s erie S e tur a n g i S Multimaster 260 MIG/TIG/STICK WELDING PACKAGE Instruction Manual 0558005188 08/2007
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,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment.
table of contents Section / Title Page 1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
table of contents 4
section 1 safety precautions 1.0 Safety Precautions 1.1 Safety - English WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
section 1 safety precautions 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 3. Welders should use the following procedures to minimize exposure to EMF: 2. Connect the workpiece to a good electrical ground. A. Route the electrode and work cables together. Secure them with tape when possible. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. B.
section 1 safety precautions 5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.) 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2.
section 1 safety precautions 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances." Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
section 1 sEGURIDAD 1.2 Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora. ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad".
section 1 sEGURIDAD 1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de tierra física. 3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal. 4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.
section 1 sEGURIDAD 5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.) 1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo. 2.
section 1 sEGURIDAD SIGNIFICADO DE LOS sImbolOs -- Según usted avanza en la lectura de este folleto: Los Símbolos Significan ¡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. Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte. Significa el posible riesgo que puede resultar en menores daños a la persona.
section 1 sÉCURITÉ 1.3 Safety - French INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. Par conséquent : AVERTISSEMENT : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires.
section 1 sÉCURITÉ 1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée. 2. Branchez la pièce à traiter à une bonne mise de terre électrique. 3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d'éviter le risque de choc électrique mortel. 4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés. 5.
section 1 sÉCURITÉ 5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.) ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent : 1.
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. ATTENTION Signifie un danger qui peut entraîner des blessures corporelles mineures.
section 2 description 2.0 Description Industrial Ready-To-Weld Multi-Process Package Multimaster 260 • • • • • • • Advanced SuperSwitchTM technology makes multiprocess welding a breeze.
section 2 description Digital Meter Volts, Amps, and Wire feed speed Status Indicators Voltage Preset Process Selector Voltage/Current Control Wire Feed Speed Control Remote Control Option “Spool-on-Gun” Option Optional Equipment Pre/Post Flow/Spot/Burnback module...................................... 0558002889 Inductance Control Module.......................................................... 0558002888 Remote Control Module.................................................................
section 2 description 2.1 GENERAL This manual has been prepared for experienced welders. 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. This manual is intended for use in familiarizing personnel with the design and operation of this equipment. All information presented here should be read carefully before installing and using this equipment. 2.
section 2 description 2.6 CONTROLS The Multimaster 260 can be used to weld solid and flux cored wires. The operator selects the process desired on a three position switch located on the front panel. A detailed description of the power source controls is included in Section 4 (Operation) of this manual. 2.
section 2 description Choice of Argon or CO2 Regulator/ Flowmeter 6’ Gas Hose Eyetech Automatic Helmet (Optional) Simple To Use Weld Controls Cylinder Safety Chain Large, Easy To Read Digital Displays for Wire Speed, Amps and Volts Welding Gloves (not shown, optional) Simple and quick polarity change-over Factory Installed Two Cylinder Easy Load Running Gear 15’ Gun Master 250 Mig Gun Stick Electrode Holder (Optional) 15’ Work Cable and Clamp HW-17 Tig Torch (Optional) Figure 1A - Components 21
section 2 description Inductance Burnback Preflow/postflow Spot (Options) Hinged Wire Compartment Door Handle 4 Roll Drive Stand 2 Cylinder Low Mount Tray Wheel Kit Installed Adaptable Spindle Assembly Tool Box with Small Parts Tray Voltage Switch Compartment Figure 1B - Components 22
section 3 installation 3.0 INSTALLATION 3.1 LOCATION Several factors should be considered when selecting an installation site. Adequate ventilation is necessary to provide cooling, and the amount of dirt and dust to which the machine is exposed should be minimized. There should be at least 18 inches of unrestricted space between the machine’s side and rear panels and the nearest obstruction to provide freedom of air movement through the power source.
section 3 installation 3.2 Handle Assembly Installation The Multimaster 260 is factory assembled except for the front handle assembly which is mounted to the machine upside down for shipping purposes. The handle assembly consists of two brackets and a cross bar. To install the handle in its proper position, do the following: A. Remove the two sheet metal screws from the brackets on each side of the front handle assembly. See Figure 3A. B.
