Miller Electric Welder 273 User Manual

OM-223 194E

2006−09

Effective with serial number 226 213

Processes

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Description

Arc Welding Power Source

Wire Feeder

Migmatic

271/273/293/333/383

www.MillerWelds.com

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-5. Installing Wire Spool and Adjusting Hub T e nsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-6. Positoning Jumper Links (230/400V 3-Phase Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3-8. Selecting a Location and Connecting Input Power (1-Phase and 3-Phase) . . . . . . . . . . . . . . . . . . . . . . 12

3-9. Installing Drive Rolls and Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3-10. Aligning Drive Rolls and Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3-1 1 . Threading Welding Wire and Adjusting Pressure Roll T e nsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3-12. Using Gun/Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3-13. Setting Gun Polarity for Wire Type (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4-1. Controls for Migmatic 271/273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4-2. Controls for Migmatic 293/333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4-3. Controls for Migmatic 383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-4. Run-In, Burnback (Optional) and Spot Weld Timer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION 5 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5-3. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

WARRANTY

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Declaration of Conformity for

European Community (CE) Products

This information is provided for units with CE certification (see rating label on unit).

NOTE

Manufacturer:

European Contact:

ITW Welding Products Italy S.r.l.

Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

Phone: 39(02)98290-1

Mr. Danilo Fedolfi,

Managing Director

ITW Welding Products Italy S.r.l.

Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

Phone: 39(02)98290-1

Fax: 39(02)98290203

European Contact Signature:

Declares that this product:

Migmatic 271/273/293/333/383

conforms to the following Directives and Standards:

Directives

Electromagnetic Compatibility Directives: 89/336/EEC

Low Voltage: 73/23/EEC

Machinery Directives: 89/392/EEC

And their amendments 91/368/EEC, 92/31/EEC, 93/44/EEC, 93/68/EEC, 98/37/EC

Standards

Electromagnetic compatibility (EMC) EN50199: August 1995

Safety Requirements for Arc Welding Equipment Part 1: EN 60974-1: 1998

And their amendments EN60974-1:2005, EN60974-10:2003

The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

dec_stat_Milan_6/05

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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _3/05

Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1-5. Read and follow all

Safety Standards.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

Only qualified persons should install, operate, maintain, and

repair this unit.

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

During operation, keep everybody, especially children, away.

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

ELECTRIC SHOCK can kill.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

Do not connect more than one electrode or work cable to any

single weld output terminal.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

groundedequipment is a hazard.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present on

unit.

SIGNIFICANT DC VOLTAGE exists in inverter-type

welding power sources after removal of input

power.

Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

FUMES AND GASES can be hazardous.

Additionalsafety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomaticDC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

If ventilation is poor, wear an approved air-supplied respirator.

Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, or

cadmiumplated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

groundedreceptacle outlet.

When making input connections, attach proper grounding conduc-

tor first − double-check connections.

Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

OM-223 194 Page 1

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ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use

approved air-supplied respirator.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

Wear an approved welding helmet fitted with a proper shade of fil-

ter lenses to protect your face and eyes when welding or watching

(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

HOT PARTS can cause severe burns.

Wear approved safety glasses with side shields under your

helmet.

Do not touch hot parts bare handed.

Allow cooling period before working on gun or

torch.

To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

MAGNETIC FIELDS can affect pacemakers.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

Pacemaker wearers keep away.

Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

NOISE can damage hearing.

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

Noise from some processes or equipment can

damagehearing.

Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

Wear approved ear protection if noise level is

high.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

CYLINDERS can explode if damaged.

Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, and fire

hazards.

Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

Do not use welder to thaw frozen pipes.

Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder − explosion will result.

Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is in

use or connected for use.

FLYING METAL can injure eyes.

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

Wear approved safety glasses with side

shields even under your welding helmet.

Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-223 194 Page 2

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1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

MOVING PARTS can cause injury.

Do not install or place unit on, over, or near

combustiblesurfaces.

Do not install unit near flammables.

Keep away from moving parts such as fans.

Keep all doors, panels, covers, and guards

closed and securely in place.

Have only qualified persons remove doors,

panels, covers, or guards for maintenance as

necessary.

Reinstall doors, panels, covers, or guards

when maintenance is finished and before re-

connecting input power.

Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

Use equipment of adequate capacity to lift and

support unit.

If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Use only genuine Miller/Hobart replacement

parts.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communicationsequipment.

