ESAB Multimaster-260 Mig/Tig/Stick Welding Package Installation guide

Brand: ESAB

Model: Multimaster-260 Mig/Tig/Stick Welding Package

Category: Welding System

Type: Installation guide

Multimaster-260

MIG/TIG/STICK WELDING PACKAGE

INSTALLATION AND OPERATION for

F15-611-F

October, 2008

Console - P/N 0558001513 (208/230 vac 1 Phase)

Console - P/N 0558001514 (230/460/575 vac 1 Phase)

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!

TABLE OF CONTENTS

SECTION TITLE................................................................................................................................................ PAGE

SECTION 1 SAFETY PRECAUTIONS .........................................................................................................................................................5

1.0 Safety Precautions .....................................................................................................................................................................5

1.1 Safety - English ...........................................................................................................................................................................5

1.2 La seguridad - español.............................................................................................................................................................9

1.3 La sûreté - français .................................................................................................................................................................. 13

SECTION 2 DESCRIPTION .........................................................................................................................................................................17

2.1 General ..................................................................................................................................................................................... 17

2.2 RECEIVING-HANDLING .......................................................................................................................................................... 17

2.3 DESCRIPTION ........................................................................................................................................................................... 17

2.4 OPTIONAL EQUIPMENT ........................................................................................................................................................ 18

SECTION 3 INSTALLATION ....................................................................................................................................................................... 21

3.1 LOCATION ................................................................................................................................................................................ 21

3.2 HANDLE ASSEMBLY & INSTALLATION .............................................................................................................................. 21

3.3 ELECTRICAL INPUT CONNECTIONS .................................................................................................................................. 21

3.4 VOLTAGE CHANGEOVER ....................................................................................................................................................... 22

3.5 SECONDARY OUTPUT CONNECTIONS ............................................................................................................................ 22

3.6 “NAS” TORCH CONNECTION................................................................................................................................................22

3.7 WIRE FEEDER MECHANISM ................................................................................................................................................. 22

3.8 CONNECTION OF SHIELDING GAS SUPPLY .................................................................................................................... 24

SECTION 4 OPERATION ............................................................................................................................................................................. 25

4.1 STANDARD CONTROLS .........................................................................................................................................................25

4.2 OPTIONAL CONTROLS .......................................................................................................................................................... 27

4.3 OPERATING PROCEDURES ...................................................................................................................................................28

4.4 MIG WELDING SET-UP ........................................................................................................................................................... 30

4.5 TIG WELDING SET-UP ............................................................................................................................................................. 32

4.6 STICK WELDING SET-UP ........................................................................................................................................................33

SECTION 5 MAINTENANCE ...................................................................................................................................................................... 35

5.1 MAINTENANCE AND SERVICE ............................................................................................................................................35

5.2 INSPECTION AND SERVICE .................................................................................................................................................. 35

Schematics ................................................................................................................................................................................37

SECTION 6 REPLACEMENT PARTS ........................................................................................................................................................43

6.0 Replacement Parts ................................................................................................................................................................. 43

6.1 General ....................................................................................................................................................................................... 43

6.2 Ordering ..................................................................................................................................................................................... 43

TABLE OF CONTENTS

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.

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.

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"

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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Table 1 Multimaster 260 Specications

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 information

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 dam-

age 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 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.

2.3.1 PACKAGES

The following part numbers and descriptions are for the

Multimaster 260 as packaged with choice of gun length,

gas owmeter regulator, and primary input voltage.

Multimaster 260 Console with:

0558001519 12-ft gun Argon 208/230vac 1ph 50/60Hz.

0558001523 12-ft gun CO

208/230vac 1ph 50/60Hz.

0558001521 12-ft gun Argon 230/460/575vac 1ph 50/60Hz.

0558001525 12-ft gun CO

230/460/575vac 1ph 50/60Hz.

0558001520 15-ft gun Argon 208/230vac 1ph 50/60Hz.

0558001524 15-ft gun CO

208/230vac 1ph 50/60Hz.

