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MobileFeed 201 AVS
Instruction manual
0558 012 084 US 20150409 Valid for: serial no.WORK427XXXX
TABLE OF CONTENTS
1 2 3 4 5
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2.1
2.2
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...................................................................................................
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
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11 Selection of drive rolls and guide tubes
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11 Installing drive rolls and guide tubes
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5.1
5.2
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
Connections and control devices
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6 7
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6.1
6.2
6.3
6.4
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Rights reserved to alter specifications without notice.
0558 012 084 © ESAB AB 2015
1 SAFETY PRECAUTIONS
1 SAFETY PRECAUTIONS
NOTE!
Be sure this information reaches the operator. You can obtain extra copies via your supplier.
CAUTION!
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc, 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. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or insert when installed, operated, maintained and repaired in accordance with the instruction provided. This equipment must be checked periodically. Malfunctioning or poorly maintained 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 Authorised Distributor from whom it was 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.
WARNING!
These Safety Precautions are for your protection. They summarise precautionary information from the references listed in the Additional Safety Information section.
Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe the Safety Precautions could result in injury or death.
PROTECT YOURSELF AND OTHERS Some welding, cutting and gouging processes are noisy and require hearing protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure the skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields and goggles are also required.
2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck and ears from sparks and rays of the arc when operating or observing operations.
Warn bystanders not to look at the arc and not to expose themselves to the rays of the electric-arc or hot metal.
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1 SAFETY PRECAUTIONS 3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes and a welding helmet or cap for protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned and open pockets eliminated from the front of the clothing.
5. Protect other personnel from arc rays and hot sparks using a suitable nonflammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly for long distances. Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS The heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coating paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.
3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned, to ensure there are no substances on the workpiece which might produce flammable or toxic vapors. Do not perform hot work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.
6. After completing work, inspect the work area to make sure there are no hot sparks or hot metal that could cause a fire later. Use fire watchers when necessary.
7. For additional information refer to NFPA Standard 51B, "“Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK Contact between live electrical parts and earth can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the earth system of the input power.
2. Connect the workpiece to a good electrical earth.
3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power source.
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1 SAFETY PRECAUTIONS 6. Make sure that all parts of your body are insulated from the workpiece and from earth.
7. Do not stand directly on metal or the ground while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power, before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific earthing recommendations. Do not mistake the work lead for a earth cable.
ELECTRIC AND MAGNETIC FIELDS May be dangerous. Electric current flowing through any conductor causes localised Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:
1. Welders with pacemakers fitted should consult their doctor before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimise exposure to EMF: a) Route the electrode and work cables together. Secure them with tape when possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on the same side of your body.
d) Connect the work cable to the workpiece as close as possible to the area being welded.
e) Keep the welding power source and cables as far away from your body as possible.
FUMES AND GASES Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. Therefore:
1. Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanised steel, stainless steel, copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is provided. Do not breathe in the fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc can react with chlorinated hydrocarbon vapours to form phosgene, a highly toxic gas and other irritant gases.
3. If you develop momentary eye, nose or throat irritation while operating, this is an indication that the ventilation is not adequate. Stop work and take the necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
5. WARNING: This product when used for welding or cutting, produces fumes or gases that contain chemicals known to the State of California to cause birth defects and in some cases cancer (California Health & Safety Code §25249.5 et seq.) 0558 012 084
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© ESAB AB 2015
1 SAFETY PRECAUTIONS
CYLINDER HANDLING Cylinders, if mishandled, can rupture and violently release gas.
Sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow the manufacturer's operating instructions for mounting a regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position, by chain or strap, to suitable hand trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks.
4. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
WARNING!
EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1. Always have qualified personnel perform the installation, troubleshooting and maintenance work. Do not perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.
3. Maintain cables, earthing wire, connections, power cord and power supply in safe working order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
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1 SAFETY PRECAUTIONS
CAUTION!
ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 . "Recommended Practices for Plasma Arc Welding" 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon, Arc Gouging and Cutting" 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding" 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc welding" 7. AWS SP - "Safe practices" - Reprint, Welding Handbook 8. ANSI/AWS F4.1 - "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances"
MEANING OF SYMBOLS As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards that, if not avoided, will result in immediate, serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed, in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment. Incorrect operation of the equipment may lead to hazardous situations, which could result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with: ○ its operation ○ ○ the location of emergency stops its function ○ ○ the relevant safety precautions welding and cutting or other applicable operation of the equipment 0558 012 084
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1 SAFETY PRECAUTIONS 2. The operator must ensure that: ○ no unauthorised person is within the working area of the equipment when it is started up ○ no-one is unprotected when the arc is struck or work is started with the equpment 3. The workplace must: ○ be suitable for the purpose ○ be free from drafts 4. Personal safety equipment: ○ Always wear recommended personal safety equipment, such as safety glasses, flame-proof clothing, safety gloves ○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns 5. General precautions: ○ Make sure the return cable is connected securely ○ ○ Work on high voltage equipment
electrician may only be carried out by a qualified
Appropriate fire extinquishing equipment must be clearly marked and close at hand ○ Lubrication and maintenance must operation
not
be carried out on the equipment during
CAUTION!
Read and understand the instruction manual before installing or operating.
CAUTION!
Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in such locations, due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at a recycling facility!
To conform with the European Directive 2012/19/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary welding protection and accessories.
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2 INTRODUCTION
2 INTRODUCTION 2.1
Overview
The MobileFeed 201 AVS (Arc Voltage Sensing) is a portable wire feeder. The unit is powered entirely on the arc voltage from a constant current (CC) or constant voltage (CV) welding power source. It operates with reversed polarity, Direct Current Electrode Positive (DCEP), or straight polarity, Direct Current Electrode Negative (DCEN). The MobileFeed 201 AVS is available with two connections, EURO and TWECO. A remote voltage control option is available with the Warrior power source (requires software update to the power source).
The unit is designed for use with hard, soft, and cored electrodes (gas-shielded or self-shielded) from 0.030” (0.8 mm) to 5/64” (1.98 mm) diameter with a wire feed speed from 50 to 750 in/min (1.3 - 19.0 m/min). The feeder components are totally enclosed in a rugged case.
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of this manual.
• •
2.2
Equipment
The MobileFeed 201 AVS is supplied with: Instruction manual Voltage pickup cable with clamp 0558 012 084
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3 TECHNICAL DATA
3 TECHNICAL DATA
NOTE!
The MobileFeed 201 AVS is not recommended for short circuiting transfer using constant current power sources due to the limited short circuit current available on constant current power sources.
MobileFeed 201 AVS Wire feed speed
50 – 750 in/min (1.3 – 19.0 m/min)
Primary input
(open circuit voltage or arc voltage) Not for use with AC power Minimum Maximum
Standard spindle hub
14.0 V DC 100 V DC (113 V peak) 2” (5.1 cm) ID
Standard spool Wire diameters
Hard 8” (20.3 cm) OD .030” (0.8 mm), .035” (0.9 mm), Soft .045” (1.2 mm), .052” (1.4 mm), 1/16” (1.6 mm) .035” (0.9 mm), 3/64” (1.2 mm), Cored 1/16” (1.6 mm) .030” (0.8 mm), .035” (0.9 mm), .045” (1.2 mm), .052” (1.4 mm),
Wire package Motor type Brake type (wire) Control Feed system On-Off switch
Drag Solid state Push Standard
Ramp start Height × Width × Length
Standard 14.50" × 7.375" × 18.50" (368.3 × 187.3 × 470 mm)
Weight
(with contactor, without spool) 28 lbs (12.7 kg)
Enclosure class
1/16” (1.6 mm), 5/64” (2.0 mm) 8” (203 mm) diameter spool DC permanent magnet pre-lubricated, enclosed IP23S
Enclosure class
The
IP
code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water.
Equipment marked
IP 23S
operated in precipitation.
is intended for indoor and outdoor use; however, should not be 0558 012 084
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4 INSTALLATION
4 INSTALLATION 4.1
Receiving and handling
Before installing this equipment, clean all packing material from around the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading and freight bill will be furnished by the carrier on request if occasion to file claim arises.
