15087-E

1 INSTRUCTIONS for F-15-087-E. August, 1997. MIGMASTER 250. WELDING PACKAGES. F-15-087-E. NOTE: This manual is also suitable for use with L-TEC Migmaster 250 package. These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for electric welding 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.

2 If you do not fully understand these Instructions, contact your supplier for further information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment. Be sure this information reaches the operator. You can get extra copies through your supplier. 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.

3 Defective equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. 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.

4 2. TABLE OF CONTENTS. SECTION NO. PAGE NO. SECTION 1 - GENERAL SAFETY RULES FOR WELDING. AND CUTTING .. 4. GENERAL PRECAUTIONS .. 4. PRECAUTION SYMBOL DEFINITIONS .. 5. SECTION II - INTRODUCTION .. 6. GENERAL .. 6. RECEIVING-HANDLING .. 6. DESCRIPTION, Available Packages/Contents .. 6. OPTIONAL ACCESSORIES .. 7. SAFETY .. 9. SECTION III - INSTALLATION .. 9. LOCATION .. 9. ELECTRICAL INPUT CONNECTIONS .. 9. SECONDARY OUTPUT CONNECTIONS .. 12. TORCH CONNECTIONS .. 12. WIRE FEEDER MECHANISM .. 12. CONNECTION OF THE SHIELD GAS .. 13. WELDING CABLE CONNECTIONS.

5 14. ASSEMBLE REAR WHEELS .. 14. INSTALLING OPTIONAL SPOT/STITCH/ANTI-STICK MODULE .. 14. INSTALLING OPTIONAL DIGITAL METER .. 14. SECTION IV - OPERATION .. 15. CONTROLS .. 15. PROCESS SETUP .. 16. OPERATING PROCEDURES .. 19. SECTION V - SERVICE .. 22. MAINTENANCE .. 22. INSPECTION AND SERVICE .. 22. TROUBLESHOOTING .. 23. SECTION VI - PARTS .. 26. SPARE PARTS .. 26. REPLACEMENT PARTS .. 26. ORDERING .. 26. 3. SAFETY PRECAUTIONS. WARNING: These Safety Precautions are for 5. Do not use equipment beyond its ratings. For example, your protection.

6 They summarize precautionary overloaded welding cable can overheat and create a fire information from the references listed in Addi- hazard. tional Safety Information section. Before per- 6. After completing operations, inspect the work area to make forming any installation or operating procedures, be sure to certain there are no hot sparks or hot metal which could read and follow the safety precautions listed below as well cause a later fire. Use fire watchers when necessary. as all other manuals, material safety data sheets, labels, etc. 7.

7 For additional information, refer to NFPA Standard 51B, Failure to observe Safety Precautions can result in injury or "Fire Prevention in Use of Cutting and Welding Processes", death. available from the National Fire Protection Association, PROTECT YOURSELF AND OTHERS -- Batterymarch Park, Quincy, MA 02269. Some welding, cutting, and gouging processes are noisy and require ear ELECTRICAL SHOCK -- Contact with live protection. The arc, like the sun, emits electrical parts and ground can cause se- ultraviolet (UV) and other radiation and vere injury or death.

8 DO NOT use AC weld- can injure skin and eyes. Hot metal can cause burns. ing current in damp areas, if movement is Training in the proper use of the processes and equip- confined, or if there is danger of falling. ment is essential to prevent accidents. Therefore: 1. Be sure the power source frame (chassis) is connected to 1. Always wear safety glasses with side shields in any work the ground system of the input power. area, even if welding helmets, face shields, and goggles 2. Connect the workpiece to a good electrical ground. are also required.

9 3. Connect the work cable to the workpiece. A poor or 2. Use a face shield fitted with the correct filter and cover missing connection can expose you or others to a fatal plates to protect your eyes, face, neck, and ears from shock. sparks and rays of the arc when operating or observing 4. Use well-maintained equipment. Replace worn or dam- operations. Warn bystanders not to watch the arc and not aged cables. to expose themselves to the rays of the electric-arc or hot 5. Keep everything dry, including clothing, work area, cables, metal. torch/electrode holder, and power source.

10 3. Wear flameproof gauntlet type gloves, heavy long-sleeve 6. Make sure that all parts of your body are insulated from shirt, cuffless trousers, high-topped shoes, and a welding work and from ground. helmet or cap for hair protection, to protect against arc 7. Do not stand directly on metal or the earth while working rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and in tight quarters or a damp area; stand on dry boards or sparks. an insulating platform and wear rubber-soled shoes.