0558001522 15-ft gun Argon 230/460/575vac 1ph 50/60Hz.

0558001526 15-ft gun CO

230/460/575vac 1ph 50/60Hz.

Primary Input Voltage 208 Vac 230 Vac 460 Vac 575 Vac

1 Phase 1 Phase 1 Phase 1 Phase

Primary Current

@ 260 Amp @ 27 Volt 57 Amps 52 Amps 26 Amps 20 Amps

@ 200 Amp @ 24 Volt 35 Amps 32 Amps 16 Amps 13 Amps

Duty Cycle 50% 100%

Rated DC Output 260 Amps 200 Amps

Process MIG (GMAW) TIG (GTAW) STICK (SMAW)

Output Current Range 35-300 Amps 15-300 Amps 40-300 Amps

Open Circuit Voltage (max) 39.0 Vdc 20 Vdc 70 Vdc

Wire Feed Speed Range 65-675 Inches per Minute

Dimensions Length Width Height

(with Cyl. Rack & Wheels) 42” 20” 32”

Weight (w/o Cyl.) 250 Lbs

SECTION 2 INTRODUCTION

2.3.2 PACKAGE CON TENTS STANDARD ACCESSORIES

Each Multimaster 260 package includes:

• Powersourcewiththebuilt-infourrolldrivewirefeeder.

• Factoryinstalledundercarriageanddualcylinderrack.

• GunMaster250MigGunwith.035”/.045”accessories.

• Dualgroovefeedrollsfor.035”/.045”.

• Regulatorandadjustableowmeter.

• 6’gashose.

• 15’workcableandclamp.

• 8’primarycablewithplugandreceptacle.

• MigWeldingHandbookandset-upguide.

• Multimaster260CD-ROM(782F19)

2.3.3 CONSOLES

The following part numbers and descriptions are for the

two basic Multimaster 260 consoles (no accessories).

Part Number Description

0558001513 Multimaster 260 208/230 1ph. 50/60Hz.

0558001514 Multimaster 260 230/460/575 1ph. 50/60Hz.

2.3.4 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 opera-

tions and shuts o four minutes after welding stops. The fan

will automatically re-start when welding resumes and proper

machine temperatures will be maintained.

2.3.5 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).

2.3.6 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 Sec-

tion 4 (Operation) of this manual.

2.3.7 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)

2.3.8 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.

2.3.9 RUNNING GEAR

The Multimaster 260 is equipped with running gear with

swivel front wheels and a dual gas cylinder support.

2.4 OPTIONAL EQUIPMENT

MT-250SG Spool Gun ..........................................................36779

ST-23A Spool Gun.................................................................19164

Requires Spool Gun Adaptor .....................................37301

HW-17V-2TL Heliarc Torch Assy. 12-1/2 Ft. ..................35857

Electrode Holder 175 Amp 15 Ft. ....................................0558001791

Electrode Holder 300 Amp 15 Ft. ....................................21226

Tig Spare Part Kit ..................................................................999126

Tig Welding Handbook .......................................................781F29

Tig Remote Control Module .............................................0558001792

Spool Gun Module ...............................................................0558001793

Inductance Control Module .............................................0558001794

Preow/Postow/Spot/Bbck Module ...........................0558001795

FC-5B Foot Control 30 Ft. ...................................................33646

Tee Connector (1male - 2 female)...................................13792804

Extension Cord 25 Ft. 50 amp ..........................................37833

SECTION 2 INTRODUCTION

Choiceof12’or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

Regula-

tor/Flowmeter

Simple To Use Weld

Controls

Figure 1A - Components

Welding Gloves

(Optional)

Eyetech Auto-

matic 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 INTRODUCTION

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

Cylinder

Chain

SECTION 2 INTRODUCTION

3.0 INSTALLATION

3.1 LOCATION

Several factors should be considered when selecting an in-

stallation site. Adequate ventilation is necessary to provide

cooling, 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 ma-

chine’souterenclosureformaintenance.Installingorplacing

Hex Bolt and Washer

Sheetmetal Screws

Figure 3 - Handle Mount

3.3 ELECTRICAL INPUT CONNECTIONS

Figure 2 - Dimensions

any type of ltering device will restrict the volume of intake

air, thus subjecting the internal components to overheating.

