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ESAB Migmaster 300i cvcc Service And Maintenance Manual

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See also: Service Manual , Instruction Manual
F-15-097-A
March, 2001
Migmaster 300i cvcc
WELDING POWER SUPPLY
SERVICE AND MAINTENANCE

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Summary of Contents for ESAB Migmaster 300i cvcc

  • Page 1 F-15-097-A March, 2001 Migmaster 300i cvcc WELDING POWER SUPPLY SERVICE AND MAINTENANCE...
  • Page 2 TABLE OF CONTENTS SECTION TITLE PAGE PARAGRAPH...
  • Page 3 TABLE OF CONTENTS - (Cont) SECTION TITLE PAGE PARAGRAPH...

  • Page 4: Safety Precautions

    SAFETY PRECAUTIONS WARNING: hese Safety Precautions are for 5. Do not use equipment beyond its ratings. For example, your protection. They summarize precaution- overloaded welding cable can overheat and create a fire ary information from the references listed in hazard. Additional Safety Information section.
  • Page 5 EQUIPMENT MAINTENANCE -- Faulty or FUMES AND GASES -- Fumes and improperly maintained equipment can gases, can cause discomfort or harm, cause injury or death. Therefore: particularly in confined spaces. Do not breathe fumes and gases. Shield- 1. Always have qualified personnel perform the installa- ing gases can cause asphyxiation.

  • Page 6: Volt-Ampere Curves

    II. INTRODUCTION 2.3.1 VOLT/AMPERE CURVES (Figure 2-2) The Volt/Ampere curves show the output voltage 2.1 GENERAL available at any given output current. The actual operating point of load Voltage and Current is This manual has been prepared for experienced weld- determined by process, electrode, shield gas, wire ers.
  • Page 7 Table 2-1. Specifications 40% duty cycle 300 amps @ 32 V dc Rated dc Output 60% duty cycle (NEMA Class I) 250 Amps @ 30 V dc Mig (GMAW) 35 - 300 amps Tig (GTAW) 10 - 300 amps Output Current Range Stick (SMAW) 40 - 300 amps Mig (GMAW)

  • Page 8: Optional Equipment

    2.5 OPTIONAL EQUIPMENT Table 2-2. Contact Tips and Liners Table 2-3. Guide Tubes and Feed Rolls Wire Standard Duty Contact Tips* Liners Wire Guide Feed Size & Type Size & Type Tube Roll Short Medium Long 10’ 12" 15’ Hard Wires - Hard Wires &...
  • Page 9 2.6 SAFETY Table 2-4. Slide-on Nozzles (MT-200cc & MIG-41A) Nozzle* Standard Heavy Desc. I.D. Duty Duty #6 Tapered 3/8" 998895 1/2" 998893 999471 5/8" 998894 999472 3/4" 999473 #12 Spot 3/4" 17316 999625 #10 Stud 5/8" 17173 *Uses Nozzles Adapter P/N 999452.

  • Page 10: Power Source

    III. OPERATIONAL DESCRIPTION 3.1 GENERAL 3.2 POWER SOURCE 3.3 DISPLAY AND CONTROLS UPPER LINE WITH 16 CHARACTERS lower line with 16 characters LEFT KEYPAD MIDDLE RIGHT KEYPAD KEYPAD...
  • Page 12 3.4 FINDING WELDING PARAMETERS IN MIG 3.6 SERVO FUNCTIONS SYNERGIC RELATIONSHIPS AND FUNCTIONS...

  • Page 13: Fault Conditions

    3.7 SAVING WELDING CONDITIONS Table 3-1. Parameter Defaults In MIG process: Top row Bottom row 3.8 FAULT CONDITIONS SEL SET-UP TYPE guided mode SEL WIRE TYPE mild steel SEL WIRE SIZE .035" dia. SEL GAS SHIELD 90Ar+8C02+202 SEL PLATE SIZE 16ga .060"...

  • Page 14: Electrical Input Connections

    IV. INSTALLATION OF POWER SOURCE AND ACCESSORIES 4.1 LOCATION 4.2 ASSEMBLY OF REAR WHEELS 4.3 ELECTRICAL INPUT CONNECTIONS...

  • Page 15: Secondary Output Connections

    4.4 SECONDARY OUTPUT CONNECTIONS CONTROL POWER DISPLAY SWITCH TIG STICK SCREEN TORCH CONNECTOR (RECEPTACLE (J4) PROCESS SELECTOR HOSE SWITCH Migmaster 300i MIG-41A POWER LEAD CONNECTOR ELECTRODE -(J6) AND + (J5) OUTPUT RECEPTACLES ELECTRODE POWER CORD CABLE Figure 4-3. Controls and Welding Cable Connections...
  • Page 16 4.6 INSTALLATION FOR MIG WELDING 4.5 WELDING CABLE CONNECTIONS (WORK CABLE)

  • Page 18: Connection Of Shielding Gas Supply

    CONNECTION OF SHIELDING GAS SUPPLY Argon 10-40 CFH Helium 25-125 CFH Nitrogen 10-50 CFH C-25 10-40 CFH...

