ESAB Multimaster 260 Instruction Manual
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ESAB Multimaster 260 Instruction Manual

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Multimaster 260
MIG/TIG/STICK WELDING PACKAGE
INSTRUCTION MANUAL
This manual provides instructions for units starting with serial No. MORJ125051
F15-692-G
06 / 2009

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Summary of Contents for ESAB Multimaster 260

  • Page 1 Multimaster 260 MIG/TIG/STICK WELDING PACKAGE INSTRUCTION MANUAL This manual provides instructions for units starting with serial No. MORJ125051 F15-692-G 06 / 2009...

  • Page 2: User Responsibility

    Be SURe ThIS INFORMATION ReACheS The OpeRATOR. YOU CAN GeT exTRA COpIeS ThROUGh YOUR SUppLIeR. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “precautions and Safe practices for Arc Welding, Cutting, and Gouging,”...

  • Page 3: Table Of Contents

    TABLe OF CONTeNTS Section / Title page Safety Precautions ..................5 Safety - English .
  • Page 4 TABLe OF CONTeNTS...

  • Page 5: Safety Precautions

    SeCTION 1 SAFeTY pReCAUTIONS Safety precautions Safety - english WARNING: These Safety Precautions are FIReS AND expLOSIONS -- heat from for your protection. They summarize pre- flames and arcs can start fires. hot cautionary information from the references slag or sparks can also cause fires and listed in Additional Safety Information sec- explosions.
  • Page 6 SeCTION 1 SAFeTY pReCAUTIONS 1. Be sure the power source frame (chassis) is con- 3. Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: 2. Connect the workpiece to a good electrical A.
  • Page 7 SeCTION 1 SAFeTY pReCAUTIONS 5. WARNING: This product, when used for welding 1. Always have qualified personnel perform the instal- or cutting, produces fumes or gases lation, troubleshooting, and maintenance work. which contain chemicals known to Do not perform any electrical work unless you are the State of California to cause birth qualified to perform such work.
  • Page 8 SeCTION 1 SAFeTY pReCAUTIONS 5. AWS C5.5 - "Recommended Practices for Gas Tung- sten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Hand- book. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."...

  • Page 9: Safety - Spanish

    SeCTION 1 SeGURIDAD Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas ADVeRTeNCIA: Estas Precauciones de Se- de seguridad y careta protectora. guridad son para su protección. Ellas hacen resumen de información proveniente de las FUeGO Y expLOSIONeS -- el calor de referencias listadas en la sección "Información Adi- las flamas y el arco pueden ocacionar...
  • Page 10 SeCTION 1 SeGURIDAD 1. Asegúrese de que el chasis de la fuente de poder 3. Los soldadores deberán usar los siguientes proced- esté conectado a tierra através del sistema de imientos para minimizar exponerse al EMF: electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de A.
  • Page 11 SeCTION 1 SeGURIDAD 5. ADVeRTeNCIA-- este producto cuando se uti- 1. Siempre tenga personal cualificado para efec- liza para soldaduras o cortes, tuar l a instalación, diagnóstico, y mantenimiento produce humos o gases, los del equipo. No ejecute ningún trabajo eléctrico a cuales contienen químicos menos que usted esté...
  • Page 12 SeCTION 1 SeGURIDAD SIGNIFICADO De LOS SIMBOLOS -- Según usted avanza en la lectura de este folleto: Los Símbolos Sig- nifican ¡Atención! ¡esté Alerta! Se trata de su seguridad. Significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

  • Page 13: Safety - French

    SeCTION 1 SÉCURITÉ Safety - French INCeNDIeS eT expLOSIONS -- La chaleur provenant des flammes ou de AVeRTISSeMeNT : Ces règles de sécurité l'arc peut provoquer un incendie. Le ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution laitier incandescent ou les étincelles provenant des références dans la section peuvent également provoquer un...
  • Page 14 SeCTION 1 SÉCURITÉ 1. Assurez-vous que le châssis de la source 3. Les soudeurs doivent suivre les procédures suivantes d'alimentation est branché au système de mise à pour minimiser l'exposition aux champs électriques la terre de l'alimentation d'entrée. et magnétiques : 2.
  • Page 15 SeCTION 1 SÉCURITÉ 5. AVeRTISSeMeNT : Ce produit, lorsqu'il est utilisé eNTReTIeN De L'ÉQUIpeMeNT -- Un équipe- dans une opération de soudage ou de ment entretenu de façon défectueuse ou coupage, dégage des vapeurs ou des inadéquate peut causer des blessures gaz contenant des chimiques consid- graves ou mortelles.
  • Page 16 SeCTION 1 SÉCURITÉ SIGNIFICATION DeS SYMBOLeS Ce symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu. DANGeR Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles. AVeRTISSeMeNT Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