WARNING!
Secure the equipment particularly if the ground is uneven or sloping.
4.2
Selection of drive rolls and guide tubes
WARNING!
When the wire feeder is connected to the power source, the work lead from the power source is connected to the workpiece and the power source is energized.
Closing the torch trigger will cause the welding wire to become electrically hot and will cause the drive rolls to turn. Keep fingers clear!
The drive rolls have two grooves. The unit is supplied ready to feed 0.045”, .052” or 1/16” (1.2 to 1.6 mm) diameter cored wires or .035” - .045” (0.9 - 1.2 mm) hard wires depending on the part number ordered.
Other drive rolls are available to feed other sizes of hard wire, soft wire, and cored wire. See Drive Roll and Guide Tube Selection Chart in the WEAR PARTS chapter.
Two lower drive rolls are required for four-roll drive systems.
4.3
Installing drive rolls and guide tubes
CAUTION!
Turn off the power source and the wire feeder.
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4 INSTALLATION 1. Release the pressure roll assembly lever (1) and lift the pressure roll assembly (2) up.
2. Remove the knurled screw (3) while holding the drive roll (4).
3. Check and install the correct guide tubes.
4. Keep or replace the drive roll (4) with the required size; the designation is marked on the side of the roll facing out.
5. Put the knurled screw (3) back in position on the drive roll (4) and tighten it.
6. Thread the wire and fasten the pressure roll assembly (2).
4.4
Installing the welding wire
CAUTION!
Turn off the power source and the wire feeder.
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4 INSTALLATION 1. Remove the spool retainer (1).
2. Put the wire spool (2) on the hub to rotate counterclockwise as the wire unwinds. The hub pin must engage the hole in the wire spool.
3. Install the spool retainer (1) and hand tighten it.
4.5
Threading the welding wire
CAUTION!
Before threading the wire, make sure that the chisel point and burrs have been removed from the end of the wire to prevent the wire from jamming in the torch liner.
1. Turn off the power source and the wire feeder.
2. Release the pressure roll assembly lever and lift the pressure roll assembly up.
3. Check that the drive roll, groove position, and wire guides are correct.
4. Feed the wire from the spool through the inlet guide along the drive roll groove and into the outlet guide tube.
5. Lower the pressure roll assembly and adjust the drive roll pressure to make sure that there is no wire slippage, but not too tight to create excess pressure.
6. Turn on the power source and the wire feeder.
7. Push the torch trigger switch or operate the jog switch to feed wire through the torch.
4.6
Adjusting the brake drag
CAUTION!
Turn off the power source and the wire feeder.
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4 INSTALLATION Brake disc friction should provide enough drag to keep the wire spool from spinning freely after the wire feed stops.
The brake hub is adjusted when delivered, if adjustment is required, follow the instructions below. Adjust the brake hub so the wire is slightly slack when the wire feed stops.
1. Remove the spool retainer (1) by turning it counterclockwise.
2. To increase the braking torque, use a 1 1/16" (27 mm) wrench and turn the drag adjusting nut (2) clockwise.
3. To reduce the braking torque, use a 1 1/16" (27 mm) wrench and turn the drag adjusting nut (2) counterclockwise.
4.7
Torch connection
CAUTION!
Make sure the chosen torch has the correct rating for the welding current to be used, has the correct size and type of liner, and has the correct contact tip and guide tube.
WARNING!
Turn off the power to the welding power source and the wire feeder before making any connections between the wire feeder and the welding power source.
The torch adapter on the MobileFeed connects directly to the wire feeder wire drive assembly, power and shielding gas supply.
1. Line up the torch connector with the wire feeder adapter and push it on firmly.
2. Hand tighten the locking collar on the Euro connector.
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4 INSTALLATION
4.8
Supply connections
CAUTION!
Turn off the power source and the wire feeder.
The MobileFeed 201 AVS can be used with either DC Electrode Positive (DCEP) or DC Electrode Negative (DCEN) polarity without modifications.
1. Connect the welding cable (1) from the power source to the weld cable lug connection extending from the rear of the MobileFeed 201 AVS feeder.
a) Positive terminal for gas-shielded flux cored or solid wires.
b) Negative terminal for most gasless self-shielded cored wires.