Have only qualified persons familiar with

electronic equipment perform this installation.

OVERUSE can cause OVERHEATING

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before

starting to weld again.

Do not block or filter airflow to unit.

The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

If notified by the FCC about interference, stop using the

equipmentat once.

STATIC (ESD) can damage PC boards.

Have the installation regularly checked and maintained.

Put on grounded wrist strap BEFORE handling

boards or parts.

Use proper static-proof bags and boxes to

store, move, or ship PC boards.

Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

MOVING PARTS can cause injury.

Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

Be sure all equipment in the welding area is

electromagneticallycompatible.

Keep away from moving parts.

Keep away from pinch points such as drive

rolls.

To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

WELDING WIRE can cause injury.

Do not press gun trigger until instructed to do

so.

Be sure this welding machine is installed and grounded

according to this manual.

Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

Welding or cutting equipment 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 Section 25249.5 et seq.)

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductiveharm. Wash hands after handling.

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

OM-223 194 Page 3

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1-5. Principal Safety Standards

Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:

800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-

ternational.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11

West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,

website: www.ansi.org).

Recommended Safe Practices for the Preparation for Weldingand Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1 from Global Engineering Documents (phone:

1-877-413-5184,website: www.global.ihs.com).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:

617−770−3000,website: www.nfpa.org).

NationalElectrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269−9101(phone: 617−770−3000, website: www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-

site: www.cganet.com).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there

are 10 Regional Offices−−phone for Region 5, Chicago, is

312−353−2220,website: www.osha.gov).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined.Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor before welding or going near

welding operations. If cleared by your doctor, then following the above

procedures is recommended.

To reduce magnetic fields in the workplace, use the following

procedures:

OM-223 194 Page 4

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SECTION 2 − DEFINITIONS

Warning! Watch Out! There are possible

hazards as shown by the symbols.

2.1 Keep your head out of the fumes.

Arc rays can burn eyes and injure

skin.

2.2 Use forced ventilation or local

exhaust to remove the fumes.

Electric shock can kill.

4.1 Wear hat and safety glasses. Use

ear protection and button shirt collar.

Use welding helmet with correct

shade of filter. Wear complete body

protection.

2.3 Use ventilating fan to remove fumes.

1.1 Wear dry insulating gloves. Do not

touch electrode with bare hand. Do

not wear wet or damaged gloves.

Welding sparks can cause explosion

or fire.

1.2 Protect yourself from electric shock

by insulating yourself from work and

ground.

3.1 Keep flammables away from welding.

Do not weld near flammables.

Become trained and read the

instructions before working on the

machine or welding.

3.2 Welding sparks can cause fires.

Have a fire extinguisher nearby, and

have a watchperson ready to use it.

1.3 Disconnect input plug or power

before working on machine.

Do not remove or paint over (cover)

the label.

Breathing welding fumes can be

hazardous to your health.

3.3 Do not weld on drums or any closed

containers.

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Drive rolls can injure fingers

Welding wire and drive parts

are at welding voltage during

operation − keep hands and

metal objects away.

OM-223 194 Page 5

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Warning! Watch Out! There are

possible hazards as shown by the

symbols.

Electric shock from wiring can kill.

Disconnect input plug or power

before working on machine.

Read the Owner’s Manual before

working on this machine.

Consult rating label for input

power requirements, and

check power available at the

job site − they must match.

Read Owner’s Manual and

inside labels for connection

points and procedures.

Move jumper links as shown

on inside label to match

voltage at job site.

Having a loop of extra length,

connect grounding conductor

first.

Connect line input conductors

as shown on inside label −

double-check all connections,

jumper link positions, and

input voltage before applying

power.

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Moving parts, such as fans,

can cut fingers and hands and

cause injury. Keep away from

moving parts.

S-176 106

Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Falling unit can cause injury.

Do not move or operate unit

where it could tip.

Cylinders can expolde if

damaged. Protect

compressed gas cylinders

from excessive heat,

mechanical shock, slag, open

flames, sparks, and arcs.

OM-223 194 Page 6

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Warning! Watch Out! There

are possible hazards as

shown by the symbols.

Electrical shock from wiring

can kill.

Read Owner’s Manual before

working on this machine

Wear approved safety

glasses

Electrode Positive (Straight

Polarity)

Place terminal strips as shown.