  • Page 17: Description

    208/230 vac, 1 phase 50/60 Hz /MT-250SG ....... 0558001769 230-575 vac, 1 phase 50/60 Hz /MT-250SG ....... 0558001770 MultiMaster 260 w/ 12 ft. GM-250 “NAS” torch and spool gun, Argon 208/230 vac, 1 phase 50/60 Hz /ST-23A ......0558001771 230-575 vac, 1 phase 50/60 Hz /ST-23A ......0558001772 MultiMaster 260 w/ 15 ft.

  • Page 18: Optional Equipment

    SeCTION 2 DeSCRIpTION Digital Meter Voltage Preset Volts, Amps, and Wire feed speed Status Indicators Process Selector Wire Feed Speed Voltage/Current Control Control Remote Control Option “Spool-on-Gun” Option pulse Module Option Pulse Mig Welding of Carbon Steel, Stainless Steel and Aluminum Optional Equipment Electrode Holder Assembly - 175 amp (15 ft.) Pre/Post Flow/Spot/Burnback module ........

  • Page 19: General

    2.4.3 CONTROLS The Multimaster 260 can be used to weld solid and flux cored When requesting information regarding this equipment, wires. The operator selects the process desired on a three posi- make sure that you include product name, part num ber, and tion switch located on the front panel.
  • Page 20 SeCTION 2 DeSCRIpTION Choice of Argon or CO Regulator/ Flowmeter 6’ Gas Hose Eyetech Auto- matic Helmet (Optional) Simple To Use Weld Controls Cylinder Safety Chain Large, Easy To Read Digital Displays for Wire Welding Gloves Speed, Amps and Volts (Optional) Simple and quick polarity change-over...
  • Page 21 SeCTION 2 DeSCRIpTION Hinged Wire Compartment Door Handle Inductance Burnback Preflow/postflow Spot (Options) Cylinder Chain 4 Roll Drive Stand 2 Cylinder Low Mount Tray Adaptable Spindle Assembly Wheel Kit Installed Tool Box with Small Voltage Switch Parts Tray Compartment Figure 1B - Components...
  • Page 22 SeCTION 2 DeSCRIpTION...

  • Page 23: Installation

    3.0 INSTALLATION 3.2 hANDLe ASSeMBLY INSTALLATION 3.1 LOCATION The Multimaster 260 is factory assembled except for the front handle assembly which is mounted to the machine upside Several factors should be considered when selecting an in- down for shipping purposes. The handle assembly consists stallation site.

  • Page 24: Electrical Input Connections

    The voltage changeover terminal board is located in the tool compartment on the left side of the machine. As shipped from the factory, the Multimaster 260 is configured for the highest connectable voltage. If using the other input voltages, the links on the terminal board (TB) inside the unit must be repositioned for the appropriate input voltage.

  • Page 25: Secondary Output Connections

    C. Swing clear panel down and secure with screw. 3.5 SeCONDARY OUTpUT CONNeC TIONS (Figure 5) The Multimaster 260 Welding System is completely self- contained so that the front panel gun/torch connections are internally connected to the welding polarity (DCEP or DCEN)

  • Page 26: Nas" Torch Connections

    SeCTION 3 INSTALLATION 3.7.2 WeLDING WIRe SpOOL INSTALLATION 3.6 “NAS” TORCh CONNeCTIONS (Figure 6) To install a Gun Master Mig Gun 250, remove the locking knob on the side of the NAS connector and insert the male power As with any work area, make sure safety glasses with side pin of the gun.

  • Page 27: Connection Of Shielding Gas Supply

    Close the flow control valve on the flowmeter. G. Attach the gas hose from the rear of the Multimaster 260 to the regulator outlet connection. When the power switch is on, and gun trigger is de- pressed, the electrode wire becomes electrically hot, and the wire drive rolls will rotate.
  • Page 28 SeCTION 3 INSTALLATION Flow Tube Cylinder Valve Connection Control Valve Pressure Gauge Figure 10 - R-33 Regulator Never stand directly in front of or behind the regulator when opening the cylinder valve. Always stand to one side. H. Open the cylinder valve SLOWLY a fraction of a turn. This will prevent damage to the gauge and critical components in the regulator.

