Migmaster 300i cvcc MIG/TIG/STICK WELDING PACKAGE P/N 34677 INSTALLATION AND OPERATION for Be sure this information reaches the operator. You can get extra copies through your sup- plier. F-15-094-A October, 1994 F-15-094-A These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for electric welding 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. ESAB Welding & Cutting Products PO Box 100545 Florence SC 29501-0545
Transcript
Migmaster 300i cvccMIG/TIG/STICK WELDING PACKAGE
P/N 34677
INSTALLATION AND OPERATION for
Be sure this information reaches the operator.You can get extra copies through your sup-plier.
F-15-094-AOctober, 1994
F-15
-094
-A
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safepractices for electric welding 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 NOTattempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fullyunderstand these instructions, contact your supplier for further information.
This equipment will perform in conformity with the description thereof contained in this manual andaccompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with theinstructions provided. This equipment must be checked periodically. Defective equipment should not be used.Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should suchrepair or replacement become necessary, the manufacturer recommends that a telephone or written requestfor service advice be made to the Authorized Distributor from whom 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 improperuse, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or aservice facility designated by the manufacturer.
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TABLE OF CONTENTS
SECTION NO. PAGE NO.
SECTION 1 - GENERAL SAFETY RULES FOR WELDING AND CUTTING ........................... 2
GENERAL PRECAUTIONS....................................................................................................... 2ADDITIONAL SAFETY INFORMATION .................................................................................... 4PRECAUTION SYMBOL DEFINITIONS.................................................................................... 5
5.1 INSPECTION AND SERVICE ....................................................................................... 28
4
SAFETY PRECAUTIONS
(TBS)
5
(TBS)
6
II. INTRODUCTION
2.1 GENERAL
This manual has been prepared for experienced weld-ers. Do NOT permit untrained persons to install, oper-ate or maintain this equipment. Do NOT attempt toinstall or operate this equipment until you have read andfully understand these instructions.
This manual is intended for use in familiarizing person-nel with the design and operation of this equipment. Allinformation presented here should be read carefullybefore installing and using this equipment.
2.2 RECEIVING-HANDLING
Upon receipt of this equipment, clean all packing mate-rial from around the unit and immediately inspect forany damage that may have occurred during shipment.Any claims for loss or damage occurring in transit mustbe filed with the carrier. The carrier will furnish a copyof the bill of lading and the freight bill on request, if theneed to file a damage claim arises.
When requesting information regarding this equip-ment, make sure that you include product name, partnumber, and serial number.
2.3 DUTY CYCLE
The duty cycle of the equipment is the percentage of a10 minute period which it can operate safely at a givenoutput current. The Migmaster 300i is rated at 300amps at 40% duty cycle and 250 amps at 60% dutycycle..
2.4 DESCRIPTION
The Migmaster 300i is a DC welding system designedfor Mig Welding(GMAW), Tig(GTAW) or Stick(SMAW).In the Mig mode this unit is capable of operating withshort arc or spray arc transfer and handles both solidwires and tubular cored wires. This unit is suitable forcarbon steel, stainless steel, aluminum and many otheralloys. It provides a power source with built in wirefeeder and undercarriage with provisions for one gascylinder.
2.4.1 AVAILABLE PACKAGES ANDCONTENTS
Each of the following packages include the powersource, with the built-in wire feeder, factory installed
19.5''
32.25''
undercarriage and cylinder rack, MT-200cc Mig Torch(with .035" and .045" accessories), dual groove feedrolls (.035"/.045"), regulator and adjustable flowmeter,6' gas hose, 10' work cable and clamp, 8' primary cable(with plug and receptacle), Mig Welding Handbook, TigWelding Handbook, and set-up guide.
The power source consists of an inverter DC powersource for single phase 208 or 230 primary connection.
2.4.3 WIRE FEEDER
The wire feeder is built into the power source cabinet,housed separately from the welding machine electricalcomponents. Cooling air is not drawn through the wirefeeder mechanism, reducing its exposure to dirt anddust.
The wire feeder pushes wire at speeds up to 655 ipm(inches per minute). The purge/inch switch mountedinside the power source cabinet allows the operator toadvance the wire without welding voltage.
40''
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TABLE 2.1. SPECIFICATIONS
Rated DC Output...............................................40% duty cycle..................................................300 amps @ 32 vdc
60% duty cycle (NEMA Class I).........................250 Amps @ 34 vdc
Output Current Range.......................................
Weight (no cylinder): ...........................................................................................................................175 lbs. (80 kg
The Migmaster 300i is equipped with a running gearwith swiveled front wheels and a gas cylinder support.The rear wheels are packed loose for shipping but areeasily installed, as described in Section 3.8.
2.5.2 Mig 41A Push/Pull Basic Mig Torch; does notinclude liner, feed roll or contact tip; order separately(see Form F-7036).15 ft Basic ....................................................... 2050625 ft Basic ....................................................... 205362.5.3 HW-17TV-2 (w/valve) Heliarc Tig Torch; 60 deghead, 17 ft; ................................................ 33814CSTIG weld without disconnecting the Mig torch. IncludesHW-17TV body, handle, long cap, cable cover, contactorswitch and cable, power adaptor, and gas hose.
