Instruction Manual

Installation, Operation and Service

200 MIG, 230 MIG and 280 MIG
Power Sources

Form No: 0558007453 03 / 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 opera-
tion 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. Do NOT attempt to install or operate this equipment until you
have read and fully understand these instructions. If you do not fully understand these instructions, contact
your supplier for further information. Be sure to read the Safety Precautions before installing or operating
this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance
with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly
maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contami-
nated should be replaced immediately. Should such repair or replacement become necessary, the manu-
facturer recommends that a telephone or written request for service advice be made to the Authorized
Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manu-
facturer. The user of this equipment shall have the sole responsibility for any malfunction which results
from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the
manufacturer or a service facility designated by the manufacturer.
 TABLE OF CONTENTS

1 DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1
3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2
4 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3
5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5.1 Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5.2 Assembly of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5.4 Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10
4
6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11
6.1 Connection and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11
6.2 Functions explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
12
6.3 MIG process set--up guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
12
5
7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
16
7.1 Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
16
68 FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
33
79 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
17
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
33
WEAR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
38
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
39
 DIRECTIVE

DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S--695 81 Lax, Sweden, gives its unreserved guarantee that welding
power source Migmaster 173/203/253 from serial number 421/402/429 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 EN 60974--10 in accordance with the requirements of directive
(89/336/EEC) and addendum (93/68/EEC).
--------------------------------------------------------------------------------------------------------------------------------------

Lax 16.11.2004

Henry Selenius
Vice President
ESAB Welding Equipment AB
695 81 LAX
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924


 safety precautions
Safety Precautions
WARNING: These Safety Precautions are
for your protection. They summarize pre-
cautionary information from the references
listed in Additional Safety Information sec-
tion. 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.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operat-
ing or observing operations. Warn bystanders not
to watch the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-
sleeve shirt, cuffless trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protec-
tion against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-flammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety
glasses.

Safety - English
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protec-
tive non-flammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hid-
den smoldering fire or fires on the floor below. Make
certain that such openings are protected from hot
sparks and metal.
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce flammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For ex-
ample, overloaded welding cable can overheat and
create a fire hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later fire. Use fire watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is confined, or if there is
danger of falling.
 safety precautions
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric cur-
rent flowing through any conduc-
tor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health effects which
are unknown.

3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain-
less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat ir-
ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom-
fort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
 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.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and fittings in good
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

1. Always have qualified personnel perform the instal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equip-
ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
 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."

Meaning of symbols - As used

throughout this manual: Means Atten-
tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-
mediate, serious personal injury
or loss of life.

Means potential hazards which

could result in personal injury or
loss of life.

Means hazards which could result

in minor personal injury.