Warranty is void if any type of ltering device is used.

3.2 HANDLE ASSEMBLY INSTALLATION

The Multimaster 260 is factory assembled except for the

front handle which is packed with the machine. The handle

consists of two brackets and a cross bar. To install the handle,

do the following:

A. Remove the two sheetmetal screws on each side of the

power source (see Figure 3).

B. Identify the left and right bracket and mount with the

screws just removed.

C. Place the round bar handle between the two side brackets

and attach with the hex bolts and washers provided with

the handle.

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.

Before making electrical input connections to the weld-

ing 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.

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 or

230/460/575 vac single phase 50/60 Hz.

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 conform-

ing to NEMA 6-50R congura tion (208/230 vac model only).

The receptacle should be wired to a separately fused dis-

connect 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.

20”

32”

42”

Bar

SECTION 3 INSTALLATION

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.

3.4 VOLTAGE CHANGEOVER FIGURE 4

THE VOLTAGE CHANGEOVER TERMINAL BOARD IS LOCATED

IN THE TOOL COMPARTMENT ON THE LEFT SIDE OF

THE MACHINE. 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.

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

internally connected to the welding polarity (DCEP or DCEN)

via the secondary output terminals depending on the welding

process being used.

Figure 4 - Voltage Changeover Terminal Board

208/230 Version Shown Installed

Clear Panel Hinges on

corner screw

Remove this

screw only

3.6 “NAS” TORCH CONNECTIONS FIGURE 6

To install a Gun Master Mig Gun 250, remove the locking

knob on the top of the NAS connector and insert the male

power pin of the gun. Be sure the “O” rings are securely

seated by pushing inward on the power pin while tighten-

ing the locking knob.

Figure 5 - Polarity Set-up

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:

Locking Knob

Figure 6 - NAS Gun Connector

This screw must

remain in place

Do Not Remove

SECTION 3 INSTALLATION

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

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.

3.7.2 WELDING WIRE SPOOL INSTALLATION

As with any work area, make sure safety glasses with

side shields are worn when handling or changing wire or

clipping wire o at the spool or at the end of the torch.

Hold onto the wire coming o the spool with one hand

before clipping. Serious eye injury can result due to the

resilience of the wire which can quickly unravel, or a cut

C. Feed the wire from the spool through the inlet guide,

across the drive roll grooves and center guide into the

outlet guide and NAS connection tube.

Make sure that the proper “outlet guide tube” is inserted into

the front-panel gun tting for the size and type of wire being

used, see Table for wire feed accessories.

To ensure proper wire feeding, it is important that the wire be

kept clean and that the drive rolls be periodi cally cleaned of

any chips or scale that might be carried into the gun liner.

D. Lower pressure roll assembly and secure. Turn the power

“on” and feed wire through to gun tip using the gun trig-

ger to start wire feeding.

Figure 8 - Spindle Assembly

Feed Roll Release Screws

wire end which may shoot across the room.

Install a spool of welding wire on the spindle as follows:

A. Remove the locking pin from the spindle (Figure 8).

B. Place wire spool on the spindle to rotate clockwise as

wire is unwound; spindle brake pin must engage hole

in spool.

C. Replace the locking pin into the spindle hole closest to

the spool.

3.7.3 THREADING WELDING WIRE

A. Turn o power switch.

B. Release pressure drive roll assembly. Check that proper

wire diameter grooves are in the inner position.

Before threading welding wire, make sure chisel point

and burrs have been removed from wire end to prevent

wire from jamming in gun or liner.

Locking PinSpool Spindle

Pressure Roll As-

sembly

Pressure Release

Lever

Threading the wire

through the inlet

guide

When the power switch is on, and gun trigger is depressed,

the electrode wire becomes electrically hot, and the wire

drive rolls will rotate.