WARNING!
Make sure that the welding cables are correctly insulated before applying power to the power source. Uninsulated cable and parts can arc when contacting a grounded surface. The arc may damage eyes or start a fire.
Body contact with an uninsulated weld cable connector or uncovered conductor can cause shock and severe, possibly fatal injury.
2. Connect a second welding cable (2) between the opposite polarity output connection on the power source and the workpiece.
3. Connect the wire feeder work lead/voltage pick-up cable clip (3) to the workpiece.
4. If gas-shielded wire is used, connect the inlet gas hose to the gas inlet connections on the rear of the feeder.
5. Make sure that all hose and cable connections are tight.
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4 INSTALLATION 6. Turn on the power source and close the contactor if the power source is equipped with an output contactor control switch. Open circuit voltage must be present to operate the wire feeder.
7. Turn the wire feeder power switch to "ON".
8. Check all gas connections for leaks.
WARNING!
Unless starting to weld, do not allow the welding wire to touch a grounded metal surface. The welding wire becomes electrically hot when the secondary contactor is closed. Keep fingers clear of the drive rolls; they will start turning when the torch trigger is pressed.
9. If gas-shielded wires are used, adjust the gas flow meter to the desired flow rate by closing the torch trigger switch or operating the gas purge switch.
10. Turn off the power source and the wire feeder when they are not in use.
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5 OPERATION
5 OPERATION 5.1
Overview
General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual. Read it through before you start using the equipment!
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
NOTE!
When moving the equipment, use the handle intended for transportation. Never pull the equipment by the welding torch.
CAUTION!
Before threading the wire, make sure that the chisel point and burrs have been removed from the end of the wire to prevent the wire from jamming in the torch liner.
WARNING!
Rotating parts can cause injury, take great care.
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WARNING!
Risk of crushing when replacing the wire bobbin! Do inserting the welding wire between the feed rollers.
not
use safety gloves when
WARNING!
Do not operate the feeder with the enclosure open.
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5 OPERATION
5.2
Connections and control devices
1.
2.
3.
4.
Knob for setting the wire feed speed Knob for setting the voltage Torch connection Work lead (Voltage pick-up) 5.
6.
7.
8.
Display for wire feed speed/voltage Trigger lock switch Power switch Twist lock receptacle connection, NEMA ML-1R (only applicable for NA version) 9.
Shield gas connection 10. Welding cable connection 11. Power source remote voltage control connection
Wire feed speed (Arc voltage control)
The wire feed speed is controlled by the knob for wire feed speed on the front of the wire feeder.
When the wire feeder is connected to a constant voltage (CV) type of power source, the knob for wire feed speed controls the welding current. Turning the knob clockwise increases the welding current; turning it counterclockwise decreases the welding current.
When the wire feeder is connected to a constant current (CC) type of power source, the knob for wire feed speed controls the arc voltage. Turning the knob clockwise decreases the arc voltage; turning it counterclockwise increases the arc voltage. The actual wire feed speed for any given setting varies with the arc voltage. Increasing the arc voltage causes an increase in the wire feed speed.
When the CV/CC switch inside the MobileFeed is set to "CV," the “Preset” wire feed speed will be shown on the display. The wire speed will not vary with changes in the arc voltage.
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5 OPERATION When the CV/CC switch is set to “CC”, the wire feed speed and voltage will be shown on the display. The wire speed shown is the speed that will result from the displayed voltage.
Adjusting the knob for voltage affects the wire feed speed. For example, if the display shows 300 in/min and 20 V, an adjustment of the voltage to 24 V will result in an increase to approximately 365 in/min. A change in arc voltage of 4 V will result in a change in wire speed of 65 in/min. For a step-by-step guide to setting wire speed and voltage, see the section “Setting a Welding Procedure.”
Voltage
In CC mode, the knob for setting the voltage is used to adjust the voltage, which in turn affects the wire feed speed. See the "Wire feed speed" description above.