section 3 installation 3.3 ELECTRICAL INPUT CONNECTIONS In order to provide a safe and convenient means to completely remove all electrical power from the machine, it is highly recommended that a line disconnect switch be installed in the input circuit of the machine. WARNING Before making electrical input connections to the welding machine, “Machinery Lockout Procedures” should be employed.
section 3 installation 3.3.2 INPUT PLUG The input power cord is provided with an attachment plug. The plug will mate with a 250 volt, 50 Amp receptacle conforming to NEMA 6-50R configuration (208/230 vac model only). The receptacle should be wired to a separately fused disconnect or circuit breaker by an electrician. This disconnect or breaker can be wired to a single phase system or two conductors of a three phase system.
section 3 installation Figure 4A Input Terminal Board 230/460/575 Vac Model Figure 4D Input Terminal Board 208/230 Vac Model 230 Vac Configuration 208 Vac Configuration Figure 4E Input Terminal Board 208/230 Vac Model Figure 4B Input Terminal Board 230/460/575 Vac Model 230 Vac Configuration 460 Vac Configuration Figure 4C Input Terminal Board 230/460/575 Vac Model 575 Vac Configuration 27
section 3 installation 3.5 SECONDARY OUTPUT CONNECTIONS (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) via the secondary output terminals depending on the welding process being used. Figure 5 - Polarity Set-up 3.
section 3 installation 3.7 WIRE FEEDER MECHANISM 3.7.1 DRIVE ROLLS (Figure 7 and 9) The drive roll has two grooves: the small groove feeds .035 in. diameter wire, the large groove feeds .045 in. wire. The groove nearest the gear motor feeds the wire. If the required groove is not correctly positioned, perform the following: A. B. C. D. E. Release the pressure drive roll lever. Remove the two (2) screws holding the drive rolls to the gears. Reverse the drive roll on the drive roll shaft.
section 3 installation 3.7.2 WELDING WIRE SPOOL INSTALLATION caution As with any work area, make sure safety glasses with side shields are worn when handling or changing wire or clipping wire off at the spool or at the end of the torch. Hold onto the wire coming off the spool with one hand before clipping. Serious eye injury can result due to the resilience of the wire which can quickly unravel, or a cut wire end which may shoot across the room.
section 3 installation 3.7.4 SPOOL BRAKE DRAG ADJUSTMENT Spool brake disc friction should provide enough drag to keep the wire spool from spinning freely after wire feed stops. If adjustment is required, turn the adjusting screw inside the spindle housing clockwise to increase drag or counterclockwise to decrease it. Drag should be just enough to limit wire overrun.
section 3 installation WARNING Do not clamp regulator cap in a vise or grip it with a pair of pliers. Distortion of cap can jam the internal parts and cause excessively high delivery pressure as well as weaken the threaded joint to the regulator body. This may cause the cap to fly off and possibly injure personnel in area.
section 3 installation D. Open the cylinder valve slightly, for an instant, to blow out any dust or dirt that may have collected in the valve outlet. BE SURE to keep your face away from the valve outlet to protect your eyes. E. Attach the regulator to the cylinder valve. Align the regulator so that the flowmeter is vertical and then tighten the connection nut with a 1-1/8 in. open end or adjustable wrench.
section 3 installation 34
section 4 operation 4.0 OPERATION WARNING Comply with all ventilation, fire and other safety requirements for arc welding as established in the SAFETY Section at the front of this manual. 4.1 STANDARD CONTROLS 4.1.1 POWER ON/OFF SWITCH & LAMP The main power switch is located on the front panel in the upper left-hand corner. This switch energizes the main transformer, control circuitry and illuminates the Power “ON” lamp. (Figures 12 &13) 4.1.
section 4 operation 4.1.8 TIG and STICK WELDING In the TIG and STICK process mode, you must depress and hold the PRESET button while presetting the welding current in the top display. Releasing the preset button causes the display to return to zero. Once welding begins, the display will show average welding current and volts in the top and bottom display, respectively. After welding stops, the display will again return to zero.