Electrode Negative (reverse

Polarity)

Place terminal strips as shown.

Do not discard this product with

general waste.

Reuse or recycle Waste Electrical

and Electronic Equipment (WEEE)

by disposing at a designated collec-

tion facility.

Contact your local recycling office

or your local distributor for further

information.

OM-223 194 Page 7

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SECTION 3 − INSTALLATION

3-1. Specifications

Rated Input Amperage

at Rated Output

Max.

Open

Circuit

Voltage

Rated Output

60%

Dimension

(mm)

Weight

(kg)

100%

20%

220/230 VAC 50Hz

Model

110 A

20.0 V

150 A

21.0 V

240 A

26 V

32 A

3 A*

271

480 x 800 x 1050

85 Net

Wire feed speed range 1.3 mpm to 20 mpm.

* While idling

Rated Input Amperage

at Rated Output

Max.

Open

Rated Output

Dimension

(mm)

Weight

(kg)

Circuit

Voltage

400 V

100%

60%

35%

230 V

Model

145 A

21.0 V

190 A

23.0 V

240 A

26 V

23 A

3 A*

13 A

1.38 A*

85-103

Net

273

480 x 800 x 1050

Wire feed speed range 1.3 mpm to 20 mpm.

* While idling

Rated Input Amperage

at Rated Output

Max.

Open

Circuit

Voltage

Rated Output

50%

Dimension

(mm)

Weight

(kg)

400 V

100%

35%

230 V

Model

210 A

24 V

230 A

25 V

270 A

27.5 V

30 A

3 A*

18 A

1.38 A*

90-108

Net

293

480 x 800 x 1050

Wire feed speed range 1.3 mpm to 20 mpm.

* While idling

Rated Input Amperage

at Rated Output

Max.

Open

Rated Output

Dimension

(mm)

Weight

(kg)

Circuit

Voltage

400 V

100%

50%

35%

230 V

Model

210 A

24.5 V

300 A

29.0 V

350 A

31.5 V

30 A

3 A*

18 A

1.75 A*

90-118

Net

333

480 x 800 x 1050

Wire feed speed range 1.3 mpm to 20 mpm.

* While idling

Rated Input Amperage

at Rated Output

Max.

Open

Circuit

Voltage

Rated Output

50%

Dimension

(mm)

Weight

(kg)

400 V

100%

35%

230 V

Model

38 A

3 A*

22 A

1.75 A*

280 A

28.0 V

350 A

32.0 V

380 A

33 V

105-123

Net

383

480 x 800 x 1050

Wire feed speed range 1.3 mpm to 20 mpm.

* While idling

OM-223 194 Page 8

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3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

voltage, or duty cycle before

welding.

Exceeding duty cycle can

damage unit and void

warranty.

% DUTY CYCLE

60% Duty Cycle At 400 Amperes

100% Duty Cycle At 300 Amperes

6 Minutes Welding

4 Minutes Resting

Continuous Welding

Overheating

A or V

Reduce Duty Cycle

Minutes

sduty1 5/95 / 187 478-A

3-3. Volt-Ampere Curves

The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves

of other settings fall between the curves shown.

Model 273

Model 271

MAX

MIN

Model 293

MAX

MIN

Model 333

Model 383

MAX

MIN

OM-223 194 Page 9

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3-4. Installing Gas Supply

Chain gas cylinder to running gear,

wall, or other stationary support so

cylinder cannot fall and break off

valve.

Regulator/FlowGauge

Install so face is vertical.

Gas Hose Connection

Flow Adjust

Typical flow rate is 0.9 liters per

minute. Check wire manufactur-

er’s recommended flow rate. This

flow gauge can be adjusted be-

tween 2.36 and 11.8 liters per min-

ute.

Argon Gas

CO Gas

Ref. ST-148 265-B / Ref. ST-149 827-B / Ref. ST-158 697-A

3-5. Installing Wire Spool and Adjusting Hub Tension

When a slight force is needed to turn spool, tension is set.

Tools Needed:

Nov. 16, 2005

OM-223 194 Page 10

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3-6. Positoning Jumper Links (230/400V 3-Phase Models)

230 V

400 V

3-7. Electrical Service Guide

271

230

273

293

333

383

Migmatic Model

230

400

230

400

230

400

230

400

Input Voltage

Input Amperes at Rated Output

Max Recommended Standard Fuse

or Circuit Breaker Rating in Am-

peres

2.5

** Input Conductor Size in mm

** Grounding Conductor Size in

** Power cord supplied with the unit is sized for 230V operation. Larger power cord may be required for cable lengths greater than 3 meters.

