ESAB MultiMaster 160 User Manual

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SECTION NO. PAGE NO.
SECTION 1.0 - SAFETY PRECAUTIONS.........................................................................................................................................3
SECTION 2.0 - INTRODUCTION ....................................................................................................................................................... 9
SECTION 3.0 - INSTALLATION ......................................................................................................................................................13
3.1 LOCATION..........................................................................................................................................................13
3.2 ELECTRICAL INPUT CONNECTIONS .............................................................................................................13
3.2.1 INPUT ELECTRICAL REQUIREMENTS ........................................................................................................... 13
3.2.2 INPUT PLUG ...................................................................................................................................................... 13
3.3 SECONDARY OUTPUT CONNECTIONS ......................................................................................................... 13
3.4 WIRE FEEDER MECHANISM ...........................................................................................................................13
3.4.1 DRIVE ROLLS .................................................................................................................................................... 13
3.4.2 WELD WIRE SPOOL INSTALLATION ..............................................................................................................13
3.4.3 THREADING THE WELDING WIRE .................................................................................................................14
3.4.4 SPOOL BRAKE DRAG ADJUSTMENT............................................................................................................. 14
3.5 CONNECTION OF SHIELDING GAS SUPPLY ................................................................................................14
3.5.1 R-33-FM-580 REGULATOR (OPTIONAL) ........................................................................................................ 14
3.5.2 TO REGULATE FLOW .......................................................................................................................................15
SECTION 4.0 - OPERATION ............................................................................................................................................................ 16
4.1 STANDARD CONTROLS................................................................................................................................... 16
4.1.1 POWER ON/OFF SWITCH ................................................................................................................................16
4.2.2 TEMP LAMP .......................................................................................................................................................16
4.1.3 PROCESS SELECTOR SWITCH ......................................................................................................................16
4.1.4 SECONDARY WELDING CONNECTIONS....................................................................................................... 16
4.1.5 WIRE FEED SPEED CONTROL ....................................................................................................................... 16
4.1.5 VOLTAGE CONTROL ........................................................................................................................................16
4.1.7 CURRENT CONTROL .......................................................................................................................................16
4.1.8 HOT START ....................................................................................................................................................... 16
4.2 OPERATING PROCEDURES............................................................................................................................ 18
4.2.1 MIG WELDING SET-UP.....................................................................................................................................18
4.2.2 TIG WELDING SET-UP .....................................................................................................................................19
4.2.3 STICK WELDING SET-UP.................................................................................................................................20
SECTION 5.0 - MAINTENANCE ...................................................................................................................................................... 21
5.1 MAINTENANCE AND SERVICE ....................................................................................................................... 21
5.2 INSPECTION AND SERVICE ............................................................................................................................21
5.2.1 POWER SOURCE..............................................................................................................................................21
5.2.1.1 RECTIFIERS AND TRANSISTORS .................................................................................................................. 21
5.2.1.2 FAN MOTOR ...................................................................................................................................................... 21
5.2.1.3 TRANSFORMER ................................................................................................................................................ 21
5.2.1.4 OVER-TEMPERATURE PROTECTION ............................................................................................................21
5.2.2 WIRE FEEDER ...................................................................................................................................................21
SECTION 6.0 - REPLACEMENT PARTS
........................................................................................................................................23
6.1 REPLACEMENT PARTS ...................................................................................................................................23
6.2 GENERAL ........................................................................................................................................................... 23
6.3 ORDERING.........................................................................................................................................................23
Table of Contents

ESAB MultiMaster 160 Specifications

General

Brand	ESAB
Model	MultiMaster 160
Category	Welding System
Language	English