2.4.4 MT-200cc TORCH
This air-cooled welding torch is supplied complete andready to weld 0.035 in. hard wire. The torch accommo-dates 0.045 inch wire by changing the contact tip. Otherwire sizes can be used. Refer to Table 2.2 and Table 2.3for other wire size accessories.
2.4.5 CONTROLS
The Migmaster 300i can be used to weld hard, alumi-num, and flux cored wire . Control of the power sourceand its different applications is provided by the 2 line, 32character display screen. The operator selects theprocess desired on a three position rotary switchlocated on the front panel. A detailed description of thepower source controls is included in Section III (Opera-tion) of this manual.
* Short contact tips are generally recommended to give proper wire stick out for flux cored wire welding.Medium contact tips are generally recommended to give proper wire stick out for spray arc Mig welding.Long contact tips are generally recommended to give good visibility and proper wire stick out for shortarc Mig welding.
** Requires support liner for .023" wire. Order P/N 999797. *Requires support tube. Order P/N 21169
Torch plugs into same front panel connector as the MT-200cc; convert from Mig to Tig quickly and have gascontrol through the power source. Includes body,handle, long cap, cable cover, contactor switch andcable “cc” connector.
2.5.5 HC-6 Hand Control; 25 ft. ..................... 21225Attach to welding torch for remote hand control ofoutput and trim functions.
2.5.6 FC-6 Foot Control; 25 ft. ....................... 33517Remote foot control of output and trim functions.
2.5.7 Stick Electrode Holder Assembly .......... 21226Assembly includes holder, cable and twist lock connec-tor, 15 ft.
2.5.8 Hub Adaptor .......................................... 17511Required for 8-in. spools
Table 2.4 Slide-on Nozzles(MT-200cc & MIG-41A)
*Uses Nozzles Adapter P/N 999452.
2.6 SAFETY
The safety section at the front of this manual should beread completely before attempting to install and oper-ate this equipment. Both equipment and personnelhazards are reduced if proper safety precautions aretaken. If you are unsure of yourself in any situation, askyour supervisor or other experienced personnel forhelp.
WireSize & Type
GuideTube
FeedRoll
Hard Wires -"V" Groove
21163 21155.023"(.6mm)
.030"(.8mm) 21164 21155
.035"(.9mm) 21165 21156
.045"(1.2mm) 21165 21156
Cored Wires -Serrated
21164 21160.030"(.8mm)
.035"(.9mm) 21165 21160
.045"(1.2mm) 21165 21161
.052"(1.4mm) 21166 21161
1/16"(1.6mm) 21166 21161
Soft Wires(aluminum)-"U" Groove
21167" 21158.035"(.9mm)
3/64"(1.2mm) 21168* 21158
Table 2.3 Guide Tubes and Feed Rolls
Table 2.2 Contact Tips and Liners
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Before making electrical input connections to thewelding machine, “Machinery Lockout Procedures”should be employed. If the connections are to bemade from a line disconnect switch, the switchshould be padlocked in the off position. If theconnection is to be made from a fusebox, removethe fuses and padlock the cover closed. If nolocking facilities are available, attach a red tag towarn others not to energize the circuit.
3.3.1 Input Electrical Requirements
The primary input voltage requirements are shown onthe power source nameplate. The power source isdesigned to be operated from 208/230 single phase 50/60 Hz.
Figure 3.1 Primary Connections
3.3.2 Input Conductor Connections
The input power cord is provided with an attachmentplug. The plug will mate with a 250 Volt, 50 Ampreceptacle conforming to NEMA 6-50R configuration.
The receptacle should be wired to a separately fuseddisconnect or circuit breaker. This disconnect or breakercan be wired to a single phase system or to twoconductors of a three phase system. A third conductorfor grounding should also be connected between thedisconnect and the receptacle.
The terminal labeled GRD is connected to the powersource chassis and is for ground purposes only. Itmust be connected to a good electrical ground. Donot connect a conductor from the terminal labeledGRD to any one of the L1, L2 terminals as this willresult in an electrically hot machine chassis.
III. INSTALLATION
3.1 LOCATION
Several factors should be considered when selectingan installation site. Adequate ventilation is necessaryto provide cooling, and the amount of dirt and dust towhich the machine is exposed should be minimized.There should be at least 18 inches of unrestrictedspace between the machine’s side and rear panels andthe nearest obstruction to provide freedom of air move-ment through the power source.
The installation site should permit easy removal of themachine outer enclosure for maintenance. Installing orplacing any type of filtering device will restrict thevolume of intake air, thus subjecting the power sourceinternal components to overheating. Warranty is voidif any type of filtering device is used.
Do not operate the machine without the runninggear installed.
3.2 ASSEMBLE REAR WHEELS
The units’ running gear is factory assembled except forthe rear wheels which are packed loose and in theshipping carton. The rear gear consists of 2-wheels, 4washers, 2-cotter pins, and an axle. To install the gear,do the following:
A. Insert the axle through the holes provided atthe rear of the gear.
B. Place a washer onto each end of the axle, thenslip on the wheels, then add another washer tothe outside of each wheel, and secure thewhole assembly by inserting a pin in each endof the axle.