Figure 7 - Wire Feeder Mechanism

Figure 9 - Threading the Wire

SECTION 3 INSTALLATION

3.7.4 SPOOL BRAKE DRAG ADJUSTMENT

Spool brake disc friction should provide enough drag to keep

the wire spool from spinning freely after wire feed stops. If

adjustment is required, turn the adjusting screw inside the

spindle housing clockwise to increase drag or counterclock-

wise to decrease it. Drag should be just enough to limit

wire overrun.

3.8 CONNECTION OF SHIELDING GAS SUPPLY

3.8.1 R33FM580 REGULATOR

The R-33-FM-580 regulator is an adjustable regulator designed

for use with Argon, Helium, and C-25 (75% Argon/25% CO

)

gas service. Table 2 table provides the recommended ow

ranges for the R-33-FM-580 regulator.

Argon 10-50 cfh

Helium 150-230 cfh

C-25 10-50 cfh

Table 2 - Typical Flow Rates

A. With the cylinder cap in place, CAREFULLY slide the

cylinder of gas onto the Multimaster 260 cylinder rack.

B. Secure the cylinder to the unit using the chain provid-

ed.

C. Unscrew the cylinder cap.

Do not clamp regulator cap in a vise or grip it with a pair

of pliers. Distortion of cap can jam the internal parts and

cause excessively high delivery pressure as well as weaken

the threaded joint to the regulator body. This may cause

the cap to y o and possibly injure personnel in area.

D. Open the cylinder valve slightly, for an instant, to blow

out any dust or dirt that may have collected in the valve

outlet. BE SURE to keep your face away from the valve

outlet to protect your eyes.

E. Attach the regulator to the cylinder valve. Align the

regulator so that the owmeter is vertical and then

tighten the connection nut with a 1-1/8 in. open end

or adjustable wrench. To prevent damaging the O-ring

seals and plastic tube, do not use the owmeter tube as

a‘handle’whenattachingtheregulator.

F. Close the ow control valve on the owmeter.

G. Attach the gas hose from the rear of the Multimaster 260

to the regulator outlet connection.

Never stand directly in front of or behind the regulator

when opening the cylinder valve. Always stand to one

side.

H. Open the cylinder valve SLOWLY a fraction of a turn. This

will prevent damage to the gauge and critical components

in the regulator. When the gauge needle stops moving,

then open the cylinder valve fully.

I. Using a leak test solution, such as P/N 998771 (8 oz. ctr)

or soapy water, test for leakage around the cylinder

valve stem, the regulator inlet connection, and the hose

connections at the regulator. Correct any leaks before

starting work.

3.8.1 TO REGULATE FLOW

Flow is controlled by adjusting the owmeter valve until de-

sired ow is indicated by the ball oat in the owmeter tube.

Always take the reading across the TOP of the ball.

Figure 10 - R-33 Regulator

Cylinder Valve

Connection

Nut

Flow Tube

Control Valve

Pressure

Gauge

SECTION 3 INSTALLATION

Figure 11 - Burnback Control

4.0 OPERATION

4.1 STANDARD CONTROLS

4.1.1 POWER ON/OFF SWITCH & LAMP

The main power switch is located on the front panel in the

upper left-hand corner. This switch energizes the main

transformer, control circuitry and illuminates the Power “ON”

lamp. (Figures 12 &13)

4.1.2 FAULT LAMP FIGURE 12

THE FAULT LAMP IS CONFIGURED FOR FUTURE USE AND IS

NOT CURRENTLY ACTIVATED.

4.1.3 TEMP LAMP FIGURE 12

THE TEMP LAMP ILLUMINATES IF AN OVER TEMPERATURE

CONDITION OCCURS WITHIN THE MULTIMASTER 260.

THIS CONDITION MAY BE CAUSED BY EXCESSIVE DUTY

CYCLE OR OVERCURRENT CONDITIONS. WHEN AN OVER

TEMPERATURE CONDITION OCCURS, THE WELDING OUTPUT

IS TURNED OFF AND THE UNIT MUST BE ALLOWED TO COOL.