 sEGURIDAD
Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su proteccin. Ellas hacen
resumen de informacin proveniente de las
referencias listadas en la seccin "Informacin Adi-
cional Sobre La Seguridad". Antes de hacer cualquier
instalacin o procedimiento de operacin , asegrese
de leer y seguir las precauciones de seguridad listadas
a continuacin as como tambin todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en dao a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS--
Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
proteccin para los odos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden daar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con proteccin a los lados
siempre que est en el rea de trabajo, an cuando
est usando careta de soldar, protector para su cara
u otro tipo de proteccin.
2. Use una careta que tenga el filtro correcto y lente
para proteger sus ojos, cara, cuello, y odos de las
chispas y rayos del arco cuando se est operando y
observando las operaciones. Alerte a todas las per-
sonas cercanas de no mirar el arco y no exponerse
a los rayos del arco elctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantaln de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partculas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantaln o los bolsillos. Mangas y cuellos debern
mantenerse abotonados, bolsillos al frente de la
camisa debern ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chis-
pas calientes con una cortina adecuada no-flamable
como divisin.
6. Use careta protectora adems de sus gafas de segu-
ridad cuando est removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas debern usar gafas
de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del rea
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, lquidos y gases flamables, solventes,
pinturas, papel, etc.
2. Chispas y partculas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegrese de que toda grieta y agujero est cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo est to-
talmente limpia y libre de substancias que puedan
producir gases inflamables o vapores txicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.
4. Tenga siempre a la mano equipo extintor de fuego
para uso instantneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor porttil. Asegrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operacin. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Despus de termirar la operacin del equipo, inspec-
cione el rea de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego ms
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para informacin adicional , haga referencia a la
publicacin NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a travs de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto
con las partes elctricas energizadas
y tierra puede causar dao severo o
muerte. NO use soldadura de corri-
ente alterna (AC) en reas hmedas,
de movimiento confinado en lugares estrechos o
si hay posibilidad de caer al suelo.
 sEGURIDAD
1. Asegrese de que el chasis de la fuente de poder
est conectado a tierra atravs del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra fsica.
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 elctrico fatal.
4. Use el equipo solamente si est en buenas condi-
ciones. Reemplaze cables rotos, daados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el rea de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegrese que todas las partes de su cuerpo estn
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mien-
tras trabaja en lugares estrechos o reas hmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicacin ANSI/ASC
Standard Z49.1 (listado en la prxima pgina) para
recomendaciones especficas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETI-
COS - Son peligrosos. La corriente
elctrica fluye atravs de cualquier
conductor causando a nivel local
Campos Elctricos y Magnticos
(EMF). Las corrientes en el rea de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazn debern consultar a su mdico antes de
soldar. El Campo Electromagntico (EMF) puede
interferir con algunos marca-pasos.
2. Exponerse a campos electromagnticos (EMF) puede
causar otros efectos de salud an desconocidos.
10
3. Los soldadores debern usar los siguientes proced-
imientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un slo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo ms cercano posible al rea de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo ms lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
dao, particularmente en espacios
sin ventilacin. No inhale el humo
o gases. El gas de proteccin puede
causar falta de oxgeno.
Por lo tanto:
1. Siempre provea ventilacin adecuada en el rea
de trabajo por medio natural o mecnico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berlio, o cad-
mio a menos que provea ventilacin mecnica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique sub-
stancias qumicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfgeno,
o gas txico, y otros irritant es.
3. Si momentneamente desarrolla inrritacin de
ojos, nariz o garganta mientras est operando, es
indicacin de que la ventilacin no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilacin en el rea de trabajo.
No contine operando si el malestar fsico per-
siste.
4. Haga referencia a la publicacin ANSI/ASC Standard
Z49.1 (Vea la lista a continuacin) para recomen-
daciones especficas en la ventilacin.
 sEGURIDAD
5. ADVERTENCIA-- Este producto cuando se uti-
liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen qumicos menos que usted est cualificado para hacer el
conocidos por el Estado de Cali-
fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code 25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romp-
erse y liberar violentamente
gases. Rotura repentina del
cilindro, vlvula, o vlvula de
escape puede causar dao o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseado para operar y reducir la
presin del cilindro de gas . No utilice adapta-
dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operacin del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posicin vertical
y amrrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tab-
lilleros, paredes, postes, o armazn. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito ellectrico.
3. Cuando el cilindro no est en uso, mantenga la
vlvula del cilindro cerrada. Ponga el capote de
proteccin sobre la vlvula si el regulador no
est conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede cau-
sar dao o muerte. Por lo tanto:
11
1. Siempre tenga personal cualificado para efec-
tuar l a instalacin, diagnstico, y mantenimiento
del equipo. No ejecute ningn trabajo elctrico a
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningn
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, tambin lugares hmedos como charcos
de agua , aceite o grasa, atmsferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artculos de seguridad y
coverturas del equipo en su posicin y en buenas
condiciones.
6. Use el equipo slo para el propsito que fue
diseado. No modifique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGU-
RIDAD -- Para ms informacin sobre las
prcticas de seguridad de los equipos de
arco elctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
Las siguientes publicaciones, disponibles atravs de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
 sEGURIDAD

SIGNIFICADO DE LOS sImbolOs

-- Segn usted avanza en la lectura
de este folleto: Los Smbolos Sig-
nifican Atencin! Est Alerta! Se
trata de su seguridad.

Significa riesgo inmediato que,

de no ser evadido, puede resultar
inmediatamente en serio dao
personal o la muerte.

Significa el riesgo de un peligro

potencial que puede resultar en
serio dao personal o la muerte.

Significa el posible riesgo que

puede resultar en menores daos
a la persona.