C. Remove the existing shipping supports by un-screwing from chassis. (Wooden lifting leverprovided.)
3.3 ELECTRICAL INPUT CONNECTIONS
In order to provide a safe and convenient means tocompletely remove all electrical power from the ma-chine, it is highly recommended that a line disconnectswitch be installed in the input circuit to the machine.
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Figure 3.2 Voltage Changeover Terminal Board
3.4 SECONDARY OUTPUT CONNECTIONS
The Migmaster 300i Welding System is completelyself-contained so that the front panel torch fittings areinternally connected to the welding polarity (DC reverseor DC straight) via the secondary output terminals. Themachine comes set up for DCRP welding.
3.5 TORCH CONNECTIONS
The MT-200cc torch is supplied as standard equip-ment. Line up the matching holes, push on and tightenthe locking collar. As shipped from the factory, thecommon connector type torches are set-up for DCRPwelding polarity.
3.6 WIRE FEEDER MECHANISM
3.6.1 DRIVE ROLLS
The drive roll has two grooves: the small groove feeds0.035 in. diameter wire, the large groove feeds 0.045 in.wire. The groove nearest the gear motor feeds the wire.If the required groove is not correctly positioned, per-form the following:
A. Release the pressure drive roll lever and lift theassembly upward.
B. Remove the two (2) screws holding the driveroll to the gear.
Figure 3.3 Front Panel Connections
c. Reverse the drive roll on the drive roll shaft.
d. Replace the screws and tighten.
e. Secure the pressure drive roll assembly.
3.6.2 WELDING WIRE SPOOL
As with any work area, make sure safety glasseswith side shields are worn when handling or chang-ing wire or clipping wire off at the spool or at the endof the torch. Hold onto the wire coming off thespool with one hand before clipping. Serious eyeinjury can result due to the resilience of the wirewhich can quickly unravel, or a cut wire end whichmay shoot across the room.
Install a spool of welding wire on the hub as follows:
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A. Unscrew spool nut from hub.
B. Place wire spool on hub to rotate clockwise aswire is unwound; hub pin must engage hole inspool.
C. Replace nut.
3.6.3 THREADING WELDING WIRE
A.Turn off power switch.
When the power switch is on, and gun trigger isdepressed, the electrode wire becomes electricallyhot, and the wire drive rolls will run.
B. Release pressure drive roll assembly and liftupward. Check that proper wire diametergroove is in the inner position.
Before threading welding wire through liner, makesure chisel point and burrs have been removedfrom wire end to prevent wire from jamming in gunor liner.
C. Feed the wire from the spool through the inletguide, across the drive roll groove and into gunoutlet guide.
Make sure that the proper “outlet guide tube” is insertedinto the front-panel gun fitting for the size and type ofwire being used, see Table 2.3 for wire feed accesso-ries.
To ensure proper wire feeding, it is important that thewire be kept clean and that the drive rolls be periodicallycleaned of any chips or scale that might be carried intothe gun liner and cause sticking.
D. Lower pressure roll assembly and secure.Check that the gears mesh. Feed wire throughto gun tip using the inch/purge switch.
3.6.4 SPOOL BRAKE DRAG ADJUSTMENT
Spool brake disc friction should provide enough drag tokeep the wire spool or core from spinning freely after
wire feed stops. If adjustment is required, turn adjustingscrew clockwise to increase drag, counterclockwise todecrease it. Drag should be just low enough to limit wireoverrun.
Figure 3.4 Wire Feeder Mechanism
3.7 CONNECTION OF SHIELDING GASSUPPLY
The R-50-FM-580 regulator is an adjustable regulatordesigned for use with Argon, Helium, Nitrogen, and C-25 (75% argon/25% CO2) gas service. The followingchart provides the recommended flow ranges for the R-50-FM-500 regulator.
Argon 10-40 CFH
Helium 25-125 CFH
Nitrogen 10-50 CFH
C-25 10-40 CFH
TO SET UP THE GAS SHIELDING SUPPLY:
A. With the cylinder cap in place, CAREFULLYslide the cylinder of gas onto the Migmaster300i cylinder rack.
B. Secure the cylinder to the unit, using the chainprovided.
C. Unscrew the cylinder cap.
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Never stand directly in front of or behind the regu-lator when opening the cylinder valve. Alwaysstand to one side.
E. Open the cylinder valve SLOWLY a fraction ofa turn. This will prevent damage to gauge andcritical components in the regulator. When thegauge needle stops moving, then open thecylinder valve fully.
TO REGULATE FLOW:
Flow is controlled by adjusting the flowmeter valve untildesired flow is indicated by the ball float in the flowmetertube. Always take the reading across the TOP of theball.
Using a leak test solution, such as P/N 998771 (8 oz.ctr) or soapy water, test for leakage about the cylindervalve stem, the regulator inlet connection, and the hoseconnections at the regulator and at the Migmaster 300ifor leakage. Correct any leaks before starting work.
TO STOP WORK:
If work is to be stopped for a half-hour or more, theregulator is to be removed from the cylinder, shut downthe regulator as follows:
A. Close the cylinder valve.
B. Release gas from the regulator by closing thetorch trigger lever.
C. When pressure gauge drops to zero, the regu-lator is depressurized and shut down.
Each regulator is equipped with a porous metal inletfilter, P/N 71233, pressed into the regulator inputnipple. No regulator should be connected to a cylinderor station valve unless it contains this filter. You canreplace the filter if necessary. Refer to the regulatorinstruction literature for details.
