Migmaster 250 Pro.pdf

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Migmasterr 250 Pro
Service manual
0349 300 056
060918
Valid for serial no. 528, 607−xxx−xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Migmasterr 250 Pro, 230/208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Migmasterr 250 Pro, 208/230/460/575V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:2 Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:3 Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:4 Wire feed speed, creep start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:5 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:6 Burnback time, contactor, gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:7 Thermal overload cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1
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Migmasterr 250 Pro component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AR Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AR component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AR diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2 Digital instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2:1 Calibration and voltage correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding voltage polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functions explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MIG process set−up guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the wire feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TOCe
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READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault−tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation. All component names in the wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made up to and
including September 2006.
The Migmasterr 250Pro is designed and tested in accordance with international and
European standard IEC/EN 60974−1 and EN 60974−10.
On completion of service or repair work, it is the responsibility of the person(s) etc.
performing the work to ensure that the product does not depart from the requirements
of the above standard.
INTRODUCTION
Migmasterr 250 Pro
is step controlled power source 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.
The machine is equipped with facilities for connection of the MIG ”spool−on” gun
torch (type: MT−250SG).
1sM250P
−
3
−
Edition 060918
TECHNICAL DATA
Migmasterr 250 Pro
Voltage
Permissible load at
100% duty cycle
60 % duty cycle
50 % duty cycle
Setting range (DC)
Open circuit voltage
Open circuit power
Power factor
at max load
Control voltage
Wire feed speed
Burnback time
Spot welding
Creep start
Welding gun connection
Wire dimension range
Fe
Al
FCW
CuSi
Max diameter/weight
of wire bobin
Dimensions lxwxh
Weight
Operating temperature
Enclosure class
Application classification
.023−.045” (0.6−1.1mm)
.040−3/64” (1.0−1.2mm)
.030−.045” (0.8−1.1mm)
.030−.045” (0.8−1.1mm)
12” (300mm)/33lb (15kg)
33x17x32.6” (840x430x830mm)
256lb (116kg)
14÷104F (−10
÷
+40
o
C)
IP 23
.023−.045” (0.6−1.1mm)
.040−3/64” (1.0−1.2mm)
.030−.045” (0.8−1.1mm)
.030−.045” (0.8−1.1mm)
12” (300mm)/33lb (15kg)
33x17x32.6” (840x430x830mm)
304lb (138kg)
14÷104F (−10
÷
+40
o
C)
IP 23
208V/230V, 1∼ 50/60Hz
177A
228A
250A
40A/16.0V−280A/24.6V
19−52V
280W
0.84
42V, 50/60Hz
60−750ipm (1.5−19m/min)
0.03−0.5s
0.5−3.5s
100% / 85%
EURO
Migmasterr 250 Pro
208/230/460/575V, 1∼ 50/60Hz
177A
228A
250A
40A/16.0V−280A/24.6V
19−52V
280W
0.84
42V, 50/60Hz
60−750ipm (1.5−19m/min)
0.03−0.5s
0.5−3.5s
OFF / ON (85%)
EURO
1sM250P
−
4
−
Edition 060918
WIRING DIAGRAM
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
AP1
AP2
C1, C2, CVS
EV1, EV2
KM1
L1
M1
QF1+LF1
QF2
QF3
RO
RVS
RP1
RP3
RI
ST1
TC1
TC3
TM1
V1
VH
XTM
XT1
YV1
S
S
Observe precautions for handling electrostatic
sensitive devices.
Use proper static−proof bags and boxes.
Circuit board
Digital instrument, accessory
Capacitor 0,1uF/250V
Fan
Contactor 42V, 50−60Hz
Inductor
Feed unit motor
Switch, ON/OFF (illuminated)
Rotary switch, fine welding voltage selector
Rotary switch, coarse welding voltage selector
Resistor 15Ω/20W
Resistor
Potentiometer, wire feed speed
Potentiometer with switch, spot welding, optional
Shunt, accessory
Thermal oveload cutout, operates at 130
o
C. The cutout is mounted at
the cooling fins of the diode bridge.
Control transformer
Transformer for digital instrument, accessory
Main transformer
Diode bridge
LED orange
Reconnection block (main transformer)
Terminal block
Gas valve
1sM250P
−
5
−
Edition 060918

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