Consult national and local regulations.

OM-223 194 Page 11

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3-8. Selecting a Location and Connecting Input Power (1-Phase and 3-Phase)

Have only qualified persons make

this installation.

Rating Label

Supply correct input power.

18 in (457 mm)

for airflow

GND/PE

Connect First

GND/PE

Connect First

1-Phase Primary Connection

3-Phase Primary Connection

OM-223 194 Page 12

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3-9. Installing Drive Rolls and Wire Guide

Securing Screw

Inlet Wire Guide

Loosen screw. Slide tip as close to

drive rolls as possible without

touching. Tighten screw.

Anti-Wear Guide

Install guide as shown.

Drive Roll

The drive roll consists of two differ-

ent sized grooves. The stamped

markings on the end surface of the

drive roll refers to the groove on the

opposite side of the drive roll. The

groove closest to the motor shaft is

the proper groove to thread.

Drive Roll Securing Nut.

Turn nut one click to secure drive

roll.

ꢀ

Tools Needed:

5/64 in

7/16 in

3-10. Aligning Drive Rolls and Wire Guide

Turn Off power.

View is from top of drive rolls

looking down with pressure

assembly open.

Drive Roll Securing Nut

Drive Roll

Correct

Incorrect

Wire Guide

Welding Wire

Drive Gear

Insert screwdriver, and turn screw

in or out until drive roll groove lines

up with wire guide.

Close pressure roll assembly.

Tools Needed:

Ref. 800 412-A

OM-223 194 Page 13

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3-11. Threading Welding Wire and Adjusting Pressure Roll Tension

Wire Spool

Welding Wire

Inlet Wire Guide

Pressure Adjustment Knob

Drive Roll

Outlet Wire Guide

Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

. Hold wire tightly to keep it

from unraveling.

150 mm

(6 in)

Open pressure assembly.

Pull and hold wire; cut off end.

Push wire thru guides into gun;

continue to hold wire.

. Use pressure indicator

scale to set a desired

drive roll pressure.

Tighten

Pressure

Indicator

Scale

Close and tighten pressure

assembly, and let go of wire.

Remove gun nozzle and contact tip.

Turn On.

Tighten

WOOD

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close

and latch door.

Ref. 802 064-D / S-0627-A

OM-223 194 Page 14

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3-12. Using Gun/Cable Holder

Side Panel

Latch

Cable Holder

Press latch down to release and

open door.

Holster (2)

Wrap cable around cable holder,

and place gun nozzle into holster.

Ref. 802 726-A

3-13. Setting Gun Polarity for Wire Type (Optional)

Terminal Cover

Protects Polarity Change over ter-

minals from accidental contact. Re-

move cover to gain access.

Electrode Positive (DCEP)

For solid steel, stainless steel, alu-

minum, or flux core with gas, wires

(GMAW).

Electrode Negative (DCEN)

For gasless flux core wires

(FCAW), wire drive assembly be-

comes negative.

OM-223 194 Page 15

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SECTION 4 − OPERATION

4-1. Controls for Migmatic 271/273

Voltage Control

Turn control clockwise to increase

voltage.

2T/4T Trigger Hold Function

Latching Torch Trigger

Power Switch

Work Lead Connection

MIG Torch Connection

Digital Display Function

Button*

Wire Feed Speed Control

Turn control clockwise to increase

wire feed speed.

Digital Display*

Volts/Amps/WireFeed Speed with

last value hold function. Trigger

mode (2T/4T) is shown at power on

for 3 seconds and when Trigger

mode is changed.

. Not shown:

Jog and Purge controls are lo-

cated under the hinged side

wire consumable access door.

* Optional

4-2. Controls for Migmatic 293/333

Voltage Control (Fine Adjust)

Turn control clockwise to increase

voltage.

Voltage Control (Coarse

Adjust)

Turn control clockwise to increase

voltage.

2T/4T Trigger Hold Function

Latching Torch Trigger

Power Switch

6 in

Work Lead Connection

MIG Torch Connection

Digital Display Function

Button*

Wire Feed Speed Control

Turn control clockwise to increase

wire feed speed.