Regulators in need of repair should be returned to yourwelding equipment distributor or to an authorizedremanufacturing center.For a detailed description of the regulator, refer to theR-50-FM-580 Regulator-Flowmeter Instruction Manual,F-14-238.
TO CONNECT:
Do not clamp regulator cap in a vise or grip it witha pair of pliers. Distortion of cap can jam theinternal parts and cause excessively high deliverypressure as well as weaken the threaded joint to theregulator body. This may cause cap to fly off andpossibly injure personnel in area.
A. Open the cylinder valve slightly, for an instant,to blow out any dust or dirt that may havecollected in the valve outlet. BE SURE to keepyour face away from the valve outlet to protectyour eyes.
B. Attach the regulator to the cylinder valve. Alignthe regulator so that the flowmeter is verticaland then tighten the connection nut with a1-1/8 in. open end or adjustable wrench. (Toprevent damaging the O-ring seals and plastictube, do not use the flowmeter tube as a'handle' when attaching the regulator.)
Figure 3.5 R-50 Regulator
C. Make sure that the flow control valve on theflowmeter is closed.
D. Attach the gas hose from the rear of the Mig-master 300i to the regulator outlet connection.
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If welding is performed in a confined area, shield-ing gas flow can displace oxygen, thereby endan-gering personnel entering the area.
3.8 WELDING CABLE CONNECTIONS
Connect the work clamp solidly to the workpiece orwork table. Clamp onto a bare metal area.
A good electrical connection to the work is essen-tial for proper welding operation and for preventionof electric shock.
+
—Migmaster 300i
REAR VIEWFRONT VIEW
Figure 3.6 Controls and Welding Cable Connections
Welding cables should be kept as short as possible andbe of adequate current carrying capacity. Resistanceof the welding cables and connections causes a voltagedrop which is added to the voltage drop of the arc.Excessive cable resistance may result in a reduction ofthe maximum usable current output of the equipment.
The proper operation of this equipment is to a largeextent dependent on the use of welding cables andconnections which are in good condition and of ad-equate size.
IV. OPERATION
4.1 CONTROLS
4.1.1 POWER ON/OFF SWITCH
The rotary power switch is located on the back panel inthe upper right hand corner. This switch also turns onthe fan. The twelve o’clock position is the “off” position,the “on” is one quarter turn clockwise.
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Figure 4.1 Control Display Screen
4.1.4 SECONDARY WELDING CONNEC-TIONS
The secondary output welding terminals, POS (+) andNEG (-) are located on the lower front panel, directlybeneath the common connector (see figure 3.3).
4.1.5 WIRE FEED SPEED CONTROL
Wire feed speed is controlled automatically. It can beadjusted using the arrow keys or from a remote controlwhile welding (fine tuning the arc).
4.1.6 MIG-41A PUSH-PULL GUN
The MIG-41A push-pull gun combines with the Mig-master 300i to create a high performance push-pullsystem. The MIG-41A synchronizes with the wirefeeder, providing an ideal means for feeding smalldiameter wires or soft wires long distance.
The MIG-41A connects to the front panel of the Mig-master 300i. The inlet connector of the MIG-41A isinserted into the common connector and the power leadplugs into the MIG-41A connector in the center of thefront panel.
For a detailed description of the MIG-41A, refer to theMIG-41A Push-Pull Gun Instruction manual, F-14-497.
4.2 OPERATING PROCEDURES
4.2.1 OPERATING SAFETY PRECAU-TIONS
Comply with all ventilation, fire and other safetyrequirements for arc welding as established in theSAFETY Section at the front of this manual.
Also remember the following:
A. Because of the radiant energy of the weldingarc and the possibility of drawing an arc beforethe helmet is lowered over the face, the opera-tor should wear flash goggles with filter lensesunder his helmet. The helmet filter plate shouldbe shade number 11 (nonferrous) or 12 (fer-rous). All those viewing the arc should usehelmets with filter plates, as well as flashgoggles. Nearby personnel should wear flashgoggles.
B. The radiant energy of the arc can decomposechlorinated solvent vapors, such as trichloro-ethylene and perchlorethylene to form phos-gene, even when these vapors are present inlow concentrations. DO NOT weld wherechlorinated solvents are present in at-mospheres in or around the arc.
C. DO NOT touch the electrode, nozzle or metalparts in contact with them when power is on; all
4.1.2 PROCESS SELECTOR SWITCH
The three position process selector switch is on theupper right front panel. The processor selector switchprovides the visual indication of which process (Mig, Tigor stick) has been selected.
4.1.3 CONTROL DISPLAY SCREEN(Figure 4.1)
Welding set-up options are controlled and monitored byuse of the Display Window and the control pushbuttons.The screen displays the settings required for the de-sired welding process as determined by the position ofthe Process Selector Switch. The Scroll Key is used toselect functions as required to select wire speed, volt-age, trigger type, etc. The arrow keys are used to selectoptions. For example, the operator would use the keysin order to select plate size. The scroll key is depressedseveral times, until SEL PLATE SIZE is displayed. Thearrow keys are then depressed until the desired platesize appears in the display.
