ESAB MigMaster 210, Instruction Manual

Page 1: ...MigMaster 210 F15 690 062002 Instruction Manual ...

Page 2: ...l 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...

Page 3: ...on 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 CONTENTS ...

Page 4: ...stances 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...

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 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 in...

Page 6: ...ue de passage d un courant de sortie par des chaînes de PRÉCAUTIONS DE SÉCURITÉ AVERTISSEMENT Ces règles de sécurité ont pour objet d assurer votre protection Veillez à lire et à observer les précautions énoncées ci dessous avant de monter l équipement ou de commercer à l utiliser Tout défaut d observation de ces précautions risque d entraîner des blessures graves ou mortelles 1 PROTECTION INDIVID...

Page 7: ...particulières en matière de ventilation indiquées à l alinéa 6 de la norme Z49 1 de l AWS 5 ENTRETIEN DE L ÉQUIPEMENT Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise qualité mais chose plus grave encore d entraîner des dommages corporels graves voire mortels en déclenchant des incendies ou des chocs électriques Observez par conséqu...

Page 8: ...mal 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 05...

Page 9: ...er 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 standar...

Page 10: ...ult 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 CO2 Argon CO2 Oxygen Argon CO2 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 ...

Page 11: ... specific welding application and personal preference Stainless Steel Solid Wires Carbon Steels Solid Wires Helium Argon Based Shielded Gases Argon Based Shielding Gases CO2 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 hi...

Page 12: ...Both welding time and pause time can be set steplesslybetween0 2and2sec Forwelding 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...

Page 13: ...equired 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 n...

Page 14: ...t 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 o...

Page 15: ...15 Dimension Diagram Assembly Diagram R Pin Figure 2 Assembly and Dimensional Diagrams 11 8 18 75 Spacers ...

Page 16: ...16 Recommended Welding Parameters MigMaster 210 Figure 3 Welding Parameters ...

Page 17: ...ge 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 certai...

Page 18: ...ber 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 Fi...

Page 19: ...19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 MigMaster 210 Spare Parts Figure 5 Figure 5 MigMaster 210 Front View ...

Page 20: ... 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 ...

Page 21: ...21 MigMaster 210 Spare Parts Figure 6 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 36 38 39 40 41 Figure 6 MigMaster 210 Internal Right Side View 72 ...

Page 22: ... 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 ...

Page 23: ...23 MigMaster 210 Spare Parts Figure 7 42 43 44 45 46 47B 48 49 50 51 52 Figure 7 MigMaster 210 Internal Left Side View Burn Back Time 47A 71 ...

Page 24: ... 12 in 0157349001 60 Screw 0212108041 61 Bracket 0369306001 62 Feed roller 023 030 035 Fe SS 0367556001 Optional Feed roller 030 035 Cored 0558002433 63 Insulating washer 0153043002 64 Nozzle out 0466063880 65 Power clamp 0369735001 66 Nut M8 0212602009 53 Wire Feeder Motor 0466489001 Supplied With Machine 67 Power sleeve 0369950001 68 Insulating sleeve 0368750001 69 Cable set 0367543883 70 Gun co...

Page 25: ...ure 8 MigMaster 210 Wire Feeder Assembly Welding clamp 82F31 Work Assembly 32995 MigMaster 210 Spare Parts Items Not Illustrated Option Primary Extension Cord 37833 Option V Feed Roll 023 030 035 SS 0367556001 Option Serrated Feed Roll 030 035 Cored 0558002433 ...

Page 26: ...26 ...

Page 27: ...27 ...

Page 28: ...ICAL 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 Recommendations D LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Repair Estimates Repair Status Hours 7 30 AM to 3 3...