Digital Display*

Volts/Amps/WireFeed Speed with

last value hold function. Trigger

mode (2T/4T) is shown at power on

for 3 seconds and when Trigger

mode is changed.

. Not shown:

Jog and Purge controls are lo-

cated under the hinged side

wire consumable access door.

* Optional

OM-223 194 Page 16

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4-3. Controls for Migmatic 383

Voltage Control (Fine Adjust)

Turn control clockwise to increase

voltage.

Voltage Control (Coarse

Adjust)

Turn control clockwise to increase

voltage.

2T/4T Trigger Hold Function

Latching Torch Trigger

Power Switch

Work Lead Connection − High

Inductance

Work Lead Connection − Low

Inductance

MIG Torch Connection

Digital Display Function

Button*

Wire Feed Speed Control

Turn control clockwise to increase

wire feed speed.

10 Digital Display*

Volts/Amps/WireFeed Speed with

last value hold function. Trigger

mode (2T/4T) is shown at power on

for 3 seconds and when Trigger

mode is changed.

. Not shown:

Jog and Purge controls are lo-

cated under the hinged side

wire consumable access door.

* Optional

4-4. Run-In, Burnback (Optional) and Spot Weld Timer Controls

Run-In Control*

Speed of wire prior to striking a

weldingarc. This value is a percent-

age of the set wire for welding.

Burnback Control*

Time that welding wire stays ener-

gized after trigger is released.

Spot Weld Timer

Time that welding arc is active be-

fore shutting off automatically.

Spot Timer resets after releasing

gun trigger.

* Optional

OM-223 194 Page 17

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SECTION 5 − MAINTENANCE &TROUBLESHOOTING

5-1. Routine Maintenance

. Maintain more often

Disconnect power

before maintaining.

during severe conditions.

3 Months

Replace unreadable labels

Repair or replace

cracked weld cable

Clean and tighten weld terminals

6 Months

Remove drive roll and

carrier. Apply light coat

of oil or grease to drive

motor shaft.

Blow out or vacuum inside.

Ref. 802 990

5-2. Circuit Breaker CB1

Circuit Breaker CB1

CB1 protects the unit from over-

loading of drive motor M1. If CB1

opens, wire feeding stops.

Welding Gun

Check gun liner for blockage or

kinks.

Wire Drive Assembly

Check for jammed wire, binding

drive gear or misaligned drive rolls.

Allow cooling period and reset

breaker. Close door.

5-3. Unit Overload

Thermal switches TP1 in XFMR and TP2 in SR1 protect the unit from damage due to overheating. If the thermal indica-

tor illuminates, wait for unit to cool allowing fan motor to run before trying to weld. If unit is cool and no weld output

continues, contact Factory Authorized Service Agent.

OM-223 194 Page 18

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5-4. Troubleshooting

Trouble

Remedy

Be sure line disconnect switch is On (see Section 3-8).

No weld output; wire does not feed.

Replace building line fuse or reset circuit breaker if open.

Reset circuit breaker CB1 (see Section 5-2).

Secure gun trigger connections.

Check continuity of power switch S1 and replace if necessary.

Check main transformer T1 for signs of windig failure. Check continuity across windings and check for

proper connections. Check secondary voltages. Replace T1 if necessary.

Check continuity of thermostats TP1 and TP2. Replace TP1 and TP2 if necessary.

Check main control board PC1 and connections and replace if necessary.

Connect work clamp to get good metal to metal contact.

No weld output; wire feeds.

Replace contact tip (see gun Owner’s Manual).

An overload condition occurred (see Section 5-3)

Check diodes in main rectifier SR1, and replace if necessary.

Check stabilizer Z1 for signs of winding failure. Check continuity across windings and check connections.

Replace Z1 if necessary.

Check main transformer T1 for signs of winding failure. Check continuity across windings and check con-

nections. Check secondary voltages. Replace T1 if necessary.

Check voltage switch(s). Replace if necessary.

Connect unit to proper input voltage or check for low line voltage (see Section 3-6).

Check input voltage jumper links and correct position if necessary (see Section 3-6).

Check main rectifier SR1, and replace if necessary.

Low weld output.

Check voltage switch(s). Replace if necessary.

Low, high, or erratic wire speed.

Readjust front panel settings (see Section 4-1).