  • Page 19: Installation For Tig Welding

    4.8 MIG-41A PUSH-PULL GUN 4.9 INSTALLATION FOR TIG WELDING...
  • Page 20 4.10 INSTALLATION FOR STICK WELDING 4.11 SWITCHING BETWEEN PROCESSES...
  • Page 21 V. SETUP AND USAGE OF MIGMASTER 300i 5.1 CONTROLS...

  • Page 22: Process Setup

    5.3 PROCESS SETUP...
  • Page 23 Display Action RETURN TO TOP DISPLAY AND REPEAT AS NECESSARY.
  • Page 28 Table 5-4. Migmaster 300i cvcc SET-UP OPTIONS for The MIG Process - (Cont) 1/4" .250"...
  • Page 29 Table 5-5. Migmaster 300i cvcc MANUAL SET-UP for the MIG Process Action Display...
  • Page 30 Table 5-5. Migmaster 300i cvcc MANUAL SET-UP for the MIG Process - (Cont) Display...
  • Page 31 DESCRIPTION OF TRIGGER TYPE OPTIONS Table 5-6. Trigger Type Selection...

  • Page 33: Maintenance

    VI. SERVICE 6.1 MAINTENANCE 6.2 INSPECTION AND SERVICE...

  • Page 36: Troubleshooting Guide

    ESAB representative. 2. No welding power. a. Thermostat has opened. Wait 15 minutes with fan running. If still no power, contact ESAB representative. b. Shorted diode in rectifier module. Check diodes and replace if req'd. c. Open in wiring.
  • Page 37 TROUBLESHOOTING GUIDE - (Cont) WELD CONDITION POSSIBLE CAUSE REMEDY 10. Shield gas flow low or a. Cylinder valve closed. Turn off regulator, slowly open stopped. valve, until regulator reaches 35 c.f.h. pressure. b. Cylinder empty. Replace if gauge so indicates. c.
  • Page 41 8.2 ORDERING To assure 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.
  • Page 42 15, 16 11, 12 13, 14 FIGURE 8-1. MIGMASTER 300i FRONT VIEW P/N 34677 ITEM PART CKT. REQ. DESCRIPTION DESIG. 33724 ASSEMBLY , LCD 16 CHARACTERS, 15-COND. 951262 KEYPAD, MEMBRANE 680359 SWITCH, 3-POS. 951261 RECEPTACLE, 2-POLE (HIDDEN) 993952 RECEPTACLE, CABLE BOX, 6-POS. 33619YL PANEL, LEFT SIDE 32135GY...
  • Page 43 1, 2 FIGURE 8-1A. MIGMASTER 300i REAR VIEW ITEM PART CKT. REQ. DESCRIPTION DESIG. 13736731 BRACKET, CYLINDER 678944 CHAIN - 36 IN. 08030255 NUT, HOSE CONNECTION 08030245 CONNECTION, HOSE, 3/16 INCH 33613 BASE 14 FT 95195024 HOSE, NEOPRENE, 3/16 INCH ID...
  • Page 44 24,25 19,20 17,18 FIGURE 8-2. MIGMASTER 300i LEFT (INTERIOR) VIEW...
  • Page 45 FIGURE 8-2. MIGMASTER 300i LEFT (INTERIOR) VIEW ITEM PART CKT. REQ. DESCRIPTION DESIG. 31480 P/C BOARD, CONTROL PCB1 950695 HANDLE 17725075 RESISTOR, 75 OHM, 25 W NON-INDUCTIVE 2062120 CONNECTOR, BODY PLUG, 9-POS. 2062119 CONNECTOR, BODY RECEPTACLE, 9-POS. 33618 SHELF EXTENSION 951252 PAD, THERMAL DIODE MODULE IBR1, 2...
  • Page 46 16, 17, 18 19, 20, 21 FIGURE 8-3. MIGMASTER 300i RIGHT (INTERIOR) VIEW...
  • Page 47 FIGURE 8-3. MIGMASTER 300i RIGHT (INTERIOR) VIEW ITEM PART CKT. REQ. DESCRIPTION DESIG. 951264 MOTOR, GEAR 0558001796 DRIVE STAND ASSY 23612461 GUIDE TUBE, INLET 33617 SHELF, WIRE COMPARTMENT 23600010 23605057 SUPPORT, REEL 23606237 HUB, REEL 951312 CAPACITOR, ALUM. 1300 uF, 450 V DC C2, C3 8950248 33344...
  • Page 48 ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548...

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