  • Page 29: Operation

    The TEMP lamp illuminates if an over temperature condition Selector Switch is in the MIG position. The Mig arc voltage occurs within the Multimaster 260. This condition may be can be preset by pressing the preset button and reading the caused by excessive duty cycle or over-current conditions.
  • Page 30 SeCTION 4 OpeRATION Preset WFS - IPM Button Lamp Weld Process Amps Switch Digital Meters Lamp Voltage Set - MIG Amps/Volts/WFS Current Set - STICK/TIG Power “ON” Lamp Temperature Lamp Fault Lamp Wire Feed Speed Trim Figure 12 - Control panel Mig Gun Trigger Receptacle Main...

  • Page 31: Optional Controls

    SeCTION 4 OpeRATION 4.2 OpTIONAL CONTROLS 4.2.2 pReFLOW/pOSTFLOW/SpOT/BURNBACK (OpTIONAL) pN-0558002889 (Figure 15) 4.2.1 INDUCTANCe TRIM (OpTIONAL) This optional control is mounted in place of the standard pN-0558002888 (Figure 14) burnback control inside the wire spool compartment. A Inductance is used to optimize short circuiting arc perfor- description of the module follows: mance by changing the current rise and fall time of each short circuit.
  • Page 32 Gun trigger connectors and allows the use of either the MT- source to the right of the main power switch (see Figure 13). 250SG or ST-23A spool guns with the Multimaster 260 (ST- The remote receptacle is designed for Tig current control 23A requires adaptor P/N 37301).

  • Page 33: Mig Welding Set-Up

    4.3 MIG WeLDING SeT-Up When the PROCESS switch is placed in the MIG position the Multimaster 260 is set to turn ”ON” when the Mig Gun trigger is depressed. Step 1. Choose the weld parameters based of the wire alloy, diameter, material thickness and shielding gas from Table 3 - MIG PARAMETERS CHART.

  • Page 34: Section 4 Operation

    SeCTION 4 OpeRATION Table 3 - MIG pARAMeTeRS ChART (Cont’d) Note 1: When using 100% CO sheilding gas, add 2 volts to the data table value.

  • Page 35: Tig Welding Setup

    When the PROCESS switch is placed in the TIG position, the STICK position, electrode becomes electrically “hOT”. Do Multimaster 260 turns “ON” the weld contactor so that power not allow the electrode to contact ground potential until is immediately available to the output connection. The Touch you are ready to make a weld.

  • Page 36: Stick Welding Set-Up

    Step 3. Place the WELD PROCESS 1 switch in the STICK (right) position. When the PROCESS switch is placed in the STICK position, the Multimaster 260 turns “ON” the weld contactor so that Step 4. While holding the PRESET button, turn the VOLTAGE/ power is immediately available to the output connection.

  • Page 37: Handling The Tig Torch

    SeCTION 4 OpeRATION 4.6 hANDLING The TIG TORCh Starting the Arc The arc can be struck on the workpiece itself or on a heavy There is nothing difficult or technical about starting an arc in piece of copper or scrap steel, and then carried to the starting the proper manner.
  • Page 38 SeCTION 4 OpeRATION...

  • Page 39: Maintenance

    SeCTION 5 MAINTeNANCe 5.0 MAINTeNANCe 5.1 MAINTeNANCe AND SeRVICe IF UNINSULATeD CABLe AND pARTS ARe NOT Re- pLACeD, AN ARC CAUSeD BY A BARe CABLe OR pART TOUChING A GROUNDeD SURFACe MAY DAMAGe Be SURe ThAT The BRANCh CIRCUIT OR MAIN DISCON- UNpROTeCTeD eYeS OR START A FIRe.
  • Page 40 SeCTION 5 MAINTeNANCe 5.2.1.3 TRANSFORMeR 5.2.2 WIRe FeeDeR Occasional blowing out of the dust and dirt from around the As soft wire is fed, the drive rolls may pick up metal from the transformer is recommended. This should be done periodically wire surface.

  • Page 41: Replacement Parts

    Ordering To ensure proper operation, it 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.
  • Page 42 SeCTION 6 RepLACeMeNT pARTS 20, 21 Figure 24 - Right Side Front View TORCh ADApTOR ASSeMBLY (Internal View) TORCh ADApTOR ASSeMBLY 26,27 (external View)
  • Page 43 SeCTION 6 RepLACeMeNT pARTS Figure 24 - Right Side Front View (Con’t) QTY. ITeM CIRCUIT ReQ. DeSCRIpTION SYMBOL 952895 SWITCH PB NORMALLY OPEN 672831 SWITCH TOGGLE SPDT 951474 SWITCH SEAL BLACK 0558001702Y BRACKET RH HANDLE 13730632 POT LIN 10.0K 2.00W .88L R1,R2 0558001019 KNOB 1.57 DIA.
  • Page 44 SeCTION 6 RepLACeMeNT pARTS Figure 25 - Left Side Front View of Multimaster 260 QTY. ITeM CIRCUIT ReQ. DeSCRIpTION SYMBOL 0558002555Y DOOR SPOOL(HINGE & HINGE BKACKET NOT INCLUDED) 0558002593Y TOP COVER FRONT 38196 PCB ASSY. DISPLAY PCB2 38219 PCB CONTROL MAIN...