The knob for setting the voltage can also be used to set the power source output voltage when the MobileFeed is set to CV with the remote voltage control option and a Warrior power source is being used. The power source voltage is then read on the MobileFeed display for wire feed speed and voltage.
Display for wire feed speed and voltage
The digital display shows the wire feed speed (in/min or m/min) and voltage. It also enables the welder to preset wire feed speed and power source voltage.
Trigger lock switch
The trigger lock function is a variation of 4-stroke operation. If the trigger lock function is turned on, the torch trigger can be released once the arc is established, the power source/feeder will continue to weld until the trigger is pressed and released again, or the arc established signal is lost by manually breaking the arc. The trigger will not be locked unless the arc is established before the trigger is released.
Power switch
The power switch (0/I) on the front of the wire feeder starts the wire feeder when the feeder is connected to the power source and the workpiece. The power source must be turned on with the contactor closed.
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5 OPERATION 1.
2.
Main fuse, 10 A Circuit breaker, 5 A 3.
4.
Jog/purge switch CC/CV switch
Circuit breaker, 5 A
This resettable 5-amp circuit breaker, in series with motor armature, protects the control board from damage if the motor is stalled.
Jog/Purge switch
JOG is used when you need to feed wire without welding voltage being applied. The wire is fed at the set speed for as long as the switch is pushed.
PURGE is used when measuring the gas flow or to flush any air or moisture from the gas hoses before welding starts. The gas flows as long as the switch is pushed. There is no need for welding voltage or wire feed start.
If wire has been threaded through the gun and contact tip, simply operate the jog button or cut off wire, as required, so that the wire extends about 1/2” beyond the end of the gun nozzle.
CC/CV switch
The CC/CV switch is used to set CC or CV mode. CC mode is used for constant current power sources. CV mode is used for constant voltage power sources. The selected mode also affects the functions of the wire feeder as shown below:
Mode
CC CV
Display
Wire feed speed and arc voltage shown Wire feed speed shown
Knob for setting the wire feed speed
Controls the arc voltage / Wire speed feed increase with increased voltage Controls the welding current 0558 012 084
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5 OPERATION
DIP switch settings
The DIP switches are located on the Digital Display PCB inside the MobileFeed.
NOTE!
To locate the Digital Display PCB, it is necessary to remove the cover that protects the electronic parts of the MobileFeed.
Check the setting of the DIP switches on the Digital Display PCB. These switches can be set for the display to show the wire feed speed in in/min or in m/min.
The setting (1) for the display is in/min. The setting (2) for the display is m/min.
5.3
Operating procedures
5.3.1
Operating safety precautions
Comply with all ventilation, fire, and other safety requirements for arc welding as established in the section "SAFETY PRECAUTIONS." 1. Because of the radiant energy of the welding arc and the possibility of drawing an arc before the helmet is lowered over the face, the operator should wear flash goggles with filter lenses under his helmet. The helmet filter plate should be shade number 11 (nonferrous) or 12 (ferrous). All those viewing the arc should use helmets with filter plates, as well as flash goggles. Nearby personnel should wear flash goggles.
2. The radiant energy of the arc can decompose chlorinated solvent vapors, such as trichloroethane and perchlorethylene, to form phosgene, even when these vapors are present in low concentrations. DO NOT weld where chlorinated solvents are present in atmospheres in or around the arc.
3. DO NOT touch the electrode, contact tip, or metal parts when power is ON: all are electrically energized (HOT) and can cause a possibly fatal shock. DO NOT allow electrode to touch grounded metal. It will create an arc flash that can injure eyes. It may also start a fire or cause other damage.
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5 OPERATION 4. When working in a confined space, be sure it is safe to enter. The confined space should be tested for adequate oxygen (at least 19%) with an approved oxygen measuring instrument. The confined space should not contain toxic concentrations of fumes or gases. If this cannot be determined, the operator should wear an approved air-supplied breathing apparatus. Avoid gas leaks in a confined space, as the leaked gas can dangerously reduce oxygen concentration in the breathing air. DO NOT bring gas cylinders into confined spaces. When leaving a confined space, shut OFF the gas supply at the source to prevent gas from leaking into the space. Check the breathing atmosphere in the confined space to be sure it is safe to reenter.