12
 sCURIT
Safety - French
AVERTISSEMENT : Ces rgles de scurit
ont pour but d'assurer votre protection. Ils
rcapitulent les informations de prcaution
provenant des rfrences dans la section
des Informations de scurit supplmentaires. Avant de
procder l'installation ou d'utiliser l'unit, assurez-vous
de lire et de suivre les prcautions de scurit ci-des-
sous, dans les manuels, les fiches d'information sur la
scurit du matriel et sur les tiquettes, etc. Tout dfaut
d'observer ces prcautions de scurit peut entraner
des blessures graves ou mortelles.
PROTGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit lev et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, met des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures la
peau et les yeux. Le mtal incandescent peut causer
des brlures. Une formation relie l'usage des
processus et de l'quipement est essentielle pour
prvenir les accidents. Par consquent:
1. Portez des lunettes protectrices munies d'crans la-
traux lorsque vous tes dans l'aire de travail, mme
si vous devez porter un casque de soudeur, un cran
facial ou des lunettes tanches.
2. Portez un cran facial muni de verres filtrants et de
plaques protectrices appropries afin de protger
vos yeux, votre visage, votre cou et vos oreilles des
tincelles et des rayons de l'arc lors d'une opration
ou lorsque vous observez une opration. Avertissez
les personnes se trouvant proximit de ne pas re-
garder l'arc et de ne pas s'exposer aux rayons de l'arc
lectrique ou le mtal incandescent.
3. Portez des gants ignifugis crispin, une chemise
paisse manches longues, des pantalons sans
rebord et des chaussures montantes afin de vous
protger des rayons de l'arc, des tincelles et du mtal
incandescent, en plus d'un casque de soudeur ou
casquette pour protger vos cheveux. Il est galement
recommand de porter un tablier ininflammable afin
de vous protger des tincelles et de la chaleur par
rayonnement.
4. Les tincelles et les projections de mtal incandescent
risquent de se loger dans les manches retrousses,
les rebords de pantalons ou les poches. Il est recom-
mand de garder boutonns le col et les manches et
de porter des vtements sans poches en avant.
5. Protgez toute personne se trouvant proximit des
tincelles et des rayons de l'arc l'aide d'un rideau ou
d'une cloison ininflammable.
6. Portez des lunettes tanches par dessus vos lunettes
de scurit lors des oprations d'caillage ou de
meulage du laitier. Les cailles de laitier incandescent
peuvent tre projetes des distances considrables.
Les personnes se trouvant proximit doivent gale-
ment porter des lunettes tanches par dessus leur
lunettes de scurit.
13
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les tincelles
peuvent galement provoquer un
incendie ou une explosion. Par consquent :
1. loignez suffisamment tous les matriaux combus-
tibles de l'aire de travail et recouvrez les matriaux
avec un revtement protecteur ininflammable. Les
matriaux combustibles incluent le bois, les vte-
ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revtements, le
papier, etc.
2. Les tincelles et les projections de mtal incan-
descent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
dclencher un incendie couvant l'tage infrieur
Assurez-vous que ces ouvertures sont bien protges
des tincelles et du mtal incandescent.
3. N'excutez pas de soudure, de coupe ou autre tra-
vail chaud avant d'avoir compltement nettoy la
surface de la pice traiter de faon ce qu'il n'ait
aucune substance prsente qui pourrait produire
des vapeurs inflammables ou toxiques. N'excutez
pas de travail chaud sur des contenants ferms
car ces derniers pourraient exploser.
4. Assurez-vous qu'un quipement d'extinction
d'incendie est disponible et prt servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'tre bien
instruit par rapport l'usage de cet quipement.
5. Assurez-vous de ne pas excder la capacit de
l'quipement. Par exemple, un cble de soudage
surcharg peut surchauffer et provoquer un in-
cendie.
6. Une fois les oprations termines, inspectez l'aire de
travail pour assurer qu'aucune tincelle ou projec-
tion de mtal incandescent ne risque de provoquer
un incendie ultrieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplmentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC LECTRIQUE -- Le contact avec
des pices lectriques ou les pices
de mise la terre sous tension peut
causer des blessures graves ou mor-
telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
 sCURIT
1. Assurez-vous que le chssis de la source
d'alimentation est branch au systme de mise
la terre de l'alimentation d'entre.
2. Branchez la pice traiter une bonne mise de
terre lectrique.
3. Branchez le cble de masse la pice traiter et
assurez une bonne connexion afin d'viter le risque
de choc lectrique mortel.
4. Utilisez toujours un quipement correctement
entretenu. Remplacez les cbles uss ou endom-
mags. ct de votre corps.
5. Veillez garder votre environnement sec, incluant
les vtements, l'aire de travail, les cbles, le porte-
lectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isol
de la pice traiter et des pices de la mise la
terre.
7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe-
ment sur le mtal ou sur la terre; tenez-vous sur
des planches sches ou une plate-forme isole et
portez des chaussures semelles de caoutchouc.
8. Avant de mettre l'quipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'quipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (list
la page suivante) pour des recommandations
spcifiques concernant les procdures de mise
la terre. Ne pas confondre le cble de masse avec
