EN Safety instruction for use and maintenance - Do not destroy this manualFR Instruction de securite demploi et dentretien - Conserver ce livret dinstructionsES Instrucciones de seguridad, empleo y mantenimiento - Conservar el presente manualIT Istruzioni per la sicurezza nelluso e per la manutenzione - Conservare il presente libretto

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www.airliquidewelding.comAir Liquide Welding - 13, rue dEpluches - BP 70024 Saint-Ouen LAumne

Cat. Nr.:Rev.:Date:

MAXISTAR 250T / MAXISTAR 280T

8000353060310. 02. 2009

1 EN

CONTENTSEN1.0 TECHNICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 DATA PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 DUTY CYCLE AND OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4 VOLT - AMPERE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.1 MACHINE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 CONNECTING THE POWER SOURCE TO THE MAINS ELECTRICITY SUPPLY . . . . . . . . . . . . . . 3

2.3 HANDLING AND TRANSPORTING THE POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 SELECTING A LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.5 SAFETY GAS CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.6 WIRE REEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.7 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.0 DESCRIPTION OF FRONT PANEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.1 FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.0 OPTIONAL (USE WITH CORED WIRE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1 WELDING ALUMINIUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.2 WELDING STAINLESS STEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5.0 BASIC INFORMATION REGARDING MIG WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.0 CONNECTION AND PREPARATION OF EQUIPMENT FOR WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.1 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.2 CARBON STEEL WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6.3 STAINLESS STEEL WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6.4 ALUMINIUM WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6.5 SPOT WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.0 MIG WELDING FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8.0 GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8.1 TORCH MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8.2 CONNECTING THE TORCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I - VIII

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

2 EN

TECHNICAL DESCRIPTION EN1.0 TECHNICAL DESCRIPTION

1.1 DESCRIPTION

COMPACT RANGE CONTINUOUS WIRE WELDING MA-CHINES, WITH WIRE FEED UNIT AND REEL HOLDER SPOOLHOUSED- IN A PROTECTED COMPARTMENT. MIG/MAGWELDER SWHICH CAN WELD MILD STEEL, STAINLESSSTEEL AND ALUMINIUM. OPTIONAL VERSION FOR COREWIRE WITHOUT GAS.

1.2 DATA PLATE

MAXISTAR 250T

MAXISTAR 280T

1.3 DUTY CYCLE AND OVERHEATING

The duty cycle is the percentage of a 10 minute period for whichthe welder can continue to weld without overheating. If the ma-chine overheats, the welding current is shut off and the relative in-dicator lamp illuminates. In this case, leave the machine to cool forapprox. 15 minutes and, before restarting, lower the welding cur-rent value and relative voltage or reduce the work time.

Example: 250 A - 30% means working for 3 minutes at 250 A with7 minutes rest time.

1.4 VOLT - AMPERE CURVES

The volt-ampere curves show the welder's maximum output cur-rents and voltage.

2.0 INSTALLATION

IMPORTANT: BEFORE CONNECTING, PREPARING OR USINGEQUIPMENT, READ SECTION 1.0 SAFETY PRECAUTIONS.

2.1 MACHINE ACCESSORIES

1. Unpack the equipment and components to complete the ma-chine assembly.

2. Leave the machine on the wooden pallet, and use a 13 hexwrench to remove the eight screws (four on the left and fouron the right) under the front panel; fit the two castor wheelsand refit the screws.

3. Remove the two screws securing the machine to the pallet,located on the cylinder support.

4. Raise the rear section of the machine slightly to rotate thepallet and thus release the rear section.

5. Remove the screws from the axle and proceed with assem-bly of the fixed wheels.

6. Fit the handles.

PRIMARY

Three phase supply 400 V

Frequency 50 Hz

Effective consuption 5,5 A

Maximum consuption 11 A

SECONDARY

Open circuit voltage 18 35V

Welding current 35 A 200 A

Duty cycle 25% 200 A

Duty cycle 60% 130 A

Duty cycle100% 100 A

Protection class IP 23

Insulation class H

Weight Kg. 54

Dimensions mm 440 x 670 x 750

European Standards EN 60974.1 / EN 60974.10

PRIMARY

Three phase supply 400 V

Frequency 50 Hz

Effective consuption 5,5 A

Maximum consuption 10 A

SECONDARY

Open circuit voltage 17 35V

Welding current 27 A 200 A

Duty cycle 30% 200 A

Duty cycle 60% 140 A

Duty cycle100% 110 A

Protection class IP 23

Insulation class H

Weight Kg. 71

Dimensions mm 500 x 870 x 950

European Standards EN 60974.1 / EN 60974.10

V

A

DESCRIPTION OF FRONT PANEL CONTROLS

3 EN

EN2.2 CONNECTING THE POWER SOURCE TO THE MAINS

ELECTRICITY SUPPLY.

SERIOUS DAMAGE TO THE EQUIPMENT MAY RESULT IFTHE POWER SOURCE IS SWITCHED OFF DURING WELDINGOPERATIONS.1. Ensure that the power supply socket is equipped with the

fuse specified in the table.2. Before inserting the power plug, to avoid damage to the gen-

erator, check that the mains voltage corresponds to the re-quired power supply.

2.3 HANDLING AND TRANSPORTING THE POWER SOURCE

OPERATOR SAFETY: WELDERS HELMET - GLOWES -SHOES WITH HIGH INSTEPS.The machine is easy to lift, transport and handle, though the fol-lowing procedures must always be observed:

1. Do not lift by means of the handle2. Always disconnect the power source and accessories from

main supply before lifting or handling operations.3. Do not drag, pull or lift equipment by the cables.4. To handle this machine, lift from below by means of a suitable

nylon belt.

2.4 SELECTING A LOCATION

SPECIAL INSTALLATION MAY BE REQUIRED WHERE GAS-OLINE OR VOLATILE LIQUIDS ARE PRESENT. WHEN LO-CATING EQUIPMENT, ENSURE THAT THE FOLLOWINGGUIDELINES ARE FOLLOWED:1. The operator must have unobstructed access to controls and

equipment connections. 2. Use rating plate to determine input power need