THE MACHINE WILL AUTOMATICALLY RESET WHEN THE

TEMPERATURE FALLS TO A SAFE LEVEL.

4.1.4 PROCESS SELECTOR SWITCH FIGURE 12

The three position process selector switch is located in the

upper righthand corner of the control panel. The process

selector switch provides the visual indication of which process

(Mig, Tig or stick) has been selected.

4.1.5 SECONDARY WELDING CONNECTIONS

The secondary output welding terminals, POS (+) and NEG

(-) are located in the lower right of the front panel, directly

beneath the NAS Mig Gun Connector (Figure 13). See 4.4, 4.5,

and 4.6 for Setup Guides for specic application.

4.1.6 DIGITAL DISPLAYS WFS, AMPS & VOLTS

The digital displays located on the left side of the control

panel are multi-functional depending on the welding process

being used.

4.1.7 MIG WELDING

In the Mig process mode, the digital displays will read preset

wire feed speed in inches per minute and preset arc volts

when the PRESET button is pressed. Once welding begins,

the displays will show average welding current and volts in

the top and bottom display, respectively. The displays have

a “HOLD” circuit that retains the welding conditions. After

welding stops, the display will continue to show the last

welding current and voltage sampled until welding starts

again or the preset button is pressed.

4.1.8 TIG AND STICK WELDING

In the TIG and STICK process mode, you must depress and

hold the PRESET button while presetting the welding current

in the top display. Releasing the preset button causes the

display to return to zero. Once welding begins, the display

will show average welding current and volts in the top and

bottom display, respectively. After welding stops, the display

will again return to zero. There is no “HOLD” circuit for the

display when using the TIG and STICK process modes.

4.1.9 WIRE FEED SPEED CONTROL FIGURE 12

The wire feed speed control potentiometer allows wire feed

speed adjustments between 65 and 675 inches per minute

(IPM). Selecting the Mig process and pressing the PRESET

switch allows the wire feed speed to be preset in the top

digital display by turning the wire speed knob.

4.1.10 VOLTAGE/CURRENT TRIM FIGURE 12

The arc voltage is controlled with this knob when the Process

selector switch is in the MIG position. The Mig arc voltage

can be preset by pressing the preset button and reading the

preset arc volts in the bottom digital display while turning

this knob.

The arc current is controlled with this knob when the WELD

PROCESS SWITCH is in the TIG or STICK position. The welding

current can be preset in amperes by pressing the preset button

and reading the preset amps in the top digital display while

turning this knob. The actual arc voltage will be displayed

during welding.

4.1.11 BURNBACK CONTROL FIGURE 11

The burnback control is located inside the wire spool compart-

ment above the wire feed motor. The control knob adjusts

the time between when the wire feed brake is applied and

the welding contactor is turned “o”. This determines how far

the wire will burnback towards the contact tip after welding

is stopped. If the wire is sticking in the weld pool then turn

the knob clockwise a small amount and retest. Continue this

procedure until the wire clears the top of the weld pool or

burns back the desired amount.

SECTION 4 OPERATION

Digital Meters

Amps/Volts/WFS

Power “ON”

Lamp

Temperature

Lamp

Fault

Lamp

WFS - IPM

Lamp

Amps

Lamp

Preset

Button

Weld Process

Switch

Voltage Set - MIG

Current Set - STICK/TIG

Wire Feed

Speed Trim

IPM

Figure 12 - Control Panel

Main

Power

Switch

Spool Gun Control

Module

(Option)

Remote Control

Module

(Option)

Mig Gun

NAS

Connection

Positive Output Con-

nection

Negative Output

Connection

Polarity Switch-

ing Connector

Mig Gun

Trigger

Receptacle

Figure 13 - Front Panel

SECTION 4 OPERATION

4.2 OPTIONAL CONTROLS

4.2.1 INDUCTANCE TRIM (OPTIONAL)

PN-0558001794 (Figure 14)

Inductance is used to optimize short circuiting arc perfor-

mance by changing the current rise and fall time of each

short circuit. This results in improved spatter control, weld

bead wetting and arc stability. It is HIGHLY RECOMMENDED

that the Inductance Trim option be used for optimum short

arc welding performance with stainless steel wires.