le cble de mise la terre.
CHAMPS LECTRIQUES ET MAGN-
TIQUES comportent un risque
de danger. Le courant lectrique
qui passe dans n'importe quel con-
ducteur produit des champs lec-
triques et magntiques localiss. Le soudage et le
courant de coupage crent des champs lectriques
et magntiques autour des cbles de soudage et
l'quipement. Par consquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son mdecin avant d'entreprendre une
opration de soudage. Les champs lectriques et
magntiques peuvent causer des ennuis pour cer-
tains stimulateurs cardiaques.
2. L'exposition des champs lectriques et magn-
tiques peut avoir des effets nfastes inconnus pour
la sant.
14
3. Les soudeurs doivent suivre les procdures suivantes
pour minimiser l'exposition aux champs lectriques
et magntiques :
A. Acheminez l'lectrode et les cbles de masse
ensemble. Fixez-les l'aide d'une bande adhsive
lorsque possible.
B. Ne jamais enrouler la torche ou le cble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les cbles
de masse. Acheminez tous les cbles sur le mme
D. Branchez le cble de masse la pice traiter le
plus prs possible de la section souder.
E. Veillez garder la source d'alimentation pour le
soudage et les cbles une distance approprie
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulirement
dans les espaces restreints. Ne re-
spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par consquent :
1. Assurez en permanence une ventilation adquate
dans l'aire de travail en maintenant une ventila-
tion naturelle ou l'aide de moyens mcanique.
N'effectuez jamais de travaux de soudage, de coup-
age ou de gougeage sur des matriaux tels que
l'acier galvanis, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mcaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matriaux.
2. N'effectuez jamais de travaux proximit d'une
opration de dgraissage ou de pulvrisation.
Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chlor, ceci peut dclencher
la formation de phosgne ou d'autres gaz irritants,
tous extrmement toxiques.
3. Une irritation momentane des yeux, du nez ou de la
gorge au cours d'une opration indique que la ven-
tilation n'est pas adquate. Cessez votre travail afin
de prendre les mesures ncessaires pour amliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opration si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 ( la page
suivante) pour des recommandations spcifiques
concernant la ventilation.
 sCURIT
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilis
dans une opration de soudage ou de
coupage, dgage des vapeurs ou des
gaz contenant des chimiques consi-
dres par l'tat de la Californie comme
tant une cause des malformations
congnitales et dans certains cas, du
cancer. (California Health & Safety
Code 25249.5 et seq.)
MANIPULATION DES CYLINDRES --
La manipulation d'un cylindre, sans
observer les prcautions ncessaires,
peut produire des fissures et un
chappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles-
sures graves ou mortelles. Par consquent :
1. Utilisez toujours le gaz prvu pour une opration
et le dtendeur appropri conu pour utilisation
sur les cylindres de gaz comprim. N'utilisez jamais
d'adaptateur. Maintenez en bon tat les tuyaux et
les raccords. Observez les instructions d'opration
du fabricant pour assembler le dtendeur sur un
cylindre de gaz comprim.
2. Fixez les cylindres dans une position verticale,
l'aide d'une chane ou une sangle, sur un chariot
manuel, un chssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
jamais un cylindre un poste de travail ou toute autre
dispositif faisant partie d'un circuit lectrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermes. Si le dtendeur n'est pas bran-
ch, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et dplacez les
cylindres l'aide d'un chariot manuel appropri.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres une distance approprie
de toute source de chaleur, des tincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplmentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis votre dis-
position par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
15
ENTRETIEN DE L'QUIPEMENT -- Un quipe-
ment entretenu de faon dfectueuse ou
inadquate peut causer des blessures
graves ou mortelles. Par consquent :
1. Efforcez-vous de toujours confier les tches
d'installation, de dpannage et d'entretien un
personnel qualifi. N'effectuez aucune rparation
lectrique moins d'tre qualifi cet effet.
2. Avant de procder une tche d'entretien
l'intrieur de la source d'alimentation, dbranchez
l'alimentation lectrique.
3. Maintenez les cbles, les fils de mise la terre, les
branchements, le cordon d'alimentation et la source
d'alimentation en bon tat. N'utilisez jamais un
quipement s'il prsente une dfectuosit quel-
conque.
4. N'utilisez pas l'quipement de faon abusive. Gardez
l'quipement l'cart de toute source de chaleur,
notamment des fours, de l'humidit, des flaques
d'eau, de l'huile ou de la graisse, des atmosphres
corrosives et des intempries.
5. Laissez en place tous les dispositifs de scurit et
tous les panneaux de la console et maintenez-les
en bon tat.
6. Utilisez l'quipement conformment son usage
prvu et n'effectuez aucune modification.
INFORMATIONS SUPPLMENTAIRES RELA-
TIVES LA SCURIT -- Pour obtenir de
l'information supplmentaire sur les rgles
de scurit observer pour l'quipement
de soudage l'arc lectrique et le coupage,
demandez un exemplaire du livret "Precau-
tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont galement recomman-
des et mises votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
 sCURIT

