ESAB Migmaster 300i cvcc, Service And Maintenance Manual

Page 1: ...Migmaster 300i cvcc WELDING POWER SUPPLY SERVICE AND MAINTENANCE BEFORE SERVICING READ AND COMPLY WITH THESE INSTRUCTIONS F 15 097 A March 2001...

Page 2: ...Finding Welding Parameters in MIG 12 3 5 Synergic Relationships and Functions 12 3 6 Servo Functions 12 3 7 Saving Welding Conditions 13 3 8 Fault Conditions 13 IV INSTALLATION OF POWER SOURCE AND AC...

Page 3: ...1 Stick Welding 22 5 3 2 TIG Welding 24 5 3 3 MIG Welding 24 5 3 3 1 Guided Mode of Setting Welding Parameters 24 5 3 3 2 Manual Mode of Setting Welding Parameters 24 5 4 Description of Trigger Type...

Page 4: ...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...

Page 5: ...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 Associati...

Page 6: ...nt Any claims for loss or damage occurring in transit must be filed with the carrier The carrier will furnish a copy of the bill of lading and the freight bill on request if the need to file a damage...

Page 7: ...023 030 and 034 045 regulator and adjustable flowmeter 10 gas hose 10 work cable and clamp 10 primary cable with plug and receptacle and Welding Handbooks Description Part Number Migmaster 300i cvcc...

Page 8: ...237 17718 2075238 052 1 4mm 948340 2075349 2075239 17719 2075240 1 16 1 6mm 948341 996997 2075239 17719 2075240 Soft Wires aluminum 035 9mm 996995 996996 948862 3 64 999578 996999 996998 948863 Wire S...

Page 9: ...zle Desc I D Standard Duty Heavy Duty 6 Tapered 3 8 998895 8 1 2 998893 999471 10 5 8 998894 999472 12 3 4 999473 12 Spot 3 4 17316 999625 10 Stud 5 8 17173 Uses Nozzles Adapter P N 999452 2 6 SAFETY...

Page 10: ...i cvcc Power Source Informa tion contained in this manual should be read carefully before performing service or maintenance tasks 3 2 POWER SOURCE The Power Source consists of three main components A...

Page 11: ...s selected are present in the list If SEL SET UP TYPE is guided mode you will find lines in the list that will allow the operator to specify wire type wire size shield ing gas plate size voltage trim...

Page 12: ...g param eters The wire speed and welding voltage is preset by the control unit as a function of the chosen consumables and material size Setting of the plate thickness will have the same effect as a c...

Page 13: ...hat the problem is in the following manner A Top row shows DETECTED A FAULT B Bottom row indicates the problem It may be difficult to see the message on occasion due to the function of the screen disp...

Page 14: ...assemblybyinsertingapinintoeachendofthe axle C Remove the existing shipping supports by un screwing from chassis 4 3 ELECTRICAL INPUT CONNECTIONS In order to provide a safe and convenient means to co...

Page 15: ...ARY OUTPUT CONNECTIONS The Migmaster 300i Power Source is completely self contained so that the front panel torch fittings are in ternally connected to the welding polarity dc reverse or dc straight v...

Page 16: ...ipment is to a large extent dependent on the use of welding cables and connections which are in good condition and of ad equate size 4 6 INSTALLATION FOR MIG WELDING BE SURE THE BRANCH CIRCUIT OR MAIN...

Page 17: ...4 6 3 3 THREADING WELDING WIRE A Turn off power switch WHEN THE POWER SWITCH IS ON AND GUN TRIGGER IS DEPRESSED THE ELECTRODE WIRE BECOMES ELECTRICALLY HOT AND THE WIRE FEED ROLLS ARE ACTIVATED B Rel...

Page 18: ...1 1 8in openendwrenchoranadjustablewrench To prevent damaging the O ring seals and plastic tube do not use the flowmeter tube as a handle when attaching the regulator Figure 4 6 R 50 Regulator C Make...

Page 19: ...CHING WORKPIECE WHEN INITIALLYAPPLYING POWER BE SURE THAT GAS CYLINDER VALVE IS CLOSED TO PREVENT GAS FROM BEING PRESENT WHEN INITIALLY APPLYING POWER The Migmaster 300i Power Source is not designed f...

Page 20: ...to the ELEC TRODE negative output receptacle J6 and the plug of the Work lead to the ELECTRODE positive out put receptacle J5 Refer to Section V for operational instructions NOTE The TIG or MIG Torch...

Page 21: ...the helmet is lowered over the face the opera tor should wear flash goggles with filter lenses underhishelmet Thehelmetfilterplateshould be shade number 11 nonferrous or 12 fer rous All those viewing...

Page 22: ...or wire speed for desired arc characteristics These changes can be made while welding NOTE Make small changes when fine tuning the arc Too large a change will make the arc unstable When entering setup...

Page 23: ...increase PRE FLOW or to decrease PRE FLOW Use to increase POST FLOW or to decrease POST FLOW Table 5 1 Migmaster 300i cvcc STICK Process Display Action Connect electrode holder and Work lead Select S...