The INDUCTANCE TRIM is installed inside the wire spool

compartment, above the wire feed motor, to the left of the

Burnback adjustment. The “easy to set” dial is calibrated by wire

alloy (Carbon Steel and Stainless Steel) and Shielding gas:

100% CO

Argon - 25% CO

Argon - 8 to 15% CO

Trimix (Stainless Helium Mixtures)

The short circuiting Mig arc performance will change from

a high short circuit frequency, fast reacting arc, to a lower

short circuit frequency, soft and less spattering arc as the

dial is turned clockwise. The optimized arc performances

will vary depending on shielding gas, wire diameter and

alloy. Gases and alloys other than those indicated can also

be optimized with this control. The operator can adjust this

control as desired to optimize personal preferences of weld-

ing characteristics.

4.2.2 PREFLOW/POSTFLOW/SPOT/BURNBACK

OPTIONAL PN0558001795 FIGURE 15

This optional control is mounted in place of the standard

burnback control inside the wire spool compartment. A

description of the module follows:

A. Preow/Postow - The PREFLOW control sets the time

of the preow shielding gas before the wire starts feed-

ing (0-1.5 sec.). The POSTFLOW control sets the time

the shielding gas remains “ON” after the arc is turned

“OFF” (0-7.5 sec.).

Figure 14 - Inductance Trim

Figure 15 - Preow/Postow/Spot/Burnback

B. Spot Weld Time - This dial sets the spot weld time from 0

to 5 seconds and is controlled by a current detect switch.

The timer does not start until current is detected to insure

consistent results.

C. Burnback Timer - See 4.1.11

D. Spot Weld Switch Position - With the toggle switch in

the SPOT (left) position, the SPOT timer is turned “ON”,

and the spot weld time is controlled by the SPOT WELD

TIMER dial.

E. Continuous Position - With the toggle switch in the

CONTINUOUS (center) position, the welding continues

as long as the Mig gun trigger is depressed.

F. Trigger Lock Position - With the toggle switch in the TRIG-

GER LOCK (right) position, the welding process begins

when the gun trigger is depressed. Once the welding

process has started, the gun trigger may be released with-

out aecting the welding process. To stop the welding

operation, the gun trigger must be depressed a second

time. This allows a continuous weld without having to

continuously depress the gun trigger.

Continuous

“ON”

Trigger Latch

“ON”

Spot “ON”

Spot Time

Preow

Time

Postow Time

Burnback

Time

SECTION 4 OPERATION

4.2.3 REMOTE CONTROL MODULE OPTIONAL

PN0558001792 FIGURE 16

This optional control panel mounts to the front of the power

source to the right of the main power switch (see Figure 13).

The remote receptacle can be used for a variety of options,

such as a Tig current control, foot pedal control or manual

hand current control. The module includes a toggle switch

to select between PANEL or REMOTE control of the welding

current and contactor.

Figure 16 Remote Control Module

4.2.4 SPOOL GUN CONTROL MODULE

OPTIONAL PN0558001793 FIGURE 17

This module mounts to the front panel just left of the Mig Gun

trigger connectors and allows the use of either the MT-250SG

or ST-23A spool guns with the Multimaster 260. The module

has a switch to select either spool gun or regular Mig gun

operation. See Table 3 for MIG Spool Gun Paramaters.

Figure 17 - Spool Gun Control Module

4.3 OPERATING PROCEDURES

Comply with all ventilation, re and other safety require-

ments for arc welding as established in the SAFETY Section

at the front of this manual.

SECTION 4 OPERATION

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ESAB Multimaster-260 Mig/Tig/Stick Welding Package Installation guide

Brand: ESAB

Model: Multimaster-260 Mig/Tig/Stick Welding Package

Category: Welding System

Type: Installation guide

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ESAB Multimaster-260 Mig/Tig/Stick Welding Package Installation guide

ESAB Multimaster-260 Mig/Tig/Stick Welding Package Installation guide

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