SIGNIFICATION DES SYMBOLES

Ce symbole, utilis partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
scurit est en jeu.

DANGER

Signifie un danger immdiat. La situation peut

entraner des blessures graves ou mortelles.

AVERTISSEMENT
Signifie un danger potentiel qui peut entraner des
blessures graves ou mortelles.

ATTENTION
Signifie un danger qui peut entraner des blessures
corporelles mineures.

16
SECTION 1 INTRODUCTION

1.0 Introduction

200 MIG, 230 MIG and 280 MIG are step controlled power sources 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.

200 MIG, 230 MIG and 280 MIG are equipped with facilities for connection of the MIG spool-on gun
torch (type: MT-250SG).

Prest-O-Lite accessories for the product can be found on Page 43.

1.1 equipment

The power source is supplied with:

Welding gun
Return cable 3m with return clamp
Shelf for gas cylinder
Instruction manual

17
SECTION 1 INTRODUCTION

18
The power source is supplied with:
Welding gun
Return cable 3m with return clamp
SECTION 2 TECHNICAL DATA
Shelf for gas cylinder
Instruction manual
2.0 TECHNICAL DATA
4 TECHNICAL DATA
200 MIG 173
Migmaster
Voltage 230V, 1 50/60Hz
Permissible load at
100% duty cycle 76A
60 % duty cycle 98A
20 % duty cycle 170A
Setting range (DC) 30A/15.5V--170A/18.5V
Open circuit voltage 19.5--35.0V
Open circuit power 160W
Power factor at max load 0,90
Control voltage 42V, 50/60Hz
Wire feed speed 40--670ipm (1.0--17m/min)
Burnback time 0.02--0.25s
Spot welding 0.2--2.5s
Welding gun connection EURO
Wire dimension range
Fe .023--.030 (0.6--0.8mm)
Al .035--.040 (0.9--1.0mm)
FCW .030 (0.8mm)
Max diameter/weight 12 (300mm)/33lb (15kg)
of wire bobin
Dimensions lxwxh 33x16x28 (860x420x730mm)
Weight 130lb (59kg)
Operating temperature 14104F (--10 +40oC)
Enclosure class IP 23
Application classifica-
tion

-- 6 --
MM1725e

19
SECTION 2 TECHNICAL DATA
GB
2.0 TECHNICAL DATA (con't.)

230 MIG 203

Migmaster 280 MIG 253
Migmaster
Voltage 230V, 1 50/60Hz 230V, 1 50/60Hz
Permissible load at
100% duty cycle 90A 110A
60 % duty cycle 115A 140A
20 % duty cycle 200A 250A
Setting range (DC) 30A/15.5V--200A/22V 40A/16.0V--250A/23V
Open circuit voltage 18--38V 19.5--43V
Open circuit power 140W 200W
Power factor at max load 0.83 0.92
Control voltage 42V, 50/60Hz 42V, 50/60Hz
Wire feed speed 40--670ipm (1.0--17m/min) 75--748ipm (1.9--19m/min)
Burnback time 0.02--0.25s 0--0.25s
Spot welding 0.2--2.5s 0.2--2.5s
Welding gun connection EURO EURO
Wire dimension range
Fe .023--.045 (0.6--1.1mm) .023--.045 (0.6--1.1mm)
Al .035--.040 (0.9--1.0mm) .040--3/64 (1.0--1.2mm)
FCW .030--.045 (0.8--1.1mm) .030--.045 (0.8--1.1mm)
Max diameter/weight 12 (300mm)/33lb (15kg) 12 (300mm)/33lb (15kg)
of wire bobin
Dimensions lxwxh 33x16x28 (860x420x730mm) 33x16x28 (860x420x730mm)
Weight 150lb (68kg) 216lb (98kg)
Operating temperature 14104F (--10 +40oC) 14104F (--10 +40oC)
Enclosure class IP 23 IP 23
Application classifica-
tion

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.
20
SECTION 3 INSTALLATION

GBINSTALLATION
3.0

5 installation
The INSTALLATION
must be performed by a professional.
The installation must be executed by a professional.
NOTE:
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.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the users responsibility to take adequate precautions.

3.1 PLACING
5.1 thePlacing
Position welding power source such a way that its cooling air inlets and outlets are not obstructed.
Position the welding power source such way that its cooling air inlets and outlets are
not obstructed.