  • Page 45: Section 6 Replacement Parts

    SeCTION 6 RepLACeMeNT pARTS Figure 26 - Inside Right & Rear View of Multimaster 260...
  • Page 46 SeCTION 6 RepLACeMeNT pARTS Figure 26 - Inside Right & Rear View of Multimaster 260 (cont.) QTY. ITeM CIRCUIT ReQ. DeSCRIpTION SYMBOL 948258 SPINDLE MOLDED (SEE FIGURE 28) 0558002543M REAR COVER 0558003076 TRANSISTOR REPLACEMENT KIT IGBT MATCHED PAIR 600V - 300A...
  • Page 47 SeCTION 6 RepLACeMeNT pARTS 64,65 67, 68 Figure 26 - Inside Left View of Multlimaster 260 QTY. ITeM CIRCUIT ReQ. DeSCRIpTION SYMBOL 0558001710M FAN MOUNT 0558002490 MOTOR 950592 FAN BLADE 0558001577 MAIN TRANSFORMER 208/230V 0558001580 MAIN TRANSFORMER - 230/460/575V 99511915 DIODE REV 200V 250A D1,2 99511916...
  • Page 48 SeCTION 6 RepLACeMeNT pARTS For units with serial numbers xxxJ230001 (Mid July 2002 forward) DRIVE ROLLS (See Drive Roll & Guide Tube Selection Guide on Following Pages) NOTE: Measure hole placement to distinguish between early & cur- rent version drive stands Figure 29 - Auto-Lift Mini Four Roll Geared Wire Drive System - 0558001339 For units with serial numbers starting xxxJ230001 (Mid July 2002 forward) QTY.
  • Page 49 SeCTION 6 RepLACeMeNT pARTS For units with serial Numbers between xxxJ125051-xxxJ229001 (prior to Mid July 2002) DRIVE ROLLS (See Drive Roll & Guide Tube Selection Guide on Following Pages) NOTE: Measure hole placement to distinguish between early & cur- rent version drive stands Figure 30 - Auto-Lift Mini Four Roll Geared Wire Drive System - 0558001339 For units with serial Numbers between xxxJ125051 - xxxJ229001 (prior to Mid July 2002) QTY.
  • Page 50 SeCTION 6 RepLACeMeNT pARTS Table 6 - Drive Roll and Guide Tube Selection Wire Type Guide Tube Roll Drive* & Diameter hard Wires (“V” groove) .023 in. (0.6 mm) 21155 0558001499 .030 in. (0.8 mm) 21155 0558001499 .035 in. (0.9 mm) 21156 0558001498 .045 in.
  • Page 51 SeCTION 6 RepLACeMeNT pARTS Figure 28 - Spindle Assembly for Multimaster 260 QTY. ITeM CIRCUIT ReQ. DeSCRIpTION SYMBOL 0558002561M WIRE SPOOL MOUNT BRACKET 948258 MOLDED SPINDLE 634347 CLIP HITCH .16D X 3.25L 948255 BRAKE PADS 36756 “D” SHAFT ALUMINUM 23600952 “D”...
  • Page 52 NOTeS...
  • Page 53 NOTeS...
  • Page 54 NOTeS...

  • Page 55: Revision History

    ReVISION hISTORY Revision B - 04/2005 - Figure 29, Replacement Parts section - chgd item 1, feed plate p/n from: 0558003543 to: 0558001743, item 20, axle gear adaptor p/n chgd from: 0558003540 to: 0558001756 & item 25, screw p/n chgd from: 0558003541 to: 23612462. Updated format. Revision C - 10/2005 - Figure 29, Replacement Parts section - changed Item 20 part number from 0558001756 to 0558003540 and Item 27 from 0558003544 to 0558001758 per Mike Palumbo.
  • Page 62 Welding & Cutting products, Florence, SC Welding equipment COMMUNICATION GUIDe - CUSTOMeR SeRVICeS CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns ENGINEERING SERVICE:...

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