section 4 operation WFS - IPM Lamp Amps Lamp Digital Meters Amps/Volts/WFS Preset Button Weld Process Switch Voltage Set - MIG Current Set - STICK/TIG Power “ON” Lamp Temperature Lamp Fault Lamp Wire Feed Speed Trim IPM Figure 12 - Control Panel Main Power Switch Mig Gun EURO Connection Positive Output Connection Remote Control Module (Optional, blank panel shown) Polarity Switching Connector Spool Gun Control Module (Optional, blank panel shown) Negative Output Connection Figure 13 - Front
section 4 operation 4.2 OPTIONAL CONTROLS 4.2.1 INDUCTANCE TRIM (OPTIONAL) P/N-0558002888 (Figure 14) Inductance is used to optimize short circuiting arc performance by changing the current rise and fall time of each short circuit. This results in improved spatter control, weld bead wetting and arc stability. It is HIGHLY RECOMMENDED that the Inductance Trim option be used for optimum short arc welding performance with stainless steel wires.
section 4 operation 4.2.2 PREFLOW/POSTFLOW/SPOT/BURNBACK (OPTIONAL) P/N-0558002889 (Figure 15) This optional control is mounted in place of the standard burnback control inside the wire spool compartment. A description of the module follows: A. Preflow/Postflow - The PREFLOW control sets the time of the preflow shielding gas before the wire starts feeding (0-1.5 sec.). The POSTFLOW control sets the time the shielding gas remains “ON” after the arc is turned “OFF” (0-7.5 sec.). B.
section 4 operation 4.2.3 REMOTE CONTROL MODULE (OPTIONAL) P/N-0558002605 (Figure 16) This optional control panel mounts to the front of the power source to the right of the main power switch (see Figure 13). The remote receptacle can be used for a variety of options, such as a Tig current control, foot pedal control or manual hand current control. The module includes a toggle switch to select between PANEL or REMOTE control of the welding current and contactor. See Instruction Literature F15-618.
section 4 operation 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. Set the polarity as shown in Table 3 for the process being used. Step 2. Place the WELD PROCESS 1 switch in the MIG (center) position then press the PRESET button.
section 4 operation Table 3 - MIG PARAMETERS CHART (Cont’d) Note 1: When using 100% CO2 sheilding gas, add 2 volts to the data table value. 4.4 TIG WELDING SETUP When the PROCESS switch is placed in the TIG position, the Multimaster 260 turns “ON” the weld contactor so that power is immediately available to the output connection. The Touch TIG starting system is then enabled. Step 1.
section 4 operation NOTE: The Wirespeed 3 knob has no effect in the TIG mode.
section 4 operation WARNING Comply with all ventilation, fire and other safety requirements for arc welding as established in the SAFETY Section at the front of this manual. 4.5 HANDLING THE TIG TORCH Starting the Arc There is nothing difficult or technical about starting an arc in the proper manner. We recommend the particular procedure outlined briefly below, to ensure maximum protection of the workpiece from the atmosphere at the start of welding operations.
section 4 operation 4.6 STICK WELDING SET-UP When the PROCESS switch is placed in the STICK position, the Multimaster 260 turns “ON” the weld contactor so that power is immediately available to the output connection. This means that the STICK electrode holder is “HOT”, and an arc will strike when the electrode comes in contact with the workpiece or any other object at ground potential. Step 1.
section 4 operation 46
section 5 maintenance 5.0 MAINTENANCE 5.1 MAINTENANCE AND SERVICE WARNING BE SURE THAT THE BRANCH CIRCUIT OR MAIN DISCONNECT SWITCH AND MULTIMASTER POWER SWITCH ARE OFF OR ELECTRICAL INPUT FUSES ARE REMOVED BEFORE ATTEMPTING ANY INSPECTION OR WORK INSIDE THE POWER SOURCE. PLACING THE POWER SWITCH ON THE POWER SOURCE IN THE OFF POSITION DOES NOT REMOVE ALL POWER FROM INSIDE THE EQUIPMENT.
