ESAB MIGMATIC 250 User manual

MIGMATIC 250

MIG/MAG Power Source

Instruction manual

MIGMATIC 250

Instruction manual

For

Installation, Operation & General maintenance

CONTENTS

Item

Page No.

SAFETY

1-2

MIGMATIC 250 POWER SOURCE

Assembling

Accessories List

Rating

Cautions for Installation

Items for Installation

Front Panel

Welding Operation

7-9

Maintenance & Inspection

After Sales Service

Fault Finding

MIGMATIC WIRE FEEDER

Rating

Accessories List

Connection

Preparation for use

13-14

Maintenance

WIRING DIAGRAM

SPARES LIST FOR POWER SOURCE AND WIRE FEEDER

TORCH PSF 250

Rated Specification and Accessories

Operation

18-19

Maintenance

List of Consumables & Accessories

WELD DEFECTS, POSSIBLE CAUSES & CORRECTIVE ACTIONS

22-24

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 recommendations should be observed in addition to the

standard regulations that apply to the workplace.

Trained personnel well acquainted with the operation of the welding equipment must

carry out all the work. 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:

• its operation

• location of emergency stops

• its function

• relevant safety precautions

• welding

2. The operator must ensure that:

• no unauthorized person is stationed within the working area of the equipment when

it is started up.

• no one is unprotected when the arc is struck

3. The workplace must:

• be suitable for the purpose

• be free from drafts

4. Personal safety equipment

• Always wear recommended personal safety equipment, such as safety glasses,

flameproof clothing, and safety gloves.

• Do not wear loose—fitting items, such as scarves, bracelets, rings, etc., which could

become trapped or cause burns.

5. General precautions

• Make sure the return cable is connected securely.

• Only a qualified electrician may carry out work on high voltage equipment.

• Appropriate fire extinguishing equipment must be clearly marked and close at hand.

• Lubrication and maintenance must not be carried out on the equipment during

operation.

Read and understand the instruction manual before installing or operating.

ESAB can provide you with all necessary welding protection and accessories.

WARNING

Arc welding and cutting can be injurious to yourself and others. Take

precautions when welding.

Ask for your employer’s safety practices which should be based on manufacturers’

hazard data.

ELECTRIC SHOCK –Can kill

• Install and earth the welding unit in accordance with applicable

standards.

• Do not touch live electrical parts or electrodes with bare skin, wet

gloves or wet clothing.

• Insulate yourself from earth and the workpiece.

• Ensure your working stance is safe.

FUMES AND GASES –Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone and the general area.

ARC RAYS –Can injure eyes and burn skin.

• Protect your eyes and body. Use the correct welding screen and filter

lens and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable materials nearby.

NOISE –Excessive noise can damage hearing

• Protect your ears. Use earmuffs or other hearing protection.

• Warn bystanders of the risk.

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

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding

Do not dispose of electrical equipment together with normal waste!

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 the local representative. By applying this Directive you

will improve the environment and human health

ASSEMBLING

The complete Installation should consist the following instruments.

Description

Type

Quantity

Welding Power Source

MIGMATIC 250 Power

Source

Wire Feeder

MIGMATIC WIRE FEEDER

with accessories

Welding Torch

PSF 250

CO2Regulator cum Flowmeter or

CO2Regulator with Flowmeter

CO2Heater Core

ACCESSORIES LIST FOR MIGMATIC 250 MIG/MAG WELDING POWER SOURCES

Fuse, element 3A

2 piece

Fuse, element 8A

1 piece

Instruction Manual

1 piece

RATING OF MIGMATIC 250 MIG/MAG WELDING POWER SOURCE

Characteristics

Constant Potential Type

Input

Supply Voltage phase & frequency

3 phase, 415 V ±10 %, 50 Hz

Maximum Input Current

13 Amps

Maximum Rating

9.5 KVA at 60% duty cycle

Output

Output current range

40-250 Amps

Max. Output current at 60% Duty Cycle

250 Amps

Max. Output Current at 100% Duty Cycle

190 Amps

Open circuit voltage control

16-34 volts DC

Type of Welding Voltage Control

In 10 Steps single Knob control

Welding time

0.2-2 Sec.