5.2 ASSEMBLY
3.2 Assembly of components
OF COMPONENTS

NOTE:
WARNING!
For packing and shipment of the machine the wheels are detached from the unit. Before use
For packing and shipment of the machine the wheels are detached from the unit.
attach the wheels per illustrations below.
Before use attach the wheels according to instruction.

1.

2.

3.

21
SECTION 3 INSTALLATION

3.3 ELECTRICAL INSTALLATION

Mains voltage

The single voltage machines are factory-configured for 230V, the multi voltage machines are factory
configured for highest rated voltage and are fitted with appropriate marking tape on the mains cable.

Mains voltage selection

Machines 230 MIG and 280 MIG can be supplied from 230V or 208V mains (1 ph.).
Factory configuration is for 230V. In order to adapt the machine for 208V following must be carried
out (refer to the diagrams on page 38 and 39):

reconnect the primary winding of the TM1 at the auxiliary terminal block XTM, as indicated with
dashed lines (208V taps),
reconnect the wire No 10:
280 MIG - from terminal 7 onto 5 on the control transformer TC1,
230 MIG - from terminal 6 onto 4 on the control transformer TC1.

Welding voltage polarity

Welding voltage polarity may be changed as shown below.
200 MIG

22
SECTION 3 INSTALLATION
GB
3.3 ELECTRICAL INSTALLATION (con't.)
Migmaster 203/253
230 MIG, 280 MIG

3.4 MAINS POWER SUPPLY

Check
5.4 thatMains
the unit power
is connected to the correct mains power supply voltage, and that it is protected by
supply
the correct fuse size. A protective earth connection must be made, in accordance with regulations.
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

Migmaster
200 MIG 173 Migmaster
230 MIG 203 Migmaster
280 MIG 253
Voltage 230V, 1 50/60Hz 208/230V, 1 50/60Hz 208/230V, 1 50/60Hz
Current A
at 100% duty cycle 10.5 15.5/14.0 18.6/16.8
at 60% duty cycle 14.5 20.5/18.5 25.9/23.4
at 20% duty cycle 28.0 41.0/37.0 53.1/48.0
Cable area AWG 3 x 10 3 x 10 3 x 10
Fuse slow A 16 25 35

23
SECTION 3 INSTALLATION

24
6 OPERATION
SECTIONsafety
General 4 OPERATION
regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
4.0 OPERATION

General GBsafety regulations for the handling of the equipment can be found on
WARNING!
Page 5. Read thoroughly before you start using the equipment!
Rotating6parts can
OPERATION
cause injury, take great care.
ROTATING
General safety regulations PARTS
for the handling CAN
of the CAUSEcan
equipment INJURY, TAKE
be found on GREAT
CARE.
page 4. Read through before you start using the equipment!

WARNING -- TIPPING tippingRISK!risk! - there is a risk of tipping while

WARNING!
transporting and operating if the welding
CAUTION
There is a risk of tipping while transportation and operation, if the welding machine leans
Rotating parts can cause
machine
injury,
more than 10o. In that case appropriate leans
take great care.
securing has more than! 10. in that case
to be provided
appropriate securing has to be provided!

6.1
4.1
Connection
WARNING -and control
TIPPING RISK! devices
CONNECTION AND CONTROL DEVICES
There is a risk of tipping while transportation and operation, if the welding machine leans
more than 10o. In that case appropriate securing has to be provided !
1 Mains supply switch with indicating lamp 6 Knob for spot welding -- ON/OFF and time
setting
2 6.1 indicating
Orange Connection
lamp, and control devices
overheating 7 Knob for wire speed setting
3 Welding
1 voltage
Mains supplyswitch
switch with indicating lamp 6 8KnobDigital
for spot instrument -- V/A,
welding -- ON/OFF and time
200 MIG: 8 173:
Migmaster steps8 steps (option,see page 39)
setting
230 2MIG:Orange
Migmaster 12203:
steps12 steps
indicating lamp, overheating 7 Knob for wire speed setting
280 3MIG:Welding
Migmaster 12253:
steps12 steps
voltage switch 8 Digital instrument -- V/A,
Migmaster 173: 8 steps (option,see page 39)
4 EURO --Migmaster
connector 203: for welding gun
12 steps 9 Connector for spool--on gun (wire control)
5 Migmaster
Return cable with253: 12 steps
clamp, fixed 10 Knob for burn--back time setting.
4 EURO -- connector for welding gun 9 In 280
ConnectorM forMIG
253 located
spool--on
located inin(wire
gun wire
wire feeder compartment,
control)
feeder
5 Return cable with clamp, fixed 10 Knobinfor200/230
burn--back
M 170/200 MIG
time locatedononcontrol
setting.
located controlboard.
board.
In M 253 located in wire feeder compartment,
5a Connector [--] for welding gun or return 11 Electrode
in M 170/200 locatedcable withboard.
on control plug, connected to the
cable
5a (welding
Connectorpolarity change--over)
[--] for welding gun or return 11 welding
Electrode cable gun
withconnector
plug, connected (welding
to the polarity
cable (welding polarity change--over) welding gun connector (welding polarity
change--over)
change--over)