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are electrically energized (HOT) and can causea potentially fatal shock. DO NOT allow elec-trode to touch grounded metal, it will create anarc flash that can injure eyes. It may also starta fire or cause other damage.
D. When working in a confined space, be sure itis safe to enter. The confined space should betested for adequate oxygen (at least 19%) withan approved oxygen measuring instrument.The space should not contain toxic concentra-tions of fumes or gases. It this cannot bedetermined, the operator should wear an ap-proved air supplied breathing apparatus. DONOT bring gas cylinders into confined spaces.
When leaving a confined space, shut off gassupply at the source to prevent gas from leak-ing into the confined space.
E. Never operate the equipment at currents greaterthan the rated ampere capacity; overheatingwill result.
F. Never operate equipment in a damp or wetarea without suitable insulation for protectionagainst shock. Keep hands, feet and clothingdry at all times.
G. Whenever the equipment is left unattended,turn all control and power supply switches andgas supplies off and open the main line switch.
H. Wear dark substantial clothing to protect ex-posed skin from arcburn, sparks and flying hotmetal.
I. Turn off welding power before adjusting orreplacing electrodes.
4.2.2 PRE-WELD REQUIREMENTS
Before welding commences, with all power OFF, checkthe following:
A. All safety requirements have been read andunderstood.
B. All hoses and cables are in good condition,safely insulated and securely connected.
C. Turn on gas supply by slowly opening cylindervalve to full ON.
D. Spool of correct size wire is locked in place,brake tension is set, and wire is properlythreaded through the inlet guide to the gun tip.
E. The wire feeding compartment cover is closedand secure.
F. Metal to be welded is properly prepared.
4.3 SET UP FOR WELDING
Work safely and follow all safety precautions listed inthe Instruction Manual.
4.3.1 MIG WELDING: GUIDED SET-UPMODE
The Guided Set-up mode is the quickest and simplestway of using the Migmaster 300i. Welding conditionsfor a wide variety of material types, and shielding gaseshave been pre-set at the factory. All that is required toget excellent welding performance is to answer a fewquestions on the front control panel.
Table 4-1 contains the actions required to set-up theMigmaster 300i cvcc using the Guided-Set-up mode forMig welding.
TO FINE TUNE ARC: Press or to increase
or decrease voltage or wire feed speed for the desiredarc characteristics. These changes can be made whilewelding. Make small changes when fine tuning the arc.Too large a change will make the arc unstable.
To return to beginning of the list: momentarily presstorch trigger or turn process selector switch to Tig andthen back to Mig.
To reset to factory default settings: turn power off.Press center scroll key and left arrow key. While press-ing both keys, turn the power on.
4.3.2 MIG WELDING: MANUAL SETUPMODE
A manual set up mode is selectable if you want to useconditions that are not pre-set or if you want to set up fora special application or condition. In the manual modeyou can manually set wire feed speed, voltage andpower supply inductance. Table 4-2 contains theactions required to set-up the Migmaster 300i cvccusing the manual set-up mode for Mig Welding.
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4.3.3 MIG WELDING: SET-UP OPTIONS
There are a variety of set-up options that are availablefor Mig welding. Selecting the appropriate option canimprove productivity, convenience or operator comfort.
Table 4-3 contains a list of the various options that areavailable for Mig welding.
4.3.4 TIG WELDING SET-UP
Table 4-4 contains the operator actions required to set-up the Migmaster 300i cvcc for Tig welding.
4.3.5 STICK WELDING SET-UP
Table 4-5 contains the operator actions required to set-up the Migmaster 300i cvcc for Stick welding.
4.3.6 DESCRIPTION OF TRIGGER TYPEOPTIONS
A. Continuous - This is the most commonly usedtrigger option. When the torch trigger is de-pressed, welding begins. When the torchtrigger is released, welding stops. The weld iscontinuous as long as the torch trigger is de-pressed.
B. Trigger Lock - Using this mode, the weldingprocess begins when the torch trigger is de-pressed. Once the welding process has started,the torch trigger may be released without af-fecting the welding process. To stop the weld-ing operation, the torch trigger must be de-pressed a second time. This allows a continu-ous weld without having to continuously de-press the torch trigger.
C. Spot Weld - Spot welding provides a timedweld. When this trigger type is selected anoption is added to the setting list. This optionsets the time for the spot weld duration. If thescroll key is pressed after spot weld is se-lected, the option "SET SPOT TIME" is dis-played for changing the spot time duration.Once the torch switch is pressed the optionwith the spot time is moved up in the list to bequickly accessible to trim the parameter for thespot welding operation.
D. Stitch Welding - Stitch weld provides for the
automatic switching between welding "on" andwelding "off" while the torch trigger is pressed.The "on/off" time for the weld is set separately.When stitch weld is selected two options areadded to the list. "SET ON TIME" and "SETOFF TIME". The options are handled the sameas the spot weld options described above.
E. Dual Schedule - This selection is only availablewhen the active list #1 is selected. Whenselected, it provides the option to switch be-tween two welding parameters during welding.Switching is done using a short release of thetorch trigger. The first welding parameter(voltage and wire feed speed) is from list #1.The welding parameter switched to (voltageand wire feed speed) are from list #2. A shortrelease of the torch trigger returns the param-eters from list #1.