Interval time

0.2-2 Sec.

Class of Insulation

Class ‘H’

Cooling

Forced Air Cooled

Approximate dimension (LXWXH) in mm

620*390*580

Weight (Approximate)

78 kg.

CAUTIONS FOR INSTALLATION

Capacity of Equipment

•Provide a Switch Box per one Welding Power Source and use

designated fuse. Of 32 Amps.

•Tolerance of Power Voltage Variation is ± 10% of rated input

voltage.

•In case SFU is not used, use 63 Amps MCB.

Installation Place

•Install in the place where less moisture and dust exit. Avoid

direct sunlight and rain, and maintain ambient temperature within

–10º to 45º C.

•If there are any walls, then the Welding Power Source and feeder

unit has to be kept at a distance of more than 20 cm from the wall.

•In case more than one system has to be installed side by side,

then the minimum gap between the adjacent systems has to be

maintained at 20 cm.

•Keep the Gas Cylinder in a separate stand.

•Use a shield to protect the welding arc in case of excessive air

draft.

Ventilation

Adequate ventilation is recommended at the place of Installation.

•In case of the area is more than 300 square meters (per unit), no

ventilation is required, provided the room is not completely air

tight.

•In case of the area is less than 300 square metes and the torch is

used in fixed condition, and if the welding is continuously

performed, adequate ventilation is recommended with the help of

vent fan or exhaust duct.

Input Voltage

415 VAC ±10 %

Number of Phase & Frequency

3 phase, 50 Hz

Maximum rating of Equipment

9.5 KVA

Capacity of Fuse (B Class)

16 Amps HRC

Output Cable

More than 38 mm2

ITEMS FOR INSTALLATION

No.

Item

MIGMATIC 250 Welding Power Source

Wire feeder (Migmatic)

Welding Torch PSF 250

Base Metal

Gas Regulator

Gas cylinder

Switch Box

Return Cable with Earth Clamp

Inlet Gas Hose from Gas cylinder to Welding Machine

10.

CO2Heater with cable for connection to socket on Machine

List of Items

Item No.

Description / Code

Power ON Lamp / 1651685051

Power ON-OFF Selector Switch / 1651685115

Voltage Selector Switch. / 0466401001

Gas Check Switch / 1651685177

Self-Hold ON/ OFF Selector Switch / 1651685116

OCV Check Switch / 1651685177

Gas Outlet to Welding Torch /

Socket for Wirefeeder Control cable connection /

Output Power Terminals / 1651685125

Digital V/ A Meter / 1611642301

Stitch Welding Timer Control /

Spot Welding Timer control

Control Fuses

WELDING OPERATION

The welding operation can be adjusted from the front panel of the power

source.

1. The ON/OFF switch on the front panel switches on the Power Source.

This will cause the light emitting diode on the front panel to light up.

Cooling fan will start rotating.

2. Gas Supply Check:

To ensure the gas supply before welding and purge the air out of gas

line, Gas Check switch is pressed to ‘check’ position. The shielding gas

will start flowing. After confirmation of gas flow the switch is released

and it will automatically return-to weld position.

3. Welding Voltage Adjustment

The welding voltage (OCV) is set by turning the voltage selector switch.

The value of voltage set can be seen on the Voltmeter provided on the

front panel by operating the ‘OCV Check’ Switch.

Caution:

a) Keeping the ‘O.C.V. check’ switch pressed, do not turn the

welding voltage selector switch. For correct operation every time the

voltage selector switch is turned from 0 to 10 or reverse, the ‘O.C.V.

check’ switch should first be released.

b) The welding voltage selector switch should not be operated on

load, i.e. while welding torch switch must be released before the

voltage is adjusted.

Welding Current Control

The wire feed speed control potentiometer on the wire feeder unit does

welding current control.

SEAM WELDING

•The welding voltage and current are selected as described

above. The torch switch is pressed and the welding process

starts.

•First do a sample weld on a clean piece of plate. Some of the

common problems, which may be encountered during CO2

welding, are described below.

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