Change to correct size drive rolls.

Readjust drive roll pressure (see Section 3-11).

Replace inlet guide, contact tip, and/or liner if necessary.

Check position of input jumper links (see Section 3-6).

Check Wire Speed control R1, and replace if necessary.

Check diodes in main rectifier SR1, and replace if necessary.

Check main control boarf PC1 and connections and replace if necessary.

Reset circuit breaker CB1 (see Section 5-2).

No wire feed.

Rotate Wire Speed control R1 to higher setting (see Section 4-1).

Clear obstruction in gun contact tip or liner (see gun Owner’s Manual).

OM-223 194 Page 19

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Notes

OM-223 194 Page 20

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SECTION 6 − ELECTRICAL DIAGRAMS

271−Sept 27, 2005

Figure 6-1. Circuit Diagram for Migmatic 271

OM-223 194 Page 21

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273−Sept 27, 2006

Figure 6-2. Circuit Diagram for Migmatic 273 (400 VAC)

OM-223 194 Page 22

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293−Sept 27, 2006

Figure 6-3. Circuit Diagram for Migmatic 293 (400 VAC)

OM-223 194 Page 23

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333− Sept 27, 2005

Figure 6-4. Circuit Diagram for Migmatic 333 (400 VAC)

OM-223 194 Page 24

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383−Sept 27 2005

Figure 6-5. Circuit Diagram for Migmatic 383 (400 VAC)

OM-223 194 Page 25

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SECTION 7 − PARTS LIST

Figure 7-1. Wrapper Assembly, All Models

OM-223 194 Page 26

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Item

No.

Part

No.

Description

Quantity

Figure 7-1. Wrapper Assembly, All Models

. . . 1 . . . . . . . 156034005 . . Catch, side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 2 . . . . . . . 156122058 . . Side Panel, hinged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . 156034004 . . Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 4 . . . . . . . 156005098 . . Cylinder Rack, upper support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . . . 000207235 . . Label, warning, tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . 956142514 . . Rating Plate, Migmatic 271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . 956142505 . . Rating Plate, Migmatic 273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . 956142508 . . Rating Plate, Migmatic 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . 956142511 . . Rating Plate, Migmatic 383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . . . . 956142503 . . Label, F1, fuse and gas input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . . . . 156087017 . . Pin, split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 9 . . . . . . . 056054075 . . Wheel, rear, 250 O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 10 . . . . . . . 156009067 . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 11 . . . . . . . 156012113 . . Axle, rear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . . . 156121023 . . Wrapper, R/H side fixed (271/273/293) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . . . 156121027 . . Wrapper, R/H side fixed (333/383) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . . 000197555 . . Gun and cable Holder assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . . . 000207233 . . Label, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . . 056054068 . . Wheel/Caster, front 80 O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 16 . . . . . . . 316029701 . . Nameplate, lower, Migmatic 271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . 316029702 . . Nameplate, lower, Migmatic 273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . 316029706 . . Nameplate, lower, Migmatic 293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . 316029703 . . Nameplate, lower, Migmatic 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . 316029704 . . Nameplate, lower, Migmatic 383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 17 . . . . . . . 000208154 . . Front, shroud, plastic assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . . . 000207233 . . Label, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . 000207291 . . Label, primary power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . 156122059 . . Side Panel, L/H side lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . 316029698 . . Nameplate, upper Migmatic 271 and 273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . 316029699 . . Nameplate, upper Migmatic 293/333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . 316029700 . . Nameplate, upper Migmatic 383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-223 194 Page 27

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Figure 7-2. Main Assembly for Migmatic 271

April 17, 2006

OM-223 194 Page 28

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 7-2. Main Assembly for Migmatic 271

. . . 1 . . . . . . . . . . . . . . 000197555 . . Tool tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . V57052030 . . Euro Adapter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . . . . . . . . V56005028 . . Shroud, Euro adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . . . . . 156005101 . . Mounting bracket, drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . . R1 . . . 056059274 . . Potentiometer, 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . . . 000207075 . . Knob pointer, wire feed speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . . . . . . . . . . . . 116118172 . . Front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . . . . . . . . . . . 056076152 . . Dinze adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 9 . . . . . . . S3 . . . 056067251 . . Switch, main on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 10 . . . . . . PL2 . . . 056072075 . . LED indicator, orange, over temperature . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . . . . PL1 . . . 056072076 . . LED indicator, white, power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . . . . . . . . . . 056067169 . . Switch, 2T/4T trigger hold function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . PC3 . . . 057095015 . . Digital Volt/Amp/WFS Display (optional) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . . . S2 . . . 056067201 . . Switch, 10 position, voltage selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . SR1 . . 056050145 . . Rectifier, 1Ph 250 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . . . . . . . . 656014012 . . Mounting bracket, wire jog and gas purge switches . . . . . . . . . . . . . . . 1