5b Connector [+] for[+]welding

5b Connector gun
for welding gunor returncable
or return cable (welding
(welding polaritypolarity change--over)
change--over)

25

-- 11 --
SECTION 4 OPERATION

4.2 FUNCTIONS EXPLANATION

4.2.1 Switching-on and overheating protection

When machine is switched on with the illuminated switch [1], its lamp is on. If the machine is not over-
heated (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.

4.2.2 operation
Operator can manually select and set welding parameters as follows:
required welding voltage ( and thus welding current) with knob [3]
appropriate wire feed speed with knob [7]
burn-back time: for 280 MIG with potentiometer [10] located in the wire feeder compartment, for
200/230 MIG with trim potentiometer located on the control board inside the machine
spot welding, 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 con-
trolled 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: For spool-on gun current cable connection it is necessary to use the OKC T adapter (see Acces-
sories on Page 43).

Machines optionally may be fitted with V/A digital instrument [8] (with hold function i.e. memorizing
of the last values of welding voltage and current, see Page 43).

4.3 MIG process set-up guide

In the following tables, separately for each machine, recommended welding settings are shown, de-
pending on the joint type, workpiece thickness and filler wire diameter.
To set machine for welding:
find the plate thickness (T) and type of joint,
find the diameter (d) of the filler wire,
in the column corresponding to the appropriate material and shielding gas find the suggested arc
voltage and wire feed setting; if spot welding find recommended time setting,
set arc voltage selector [3], wire feed potentiometer [7], and (if necessary) the spot welding time [6]
according to values found in table.

NOTE: The given recommendations only serve as rough guide for the operator, optimal set-ups may dif-
fer from the ones in tables. It depends on mains voltage deviation, precision of the wire speed setting,
applied welding techniques, welding position, etc.

If needed, some corrections of the arc voltage and wire speed may be tried out for satisfactory results.
26
SECTION 4 OPERATION

200 MIG

27
SECTION 4 OPERATION

230 MIG

28
SECTION 4 OPERATION

280 MIG

29
SECTION 4 OPERATION

30
SECTION 5 MAINTENANCE

5.0 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

GB
NOTE:
Warranty from the supplier is void if the customer attempts any type repair work on the prod-
7 MAINTENANCE uct during the warranty period.
Regular maintenance is important for safe, reliable operation.

Note!
5.1
All INSPECTION
guarantee AND CLEANING
undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
Check regularly that the power source is free from dirt.
7.1 Inspection and cleaning
The power source should be regularly blown clean using dry compressed air at reduced pressure. More
Check regularly
frequently thatenvironments.
in dirty the power source is free from
Otherwise dirt.
the air inlet/outlet may become blocked and cause over-
heating.
The power source should be regularly blown clean using dry compressed air at reduced
pressure. More frequently in dirty environments. Otherwise the air inlet/outlet may be-
come blocked
Welding gun and cause overheating.
Welding gun
Cleaning and replacement of the welding guns wear parts should take place at regular intervals in
Cleaning
order and replacement
to achieve of wire
trouble-free the welding guns
feed. Blow wear
the wireparts
guideshould
cleantake placeand
regularly at clean the contact
regular intervals in order to achieve trouble--free wire feed. Blow the wire guide
tip.
clean regularly and clean the contact tip.

The brake hub

The hub is adjusted when delivered, if
readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly
slack when wire feed stops.

Adjusting the braking torque:

Turn the red handle to the locked position.
Insert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs anticlockwise to increase the braking torque. NB: Turn both
springs through the same amount.

31
SECTION 5 MAINTENANCE

32
 GB
SECTION 6 FAULT TRACING

8 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised service technican.

