ESAB Migmaster 280 Pro User manual

Valid for serial no. 016, 0180349 301 165 101118

Migmasterr280 Pro

Instruction manual

Manuel d’instructions Instrucciones de uso

-- 2 --

Rights reserved to alter specifications without notice.

Sous réserve de modifications sans avis préalable.

Reservado el derecho de cambiar las especificaciones sin previo aviso.

ENGLISH 3..............................................

RANÇAIS 15.............................................

ESPAÑOL 27..............................................

ENGLISH

-- 3 --

TOCe

1 DI ECTIVE 4........................................................

2 SAFETY 4...........................................................

3 INT ODUCTION 6...................................................

3.1 Equipment 6................................................................

4 TECHNICALDATA 6.................................................

5 INSTALLATION 7....................................................

5.1 Placing 7...................................................................

5.2 Electricalinstallation 7.......................................................

5.3 Weldingvoltagepolarity 8....................................................

5.4 Mainspowersupply 8........................................................

6 OPE ATION 9.......................................................

6.1 Connectionandcontroldevices 9.............................................

6.2 Switching--on and overheating protection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Operation 10................................................................

6.4 Replacingandinsertingwire 10................................................

6.5 Wirefeedpressure 11........................................................

6.6 MIGprocessset--upguide 11..................................................

7 MAINTENANCE 13....................................................

7.1 Inspectionandcleaning 13....................................................

8 FAULTT ACING 14...................................................

9 O DE INGOFSPA EPA TS 14......................................

DIAG AM 40............................................................

WEA COMPONENTS 45.................................................

ACCESSO IES 46.......................................................

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MMP280e

1 DI ECTIVE

DECLA ATION OF CONFO MITY

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-

ing power source Migmasterr280 Pro from serial number 016, 018 complies with standard IEC/EN

60974--1, in accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC)

and with standard IEC/EN 60974--10 in accordance with the requirements of directive (89/336/EEC)

and addendum (93/68/EEC).

--------------------------------------------------------------------------------------------------------------------------------------

Kent Eimbrodt

Global Director Equipment and Automation

ESAB AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 ax: + 46 584 411924

Laxå 2010--04--01

2 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well--acquainted with the operation of the welding

equipment. Incorrect operation of the equipment may lead to hazardous situations which can result

in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno--one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from draughts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

-- 5 --

MMP280e

WA NING

EAD AND UNDE STAND THE INST UCTION MANUAL BEFO E INSTALLING O OPE ATING.

A C WELDING AND CUTTING CAN BE INJU IOUS TO YOU SELF AND OTHE S. TAKE P ECAU-

TIONS WHEN WELDING. ASK FO YOU EMPLOYE ’S SAFETY P ACTICES WHICH SHOULD BE

BASED ON MANUFACTU E S’ HAZA D DATA.

ELECT IC SHOCK -- Can kill

SInstall and earth the welding unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

SKeep your head out of the fumes.

SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

A C AYS -- Can injure eyes and burn skin.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FI E HAZA D

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

P OTECT YOU SELF AND OTHE S!

WA NING!

Read and understand the instruction manual

before installing or operating.

Do not use the power source for thawing frozen pipes.

WA NING!

This product is solely intended for arc welding.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical equipment

that has reached the end of its life must be collected separately and returned to an

environmentally compatible recycling facility. As the owner of the equipment, you should

get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human health!

-- 6 --

MMP280e

3 INT ODUCTION

Migmasterr

r280 Pro is step controlled power source in a compact design, intended for welding with

solid steel, stainless steel or aluminium wire as well as flux--cored wire with or without shielding gas.

The machine is equipped with facilities for connection of the MIG ”spool--on” gun torch (type:

MT--250SG, ST23A+Adapter KIT ST--23A).

ESAB’s accessories for the product can be found on page 46.

3.1 Equipment

The power source is supplied with:

SReturn cable with clamp

SShelf for gas cylinder

SInstruction manual

4 TECHNICAL DATA

Migmasterr

r280 Pro Migmasterr

r280 Pro

Voltage 208V/230V, 1∼50/60Hz 208/230/460/575V, 1∼50/60Hz

Permissible load at

100% duty cycle 194A 194A

60 % duty cycle 250A 250A

Setting range (DC) 40A/16.0V--300A/29.0V 40A/16.0V--300A/29.0V

Open circuit voltage 16,8--57,0V 16,8--57,0V

Open circuit power 450W 450W

Power factor at max load 0.84 0.84

Control voltage 42V, 50/60Hz 42V, 50/60Hz

Wire feed speed 55--750ipm (1.4--19m/min) 55--750ipm (1.4--19m/min)

Burnback time 0.03--0.5s 0.03--0.5s

Spot welding 0.5--3.5s 0.5--3.5s

Creep start O / ON (85%) O / ON (85%)

Welding gun connection EURO EURO

Wire dimension range

CuSi

.030--.047” (0.8--1.2mm)

.040--.047” (1.0--1.2mm)

.030--.047” (0.8--1.2mm)

.030--.039” (0.8--1.0mm)

.030--.047” (0.8--1.2mm)

.040--.047” (1.0--1.2mm)

.030--.047” (0.8--1.2mm)

.030--.039” (0.8--1.0mm)

Max diameter/weight

of wire bobin 12” (300mm)/33lb (15kg) 12” (300mm)/33lb (15kg)

Dimensions lxwxh 32x21.7x34.3”

(812x552x870mm) 32x21.7x34.3”

(812x552x870mm)

Weight 341lb (155kg) 350lb (159kg)

Operating temperature 14÷104 (--10 ÷+40

C) 14÷104 (--10 ÷+40

Enclosure class IP 23 IP 23

Application classification

-- 7 --

MMP280e

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain load without overloading.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

5 INSTALLATION

The installation must be executed by a professional.