The bottom row of the display will not changeto show the set value from list #2 during weld-ing using second parameters. The measuredvoltage and current will show the second weld-ing parameters.
The two welding conditions must be set up inlist #1 and list #2 before dual schedule selec-tion is made.
4.4 WELDING OPERATION
Never operate the machine with any portion of theouter enclosure removed. In addition to a hazard,improper cooling may result in damage to thewelding transformer and the welding machinecomponents. Warranty is void if the machine isoperated with any portion of the outer enclosureremoved.
A. Turn Power switch (on unit) to ON position -- becareful not to operate the torch switch.
B. Before starting the weld, the welding wire shouldextend about 1/2-inch beyond the end of thenozzle. Adjust this length by either clipping offthe end of the wire with insulated cutters or byusing the torch switch.
(cont. to page 26)
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Table 4-1. Migmaster 300i cvcc Guided Set-up for the MIG Process
Display Action
Power on unit
Select MIG on the front panel selector switch
Set shielding gas flowmeter to 35 cfh
Press to accept active list #1
Press to accept guided set-up mode.
Press to accept mild steel or press or tochange WIRE TYPE to desired material.
Note: Wire Type Options are listed in Table 4-3.
Press to accept .035" dia or press or tochange WIRE SIZE to desired diameter.
Note: WIRE SIZE options are listed in Table 4-3.
SEL ACTIVE LIST< active list #1 >
SEL WIRE TYPE< mild steel >
SEL SET-UP TYPE< guided set-up >
SEL WIRE SIZE< .035" dia >
Press to accept 75% Ar + 25% C02 or press or to change GAS SHIELD to desired mixture.
Note: GAS SHIELD options are listed in Table 4-3.
SEL GAS SHIELD< 75% aR + 25% CO2 >
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Table 4-1 Continued
TRIM WIRE SPEEDv ^
TRIM VOLTAGEv ^
TRIM BURNBACKv ^
SEL START TYPE< slow run in >
SEL TRIGGER TYPE< continuous >
SEL PLATE SIZE< 1/4" .250" >
Display Action
Press to accept PLATE SIZE or press or
to change PLATE SIZE.
Note: PLATE SIZE options are listed in Table 4-3.
Press to accept TRIGGER TYPE.
Press to accept START TYPE.
Press to accept BURNBACK.
Press to accept VOLTAGE.
Press to accept WIRE SPEED.
The shaded boxes are the only selections required to be modified by the operator when using the guided set-up mode.
The non-shaded boxes provide advanced settings or other special functions and are detailed under the Migmaster 300imanual setup procedures.
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Power on unit.
Select MIG on the front panel selector switch.
Set shielding gas flowmeter to 35 cfh.
Press to accept displayed active list or press or to
select desired active list.
Press to change to the manual set-up mode.
Press to accept displayed wire type or press or to
change WIRE TYPE to desired material.
Note: Wire Type options are listed in Table 4-3.
Press to accept displayed WIRE SIZE diameter or press
or to change WIRE SIZE to desired diameter.
Note: Wire Size options are listed in Table 4-3.
Table 4-2. Migmaster 300i cvcc Manual Set-up for the MIG Process
Display Action
SEL WIRE SIZE< .035" dia >
SEL SET-UP TYPE< guided set-up >
SEL WIRE TYPE< mild steel >
SEL ACTIVE LIST< active list #1 >
20
Display Action
SEL GAS SHIELD< 75% Ar + 25% CO2 >
Table 4-2 Continued
Press to accept displayed GAS SHIELD mixture or press
or to change GAS SHIELD to desired mixture.
Note: Gas Shield options are listed in Table 4-3.
Press to accept displayed TRIGGER TYPE or press or
to change to desired TRIGGER TYPE.
Note: Trigger Type options are listed in Table 4-3.
This display will appear when stitch weld is selected as TRIGGERTYPE.
Press to accept displayed ON TIME.
Press to decrease ON TIME.
Press to increase ON TIME.
This display will appear when stitch weld is selected as TRIGGERTYPE.
Press to accept displayed OFF TIME.
Press to decrease OFF TIME.
Press to increase OFF TIME.
This display will appear when spot weld is selected as TRIGGERTYPE.
Press to accept displayed SPOT TIME.
Press to decrease SPOT TIME.
Press to increase SPOT TIME.
SEL TRIGGER TYPE< continuous >
SET ON TIMEv 1.2 seconds ^
SET OFF TIMEv 1.2 seconds ^
SET SPOT TIMEv 1.0 seconds ^
21
Press to accept displayed START TYPE or press or
to change to desired START TYPE.
Note: START TYPE options are listed in Table 4-3.
Press to accept displayed BURNBACK time or press or
to decrease or increase BURNBACK time.
Press to accept displayed WIRE SPEED or press or
to decrease or increase WIRE SPEED.
Press to accept displayed voltage or press or to
decrease or increase VOLTAGE.
Press to accept displayed INDUCTANCE percentage or
press or to decrease or increase INDUCTANCE.