section 5 maintenance 5.2.1 POWER SOURCE 5.2.1.1 RECTIFIERS AND TRANSISTORS It is recommended that the internal components be cleaned occasionally by blowing them out with low pressure compressed air. This cleaning operation is necessary so that maximum cooling will be accomplished by the air stream. This should be done periodically, depending upon the location of the unit and the amount of dust and dirt in the atmosphere.
section 6 replacement parts 6.0 Replacement Parts 6.1 General Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 6.2 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.
section 6 replacement parts 24 1 2,3 4 5,6 23 22 9 20, 21 * 10 19 11 18 12 14 17 13 16 15 Figure 24 - Right Side Front View TORCH ADAPTOR ASSEMBLY (Internal View) 26,27 * TORCH ADAPTOR ASSEMBLY (External View) 50
section 6 replacement parts Figure 24 - Right Side Front View (Con’t) QTY. ITEM CIRCUIT No. REQ. NO. DESCRIPTION SYMBOL 1 952895 1 SWITCH PB NORMALLY OPEN S2 2 672831 1 SWITCH TOGGLE SPDT S3 3 951474 1 SWITCH SEAL BLACK 4 0558005430 1 BRACKET RH HANDLE 5 13730632 2 POT LIN 10.0K 2.00W .88L R1,R2 6 0558001019 2 KNOB 1.57 DIA.
section 6 replacement parts 36 35 21 22 34 23 24 33 29 25 26 28 27 Figure 25 - Left Side Front View of Multimaster 260 QTY. ITEM CIRCUIT No. REQ. NO. DESCRIPTION SYMBOL 21 0558001692M 1 DOOR TOP LEFT (HINGE & HINGE BRACKET NOT INCLUDED) 22 0558002593M 1 COVER TOP FRONT 23 38196 1 PCB ASSY.
section 6 replacement parts 64,65 67, 68 69 66 61 60 62 63 Figure 26 - Inside Left View of Multlimaster 260 QTY. ITEM CIRCUIT No. REQ. NO.
section 6 replacement parts 51 (Not Shown) 52 40 48 49 43 46 42 47 50 54
section 6 replacement parts 41 44 45 Figure 27 - Inside Right & Rear View of Multimaster 260 (cont.) QTY. ITEM CIRCUIT No. REQ. NO. DESCRIPTION SYMBOL 40 1 948258 SPINDLE MOLDED (SEE FIGURE 28) 41 1 0558002543M REAR COVER 42 1 0558003076 TRANSISTOR REPLACEMENT KIT IGBT MATCHED PAIR 600V - 300A Q1-2 43 1 38186 PCB ASSY.
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 distingush between early & current verison drive stands Figure 28 - Auto-Lift Mini Four Roll Geared Wire Drive System - 0558001339 For units with serial numbers starting xxxJ230001 (Mid July 2002 forward) ITEM PART NO.
section 6 replacement parts Drive Roll and Guide Tube Selection Wire Type & Diameter Roll Drive* Guide Tube NAS Hard Wires (“V” groove) .023 in. (0.6 mm) .030 in. (0.8 mm) .035 in. (0.9 mm) .045 in. (1.2 mm) 21155 21155 21156 21156 0558001077 0558001077 0558001078 0558001078 .030 in. (0.8 mm) .035 in. (0.9 mm) .040 in. (1.0 mm) .045 in. (1.2 mm) .052 in. (1.4 mm) 1/16 in. (1.6 mm) 5/64 in. (2.
section 6 replacement parts 80 81 82 84 83 Figure 30 - Spindle Assembly for Migmaster 260 QTY. ITEM CIRCUIT No. REQ. NO. DESCRIPTION SYMBOL 80 1 0558002561M Wire Spool Mount Bracket 81 1 948258 MOLDED SPINDLE 82 1 634347 CLIP HITCH .16D X 3.
notes 59
notes 60
revision history 1. Original release - 04/2005 2. Revision - 05/2006 - Updated Handle Assembly Installation subsection per inputs from Ray Lundy. 3. Revision - 08/2007 - Changed Specifications in Sect 2 - Process: MIG (GMAW), Open Circuit Voltage (max): from: 70 Vdc to: 39.0 Vdc per D. Perkins.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. 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 B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C.