Page 24: ...rce 1 manual mode and 2 guided mode Both modes will be briefly explained here For detailed explanation refer to Section III paragraph 3 3 The selection is made when SEL SET UP TYPE ap pears The bottom...

Page 25: ...switch Power on unit Set shielding gas flowmeter to 35 cfh Use or to change WIRE TYPE to desired material Note Wire Type Options are listed in Table 4 3 Use or to change WIRE SIZE to desired diameter...

Page 26: ...e WIRE SIZE Press or to change GAS SHIELD mixture Press or to change TRIGGER TYPE COMMENT Active lists options active list 1 active list 2 active list 3 Set up options guided set up manual set up Wire...

Page 27: ...ase WIRE SPEED Press to decrease WIRE SPEED Press to increase VOLTAGE Press todecreaseVOLTAGE Table 5 4 Migmaster 300i cvcc SET UP OPTIONS for The MIG Process Cont COMMENT This option appears when TRI...

Page 28: ...ART TYPE Press or to trim BURNBACK time Press or to trim WIRE SPEED Press or to TRIM VOLT AGE Press to increase PLATE SIZE Press to decrease PLATE SIZE COMMENT This display appears on manual set up on...

Page 29: ...the guided set up is shown Use and to set wire feed speed Use and to set welding voltage Use and to set inductance percentage Use and to select TRIGGER TYPE Note Trigger Type options are listed in Tab...

Page 30: ...ble 4 3 Use or to set BURNBACK time if needed Display SEL START TYPE normal TRIM BURNBACK v 0 20 seconds The shaded boxes are the only settings required to be changed by the operator to find the weldi...

Page 31: ...duration Once the torch switch is pressed the option with the spot time is moved up in the list to be quickly accessible to locate the parameters for the spot welding operation D Stitch Welding Stitc...

Page 32: ...art method is called slow run in and may be selected when SEL START TYPE appears The other selection is normal This gives starts with the wire feed speed used during welding Refer to Table 5 7 for SEL...

Page 33: ...hazards IF UNINSULATED CABLE AND PARTS ARE NOT REPLACED AN ARC CAUSED BYA BARED CABLE OR PART TOUCHINGA GROUNDED SURFACE MAY DAMAGE UNPROTECTED EYES OR STARTA FIRE BODYCONTACT WITH A BARED CABLE CONN...

Page 34: ...d on the wire compartment shelf ac cessible from the wire feeder compartment Failure of this circuit breaker will shut off the contactor shielding gas and wire feeder 6 2 1 5 OVER TEMPERATURE PRO TECT...

Page 35: ...ned wir ing or components or any other sign of damage or discoloration VII TROUBLESHOOTING AND REPAIR 7 1 TROUBLESHOOTING If welding equipment doesn t work right despite com pliance with checklist ins...

Page 36: ...correct polarity 5 Welding output voltage a Low line voltage a Use correct voltage and or current too low b Welding cables too long or too b Use correct cable size small c Loose connection c Check all...

Page 37: ...ust setting f Drive or pressure roll dirty or f Clean rolls or replace worn 13 Wire does not feed a Kink etc in wire or wire bound a Straighten or feed wire until motor running drive on reel clear and...

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Page 41: ...is recommended that only genuine ESAB parts and products be used with this equipment The use of non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB distributor For a...

Page 42: ...80359 951261 993952 33619YL 32135GY 32995 950396 33620YL 954202 13730912 13735895 33291YL 2091514 33616GY ASSEMBLY LCD 16 CHARACTERS 15 COND KEYPAD MEMBRANE SWITCH 3 POS RECEPTACLE 2 POLE HIDDEN RECEP...

Page 43: ...REAR VIEW ITEM NO QTY REQ PART NO DESCRIPTION CKT DESIG 1 2 3 4 5 6 1 1 1 1 1 14 FT 13736731 678944 08030255 08030245 33613 95195024 BRACKET CYLINDER CHAIN 36 IN NUT HOSE CONNECTION CONNECTION HOSE 3...

Page 44: ...44 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 22 23 24 25 26 27 28 29 FIGURE 8 2 MIGMASTER 300i LEFT INTERIOR VIEW...

Page 45: ...G 9 POS CONNECTOR BODY RECEPTACLE 9 POS SHELF EXTENSION PAD THERMAL DIODE MODULE RECTIFIER OUTPUT CAPACITOR 05 uF 500 V RESISTOR 5 OHM 50 W CONNECTOR NO 2 1 0 AWG CURRENT TRANSFORMER SWITCH THERMAL 80...

Page 46: ...46 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 16 17 18 19 20 21 FIGURE 8 3 MIGMASTER 300i RIGHT INTERIOR VIEW...

Page 47: ...8950248 33344 33345 33343 17250110 13733935 13792051 23610528 23610696 23612350 92047075 23612590 21165 MOTOR GEAR DRIVE STAND ASSY GUIDE TUBE INLET SHELF WIRE COMPARTMENT NUT SUPPORT REEL HUB REEL CA...

Page 48: ...pair Stations C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Part Numbers Technical Applications Hours 8 00 AM to 5 00 PM EST Performance Features Technical Specifications Equipment Recom...