Display Action
SET INDUCTANCEv 30% ^
SET VOLTAGEv 16.9 volts ^
SET WIRE SPEEDv 143 ipm ^
TRIM BURNBACKv 0.20 seconds ^
SEL START TYPE< normal >
Table 4-2 Continued
22
DISPLAY
SEL ACTIVE LIST active list #1 >
SEL SET-UP TYPE< guided set-up
SEL WIRE TYPE mild steel >
SEL WIRE SIZE .035" dia
SEL GAS SHIELD75% Ar + 25% CO2
SEL TRIGGER TYPE< continuous >
Table 4-3. Migmaster 300i cvcc Set-Up Options for The MIG Process
ACTION
Press to accept active list num-
ber 1. Press to change to
active list number two or three.
Press to accept guided set-
up. Press to change to manual
set-up.
Press to accept displayed
WIRE TYPE. Press or
to change WIRE TYPE.
Press to accept displayed
WIRE SIZE. Press to de-
crease WIRE SIZE. Press to
increase WIRE SIZE.
Press to accept displayed GAS
SHIELD mixture. Press or
to change GAS SHIELD mix-
ture.
Press to accept displaced
TRIGGER TYPE. Press or
to change TRIGGER TYPE.
COMMENT
Active lists options: active list #1 >< active list #2 >< active list #3
See paragraph 4.3.1 for descrip-tions of the Trigger Type options.
23
DISPLAY
SET ON TIMEv 1.2 seconds ^
SET OFF TIMEv 1.2 seconds ^
SET SPOT TIMEv 1.0 seconds ^
SET WIRE SPEEDv 143 ipm ^
SET VOLTAGEv 16.9 volts ^
ACTION
Press to accept displayed ON
TIME. Press to decrease ON
TIME. Press to increase ON
TIME.
Press to accept displayed OFF
TIME. Press to decrease
OFF TIME. Press to increase
OFF TIME.
Press to accept displayed
SPOT TIME. Press to de-
crease. Press to increase
SPOT TIME.
Press to accept displayed
WIRE SPEED. Press to de-
crease WIRE SPEED. Press
to increase WIRE SPEED.
Press to accept displayed
VOLTAGE. Press to de-
crease VOLTAGE. Press to
increase VOLTAGE.
COMMENT
This option appears when TRIG-GER TYPE is set to stitch weld.
This option appears when TRIG-GER TYPE is set to stitch weld.
This option appears when TRIG-GER TYPE is set to spot weld.
This display appears on manualset-up only.
This display appears on manualset-up only.
Table 4-3 Continued
24
ACTION
Press to accept displayed IN-
DUCTANCE. Press to de-
crease INDUCTANCE. Press
to increase INDUCTANCE.
Press to accept displayed
START TYPE. Press or
to change START TYPE.
Press to accept displayed
BURNBACK time. Press or
to trim BURNBACK time.
Press to accept displayed
WIRE SPEED. Press or
to trim WIRE SPEED.
Press to accept displayed
VOLTAGE. Press or to
TRIM VOLTAGE.
Press to accept the displayed
PLATE SIZE. Press to de-
crease PLATE SIZE. Press
to increase PLATE SIZE.
DISPLAY
SET INDUCTANCEv 30% ^
SEL START TYPE< normal >
TRIM BURNBACKv .020 seconds ^
TRIM WIRE SPEEDv 143 + 0 ipm ^
TRIM VOLTAGEv 16.9 + 0.0v ^
SEL PLATE SIZEv 1/4" .250" ^
COMMENT
This display appears on manualset-up only.
Start type options: normal >
< slow run in
This display appears on guidedset-up only.
This display appears on guidedset-up only.
PLATE SIZE options: 3/8" .375" 5/16" .312" 1/4" .250" 3/16" .188" 10 ga .135" 12 ga .105" 14 ga .075" 16 ga .060" 18 ga .048" 20 ga .036" 22 ga .030" 24 ga .024"
Table 4-3 Continued
25
Table 4-4. Migmaster 300i cvcc TIG Process Set-Up Procedures
Display Action
Power on unit.
Select TIG on the front panel selector switch.
Set shielding gas flowmeter to 15 cfh.
Press to accept displayed current or press to decrease
current or to increase current.
Press to accept displayed PRE FLOW or press to
decrease PRE FLOW or to increase PRE FLOW.
Press to accept displayed POST FLOW or press to
decrease POST FLOW or to increase POST FLOW.
130 A 16.9vv 130 amps ^
SET PRE FLOWv 1.2 seconds ^
SET POST FLOWv 1.2 seconds ^
26
130 A 16.9vv 130 amps ^
Table 4-5. Migmaster 300i cvcc For The Stick Process
Display Action
Power on unit.
Select STICK on the front panel selector switch.
Press to accept the displayed current or press to
decrease current or to increase current.
This equipment is provided with a thermostat (OL)in the transformer (T1) windings which will openand prevent the contactor (CON) from closing ifthe transformer windings are overheated. If thethermostat opens, allow the equipment to idle withfan running for approximately 15-min before at-tempting to weld again.