WA NING!

This product is intended for industrial use. In a domestic environment this product may cause radio

interference. It is the user’s responsibility to take adequate precautions.

5.1 Placing

Position the welding power source such way that its cooling air inlets and outlets are

not obstructed.

5.2 Electrical installation

Mains voltage

All machines are factory configured for highest rated voltage and are fitted with appropriate marking

tape on the mains cable.

-- 8 --

MMP280e

Mains voltage selection

Migmasterr280 Pro is delivered in versions configurable for following mains voltages:

S208/230V and

S208/230/460/575V

actory configuration is set for 230V and 575V respectively.

In order to adapt the machines for the other voltages, it is necessary to reconnect the main

transformer TM1 and control transformer TC1 as shown and described on the schematic diagrams.

5.3 Welding voltage polarity

Welding voltage polarity may be changed as shown below.

5.4 Mains power supply

Check that the unit is connected to the correct mains power supply voltage, and that it is protected by

the correct fuse size. A protective earth connection must be made, in accordance with regulations.

Rating plate with supply connection data

Migmasterr

r280 Pro Migmasterr

r280 Pro

Voltage 208/230V, 1∼50/60Hz 208/230/460/575V, 1∼50/60Hz

Current A

at 100% duty cycle 40/36 40/36/24/15

at 60% duty cycle 57/51 57/51/30/21

Cable area AWG 3x6 3x6

Fuse slow A50 50

-- 9 --

MMP280e

6 OPE ATION

General safety regulations for the handling of the equipment can be found on

page 4. Read through before you start using the equipment

WA NING!

Rotating parts can cause injury, take great care.

WA NING -- TIPPING ISK!

There is a risk of tipping while transportation and operation, if the welding machine leans

more than 10

. In that case appropriate securing has to be provided !

6.1 Connection and control devices

1Mains supply switch 5b Connector [--], low inductance, for welding gun or

return cable (welding polarity change--over)

2Orange indicating lamp, overheating 6Knob for spot welding -- ON/O and time setting

2a White indicating lamp “ON” 7Knob for wire speed setting

3Welding voltage switch (fine) 8Digital instrument -- V/A

3a Welding voltage switch (coarse) 9Connector for ”spool--on gun” (control wire)

4EURO -- connector for welding gun 10 Knob for burn--back time setting

(located in wire feeder compartment)

5Connector [+] for “electrode” or return cable

(welding polarity change--over) 11 ”Electrode” cable with plug, connected to the weld-

ing gun connector (welding polarity change--over)

5a Connector [--], high inductance, for welding gun

or return cable (welding polarity change--over) 12 Creep start switch

(located in wire feeder compartment)

-- 10 --

MMP280e

6.2 Switching--on and overheating protection

When machine is switched on with switch [1], the indicating lamp “ON” is lit. If the ma-

chine is not overheated (lamp [2] is off) it is ready to work. If the internal temperature

during welding becomes too high, the welding is interrupted and disabled. This state is

indicated by permanent lighting of the orange indicating lamp [2] on the front of the unit.

It resets automatically when the temperature falls down.

6.3 Operation

Operator can manually select and set welding parameters as follows:

Srequired welding voltage (and thus welding current) with knob [3], [3a]

Warning: Operating the knobs [3], [3a] during the welding process (loaded

power source) can cause heavy damage to the unit !!!

Sappropriate wire feed speed with knob [7]

Sinitial wire speed (”creep start”) with selector [12] (wire feeder compartment)

Sburn--back time with knob [10] (wire feeder compartment)

Sspot welding (optional), activated by turning the knob [6] clockwise, spot welding

time increases while turning the knob [6] clockwise; set knob [6] in the left utmost

position in order to return to the continuous welding.

If the welding gun is used, welding process starts after its trigger is pressed and the wire

speed is controlled with potentiometer [7] on the front panel.

If the spool--on gun is used, welding process starts after its trigger is pressed, the spool--

on gun motor starts and wire speed is controlled with the potentiometer in the spool--on

gun grip.

Note: or spool--on gun current cable connection it is necessary to use the OKC ”T”

adapter or Adapter KIT ST--23A, depending on used spool gun (see Accessories on

page 46).

Machine is fitted with V/A digital instrument [8] (with ”hold” function i.e. memorising of

the last values of welding voltage and current).

6.4 eplacing and inserting wire

SOpen the side panel.

SPlace the spool on the hub and secure it with the lock.

SDisconnect the pressure sensor by folding it backwards, the pressure rollers

slide up.

SStraighten out the new wire 10--20 cm. ile away burrs and sharp edges from the

end of the wire before inserting it into the wire feed unit.

SMake sure that the wire goes properly into the feed roller track and into the outlet

nozzle and the wire guide.

SSecure the pressure sensor.

SClose the side panel.

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