. . . 17 . . . . . . . . . . . . . . 117060016 . . Baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . . TP2 . . . 000175405 . . Thermal Switch PTC 105_ C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . . . 056059257 . . Shunt (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . . . . . . . . 028021459 . . Transformer, main 220/230 VAC 50 Hz c/w . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . TP1 . . . 056159025 . . Thermal Switch PTC 130_ C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . R3 . . . 056059277 . . Potentiometer, Run-In control (optional) c/w . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . R4 . . . 056059277 . . Potentiometer, Wire burn-back control (optional) . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . . . R2 . . . 056059275 . . Potentiometer, Spot-weld timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . . . . CB1 . . 056067188 . . Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . . . . . . . . . . . . . . 156006038 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 26 . . . . . . . Z1 . . . . 058028016 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . . C1 . . . 056082091 . . Capacitor 1600 80μp VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 28 . . . . . . . . . . . . . . 058021141 . . Transformer, auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 29 . . . . . . . . . . . . . . 057079033 . . W Contactor 11Kw, 230VAC 50/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 30 . . . . . . . . . . . . . 056126073 . . Fan motor assembly, consisting of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . FM1 . . . 056126073 . . Fan motor, 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 356078037 . . Blade, 250Ø 27_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 31 . . . . . . . . . . . . . . 000176106 . . Label, safety, caution moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 32 . . . . . . . . . . . . . . . 116117074 . . Cowling, fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 33 . . . . . . . . . . . . . . 000006393 . . Relay, Fan-On-Demand (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 34 . . . . . GSV1 . . 056061042 . . Gas Solenoid Valve, 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 35 . . . . . . . . . . . . . . V56091091 . . Strain Relief, primary cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . V56018092 . . Strain Relief, nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 36 . . . . . . . . . . . . . . 057014199 . . Primary cable, 3 core 4mm 230VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . . . F1 . . . . 056092039 . . Fuse, 20mm 10 Amp 500VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 38 . . . . . . . F1 . . . . 056092094 . . Fuse Holder, 20mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 39 . . . . . . . . . . . . . . 956142503 . . Label, gas connection and F1 fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 40 . . . . . . . . . . . . . . . 116118171 . . Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 41 . . . . . . . . . . . . . . 000186436 . . Washer, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 42 . . . . . . . . . . . . . . 027061026 . . Hose, gas, braided, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 43 . . . . . . . . . . . . . . 156005108 . . Spool, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . . . . 000186435 . . Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . . PC1 . . . 057084125 . . Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . . PC1 . . . 057084127 . . Motor Control, c/w optional, PC2 run-in, burn-back control . . . . . . . . . 1

. . . 46 . . . . . . . . . . . . . . 156009075 . . Washer, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 47 . . . . . . . . . . . . . . 956142502 . . Label, run-in, wire burn-back, spot-timer and CB1 . . . . . . . . . . . . . . . . 1

. . . 48 . . . . . . . . . . . . . . 000207076 . . Knob pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 49 . . . . . . . . . . . . . . . . 178937A . . Label, safety, caution moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . . . . . . . . . . 056093022 . . Switch, push button, momentary contact, Jog/Purge . . . . . . . . . . . . . . 2

. . . 51 . . . . . . . . . . . . . . 956142504 . . Nameplate, wire jog and gas purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 52 . . . . . . . . . . . . . . 056020069 . . Knob pointer, voltage selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 53 . . . . . . . . . . . . . . 156032064 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 54 . . . . . . . . . . . . . . 156009079 . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . . . . . . . . . . . . . 156018033 . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 56 . . . . . . . . . . . . . . 156032128 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 57 . . . . . . . . . . . . . . 000058427 . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Figure 7-3. Main Assembly for Migmatic 273

April 17, 2006

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