4.4.1 SPOT WELDING MODE OPERATION
A. Perform set-up procedures, select spot weldas trigger type.
B. Replace the standard nozzle with the No. 12spot weld nozzle P/N 999625.
C. Trim the welding wire back so the end is slightlyinside the nozzle.
D. To spot weld:
i. Press the torch nozzle squarely on the topplate. Apply enough pressure to hold thetwo pieces of metal firmly together, sothere is no loose play between them.
ii. Pull the trigger, holding the gun motionlessand firmly. The electrode wire and shield-ing gas will be fed to the work, and the arcwill be maintained for the length of time setin the set-up process.
iii. After the preset time has elapsed, the wirewill stop feeding, the arc will be broken,and the shielding gas will stop flowing.
Power source contactor becomes energized themoment the torch trigger is depressed. Arcing canoccur if the wire touches an electrical ground.Keep the torch away from ground until welding is tobegin.
C. To start the weld, hold the torch so the weldingwire is approximately 1/4-in. from the work,then press the torch trigger.
D. The welding wire should be pointed into thejoint at angles of approximately 45° for filletwelds, and approximately 90° for butt welds,(Fig 4.2).
E. The torch angle relative to the length of theweld should be approximately 10° from thevertical (Fig. 4.3).
F. When welding in the vertical position, travelingeither up or down, it is very important to keepthe arc on the leading edge of the puddle toensure complete penetration.
G. Welders who are accustomed to welding withstick electrodes may tend to push the torch intothe weld. This is neither necessary nor desir-able, since the wire electrode is mechanicallyfed into the weld.
H. To stop welding, release the trigger and pull thetorch from the work. When leaving equipmentunattended, always shut off shielding gas atsource.
27
Figure 4.3. Angle of Welding Wire with Joint
Figure 4.2. Continuous/Stitch Weld Conditions
A good spot weld will penetrate throughboth layers of metal, and will have a smallnugget on the reverse side, (Fig. 4.4).
Fig. 4.4 Cross Section of Good Spot Weld
4.4.2 STITCH WELDING MODEOPERATION
A. Perform set-up procedures, select stitch weldon Trigger Type.
B. Be sure a standard nozzle (and not a spot weldnozzle) is installed on the torch.
C. When using the Stitch weld mode, before start-ing the weld the welding wire should extendabout 1/2-in. beyond the end of the nozzle.Adjust this length by either clipping off the endof the wire with insulated cutters or by using thetorch switch.
28
Check for and tighten loose hardware includingelectrical connection. Loose power connectionsoverheat during welding.
Immediately replace all worn or damaged power cablesand connectors. Check for frayed and cracked insula-tion, particularly in areas where conductors enter equip-ment.
The electrode wire and all metal parts in contact with itare electrically energized while welding. Inspect theseparts periodically for defective insulation and otherelectrical hazards.
If worn cable and parts are not replaced, an arccaused by a bared cable or part touching a groundedsurface may injure eyes, skin or start a fire. Bodycontact with a bared cable, connector, or otheruncovered conductor can shock, possible fatally.
Keep power cables dry, free of oil and grease, andprotected at all times from damage by hot metal andsparks.
Clean dirt and metal particles from drive roll grooveweekly; replace roll if badly worn.
Power source contactor becomes energized themoment the torch trigger is depressed. Arcing canoccur if the wire is brought to a ground. Keep thetorch always from ground until welding is to begin.
D. During the welding, use the same weldingtechniques as described in Section 4.4.
V. MAINTENANCE
Be sure the branch circuit or main disconnectswitch is off or electrical input circuit fuses areremoved before attempting any inspection or workon the inside of the machine. Placing the powerswitch on the welding machine in the OFF positiondoes not remove all power from inside of theequipment.
Shut OFF shielding gas supply at source.
5.1 INSPECTION AND SERVICE
Keep equipment in clean and safe operating conditionfree of oil, grease, and (in electrical part) liquid andmetallic particles which can cause short circuits.
Regularly check cylinder valves, regulators, hoses, andgas connections for leaks with soap solution.
A. CUSTOMER SERVICE QUESTIONS: Contact your Customer Service Representative, Fax: (800) 634-7548Order EntryProduct Availability Pricing Order ChangesHours: 8:30 AM to 5:00 PM ESTDelivery Saleable Goods Returns Shipping Information
B. ENGINEERING SERVICE: Telephone: (803) 664-4416 or -5550 / Fax : (800) 446-5693Welding Equipment Troubleshooting Warranty Returns Hours: 7:30 AM to 5:00
PM ESTAuthorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (803) 664-5547/ Fax: (803) 664-5575Part Numbers Technical Applications Hours: 7:30 AM to 5:00 PM ESTPerformance Features Technical Specifications
D. LITERATURE REQUESTS: Telephone: (803) 664-5501 / Fax: (803) 664-5575Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS: Telephone: (803) 664-4487 / Fax: (803) 664-5557Repair estimates Repair status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:Telephone: (803)664-5524 / Fax: (803) 664-5575
Training School Information and RegistrationsHours: 7:30 AM to 4:00 PM EST
G. TO SET UP A NEW AUTHORIZED REPAIR STATION:
Telephone: (803)664-5524 / Fax: (803)664-5575Hours: 7:30 AM to 4:00 PM EST
H. WELDING PROCESS ASSISTANCE:Telephone: (803) 664-4248 / Fax: (803) 664-4454Hours: 7:30 AM to 4:00 PM EST
I. TECHNICAL ASST. CONSUMABLES:Telephone: (800) 934-9353Hours: 7:30 AM to 5:00 PM EST
