will light to show that the thermostat has

tripped. The thermostats will automatically reset once

the unit has cooled.

Maintenance

Minimal maintenance is required to keep your

MigMaster 210 in good working order. Keep the drive

mechanism free of dust and dirt by regular cleaning

with a brush. Remove the covers and blow out unit

using soft, dry compressed air at least once per year.

Keep the cables and leads in good working condition

and away from grease, oil, solvents or water. Have

an electrical technican immediately replace any

damaged or worn cables. Replace the Mig gun wear

parts and lead as required due to normal usage wear

and tear.

Note! Faults in the electrical parts such as the control circuits, relays, switches,

transformers, etc. This should only be attended to by a qualified service technician.

Common Welding Faults

Faults

Wire does not move forward

despite rotation of feed rollers.

Irregular wire feed.

Arc will not strike.

Arc too long and irregular.

Arc to short.

Porosity

Inadequate joint fill.

Lack of fusion.

Spatter.

Uneven joint

Poor Penetration

Possible Causes

1. Pressure roller inadequately loaded.

2. Dirt in wire guide or contact nozzle.

1. Faulty worn contact tip.

2. Dirt in groove of feed roller.

3. Feed roller groove worn.

1. Poor contact between return clamp and workpiece.

2. Voltage switch in the wrong (gas purge) position.

Voltage too high.

Voltage too low

1. Incorrect gas flow.

(Recommend 8-10 l/min).

2. Inadequate gas shielding due to spatter in the

nozzle.

3. Breezy workplace.

4. Welding distance too long.

5. Incorrect gun angle.

6. Damp, oily or rusty workpiece.

1. Welding speed too high.

2. Voltage too low relative to welding speed.

1. Irregular movement of gun.

2. Voltage too low.

1. Voltage too high or too low.

2. Gas nozzle dirty.

1. Wire tip too long.

2. Current too high relative to voltage.

3. Welding speed too low.

Current too low relative to voltage.

Dimension Diagram

Assembly Diagram

R-Pin

Figure 2 - Assembly and Dimensional Diagrams

11.8”

18.75”

Spacers

Recommended Welding Parameters

MigMaster 210

Figure 3 - Welding Parameters

MigMaster 210 Electrical Drawing (1~ 208 / 230V)

Figure 4 - Electrical Diagram

The input terminal board at (K11) on Fig. 4 shows the 230V and 208V (dotted lines for the 208V change over).

Change over is made by removing the right side panel below the wire feed compartment and switching the primary

transformer taps on the terminal block. Both voltage taps (the 230V currently connected, and the (unused 208V

(200V) alternate) are marked with the input voltage requirement. All units are supplied from the factory for the highest

voltage (230VAC). Before switching the voltage taps, verify the actual voltage requirement as well as the current

voltage connection to be certain re-connection is necessary. If voltage tap re-connection is necessary re-connect as

indicated in the Electrical diagram above.

Only qualfied personnel should make these changes. Make certain the primary power has been disconnected

and all safety procedures have been followed before proceeding with these instructions.

Input Electrical Change Over - 230V to 208V

Input Electrical Change Over - 230V to 208V (200V)

OKC50* With a Short Lead

MigMaster Spare Parts List - Spare parts should be ordered from your nearest ESAB supplier.

When ordering, indicate model, serial number, description and part number according to the spare parts list.

Description Part No. Symbol

1 Platform 0367204003

2 Rubber mat 0320539006

3 Upper Right Side Panel 0558002420

4 Lower Right Side Panel 0558002421

5 Rubber Wheel (2 Req’d) 0229206402

6 R-Pin Locking (2 Req’d) 0558002422

7 Swivel castor (2 Req’d) 0369729001

8 OKC-50 Cable connector 0160362881

9 Front panel with text 0558002423

10 Indicator lamp (temp) 0369733001 K38

11 Switch (on/off) 0193317004 K5

12 Knob (voltage) 0318113003

13 Knob (timers) 0466175001

14 Left Side panel with text 0558002424

15 Knob (wire feed) 0466175002

16 Fixing handle (right) 0369559001

17 Fixing handle (left) 0369559002

18 Pipe handle 0369567002

Item

No.

MigMaster Spare Parts List (Figure 5)

Note: To replace entire Reverse Polarity 0558002432

MigMaster 210 Spare Parts (Figure 5)

Figure 5 - MigMaster 210 Front View

Item

No.

MigMaster 210 Spare Parts (Figure 6)

19 Diode bridge complete 0558002425 K2

20 Thermostat 0320918001 K31, 1

21 Resistor spiral 0367768001 K15

22 Auxiliary transformer 0367524001 K9

23 Secondary fuse (slow) 3.15A 0567900112

24 Connection block 0040705501

25 Middle plate 0466217001

26 Control PC Board 0558002745 M8

27 Switch (voltage) 0466356001 K6

28 Contactor 0193356101 K8, 4

29 Transformer (1 phase) 0367540880 K1

30 Bottom plate 0367214001

31 Inductor 0321105881 K12

32 Gas cylinder platform 0558002426

33 Rear axle 0558002427

34 Resistor 50 OHM, 50W 0192579211 M12

35 Capacitor 20,000µF 50V 0367525001 K88

36 Capacitor 1µF 0046006704 K27

37 Resistor 5.6K OHM 0191093146 K27

38 Connection block 2 pole 0193275001

39 Fan 230V 0365539001 K28

40 Air inlet grill 0319498038

41 Rear Panel 0558002428

72 Wheel Spacer (2 Req’d) 0558002429

Description Part No. Symbol

MigMaster 210 Spare Parts (Figure 6)

19 20

Figure 6 - MigMaster 210 Internal Right Side View

Item

No.

MigMaster 210 Spare Parts (Figure 7)

Description Part No. Symbol

42 Solenoid valve 0193054002

43 Gas hose 6 ft. (No Fittings) 0190315102

43A Nipple, Push 35N22

43B Nut,Hose 136Z08

44 Wire reel hub 0146967881

45 Connection block 8 pole 0162781007 K11

46 Inching button 0193793001 K5, 1

47A Wire feed unit 0369951882

47B Wire Feed Motor 0466489001 M4

48 Rubber hose 0191954101

49 Adjusting board 0481748882

50 Chain 0321173001

51 Support bracket 0318170001

52 Main cable (16 ft.) 0367764881

71 Support For Front Wheels 0558002430

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ESAB MigMaster 210 User manual

Brand: ESAB

Model: MigMaster 210

Category: Welding System

Type: User manual

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