Type of fault Actions

No arc
Welding current is interrupted
during welding
Thermal overload trips
operate frequently
Poor welding performance
Check that the mains power supply switch is turned on.
Check that the welding current supply and return cables are
correctly connected.
Check that correct current value is set.
Check whether the thermal overload trip has operated
(indicated by the orange lamp on the front).
Check the main power supply fuses.
Check to see whether the air inlets/outlets are clogged.
Make sure that you are not exceeding the rated data for the
power source (i.e. that the unit is not being overloaded).
Check that the welding current supply and return cables are
correctly connected.
Check that the correct current value is set.
Check that the correct welding wires are being used.
Check the main power supply fuses.
Check the wire feed unit -- if proper rolls are applied and
properly set the pressure of the wire feeders pressure rollers

9 ORDERING OF SPARE PARTS

Migmaster 173/203/253 is designed and tested in accordance with the international and
European standards IEC/EN 60974--1 and EN 60974--10. It is the obligation of the servi-
ce unit which has carried out the service or repair work to make sure that the product
still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.

33
SECTION 6 FAULT TRACING

34
SECTION 7 ORDERING OF SPARE PARTS

7.0 ORDERING OF SPARE PARTS

NOTE:
200/230/280 MIG is designed and tested in accordance with the international and Euro-
pean standards IEC/EN 60974-1 and EN 60974-10. It is the obligation of the service unit
which has carried out the service or repair work to make sure that the product still con-
forms to the said standard.

Spare parts may be ordered through your nearest Prest-O-Lite dealer, see the last page of this publica-
tion.

35
SECTION 7 ORDERING OF SPARE PARTS

36
SCHEMATIC DIAGRAM

200 MIG, 230V

37
 SCHEMATIC DIAGRAM

230 MIG, 208/230V

38
 SCHEMATIC DIAGRAM

280 MIG, 208/230V (valid up to machine No. 429-651-1134)

39
 SCHEMATIC DIAGRAM

280 MIG, 208/230V

40
280 MIG, 230 MIG and 280 MIG
Migmaster 173/203/253

Valid for serial no. 421/402/429--XXX--XXXX

Ordering numbers

0349 307numbers
Ordering 060 Migmaster 173 230V 1
50/60Hz
0349 306 140 Migmaster 203 208/230V 1
50/60Hz (3m torch)
0349 308 570 Migmaster 203 208/230V 1
50/60Hz (4m torch)
0349310680 200 MIG 10' MXL 200 230V 1-50/60Hz (3m torch)
0349 306 150 Migmaster 253 208/230V 1
50/60Hz (3m torch)
0349310690 230 MIG DELUXE 13' MXL 200 208/230V 1-50/60Hz (4m torch)
0349 307 920 Migmaster 253 208/230V 1
50/60Hz (4m torch)
0349310700 280 MIG DELUXE 13' MXL 270 208/230V 1-50/60Hz (4m torch)

41
Migmaster 173/203/253
280 MIG, 230 MIG and 280 MIG

Wear components

(W. F. Mechanism 0455 890 890 / 0455 890 882)

Item Denomination Ordering no. Notes
A Pressure roller 0455 907 001
0367 556 001 .023--.030/.035 (0.6--0.8/0.9mm) Fe, Ss, cored wire.
B Feed roller 0367 556 002 .030/.035--.040/.045 (0.8/0.9--1.0/1.1mm) Fe, Ss, cored wire.
0367 556 004 .035/.040--3/64 (0.9/1.0--1.2mm) Al wire.

C Inlet nozzle 0466 074 001

0455 894 001 Plastic, must be used together with item 0455 885 001,
D Insert tube for welding with Al wire.
0455 889 001 Steel, must be used together with item 0455 886 001.

0455 885 001 Must be used together with item 0455 894 001,
E Outlet nozzle for welding with Al wire.
0455 886 001 Must be used together with item 0455 889 001.

Welding with aluminium wires.

In order to weld with aluminium wires, proper rollers, nozzles and liners for aluminium wires MUST be
Welding with aluminium wires.
used. It is recommended that a 3m long welding gun be used for aluminium wires, equipped with ap-
propriate
In order towear parts.
weld with aluminium wires, proper rollers, nozzles and liners for
42
aluminium wires MUST be used. It is recommended to use 3m long welding gun for
aluminium wires, equipped with appropriate wear parts.

280 MIG, 230 MIG and 280 MIG

accessories

Digital
Meter
(200
MIG
and
230
MIG)
. ....... . 0349
307
620

Meter
Digital (280 ... . . . . . . . . . . . . . . . . . . .
MIG) 0349
310
605

43
Notes

44
Notes

45
Notes
 Revision History

Original release - 03 / 2007.

 Prest-O-Lite Welding & Cutting Products,
PO Box 100545, Florence, SC
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