5. Never operate the equipment at currents greater than the rated ampere capacity.
Overheating will occur.
6. Never operate equipment in a damp or wet area without suitable insulation for protection against shock. Keep hands, feet, and clothing dry at all times.
7. Whenever the equipment is left unattended, turn OFF all control power, power supply switches, and gas supplies. Open the main line switch.
8. Wear dark substantial clothing to protect exposed skin from arc burn, sparks, and flying hot metal.
9. Turn off welding power before adjusting or replacing electrodes.
WARNING!
When the power switch is ON and the torch trigger is pushed, the electrode wire becomes electrically hot and the wire feed rolls are activated. Do not touch the wire as it may cause a possibly fatal shock. Unless welding, do not allow the wire to touch a grounded metal surface as it will cause an arc flash. Keep clear of feed rolls and drive gears.
WARNING!
Prior to welding, it is imperative that the correct protective clothing (welding coat and gloves) and eye protection (glasses and welding helmet) be put on. Failure to comply may result in serious injury.
CAUTION!
Do not terminate the arc by removing the torch from the weld area. Release the torch trigger to stop welding before removing the torch.
WARNING!
Failure to turn off the shield gas in a confined space may result in a buildup of fumes, displacing oxygen.
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5 OPERATION
5.3.2
Setting a welding procedure Quick setup procedure
1. For a Constant Voltage (CV) Power Source: set the desired arc voltage on the power source.
2. For a Constant Current (CC) Power Source: set the desired weld current on the power source.
3. On the MobileFeed unit: Set the desired wire feed speed with the knob for the wire feed speed and use the values shown by the display as a guide.
A feeder in CV mode will show the actual wire feed speed while welding.
A feeder in CC mode will show a wire feed speed that varies with changes in arc voltage.
When not welding, the display will show what the wire feed speed will be at the displayed voltage.
5.3.3
Weld data table
The voltage (V) and current (A) values presented in the tables below are the arc voltage and the weld current.
Flux Core E70T-1 & 2 Diameter 150 / 3.8
.045” .052” 1/16” 25 V 155 A 27 V 190 A
200 / 5.1
29 V 150 A
250 / 6.35
30 V 300 A 30 V 300 A
Wire Feed Speed
(inch/min) / (m/min)
300 / 7.6
350 / 8.9
400 / 10.2
29 V 210 A 30 V 250 A 33 V 365 A 33 V 460 A 33 V 410 A 33 V 450 A
450 / 11.4
36 V 500 A
500 / 12.7
33 V 290 A 39 V 500 A
600 / 15.2
34 V 330 A 37 V 500 A
Metal Core Diameter
.045” .052”
200 / 5.1
1/16” 30 V 300 V
Steel Solid Wire Wire Feed Speed
(inch/min) / (m/min)
250 / 6.35 300 / 7.6
350 / 8.9
400 / 10.2 450 / 11.4 500 / 12.7
29 V 275 A 30 V 350 A 28 V 250 A 29 V 300 A 32 V 400 A 29 V 260 A 30 V 325 A 34 V 450 A 30 V 270 A 32 V 300 A 32 V 350 A
Diameter 200 / 5.1
.035”
250 / 6.35
300 / 7.6
Wire Feed Speed
(inch/min) / (m/min)
350 / 8.9
400 / 10.2
450 / 11.4
25 V 180 A 25 V 200 A
500 / 12.7
26 V 215 A
550 / 14.0
27 V 230 A
600 / 15.2
28 V 245 A 0558 012 084
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5 OPERATION .045” 1/16” 26 V 290 A
Al / Si Aluminum Diameter
3/64 1/16 27 V 340 A 25 V 260 A 30 V 400 A 26 V 280 A 27 V 300 A 28 V 320 A 30 V 340 A
200 / 5.1
25 V 110 A
250 / 6.35
Wire Feed Speed
(inch/min) / (m/min)
300 / 7.6
350 / 8.9
26 V 200 V 23 V 260 A 30 V 300 A 32 V 350 A
400 / 10.2
450 / 11.4
25 V 140 A 26 V 150 V 26 V 190 A 27 V 205 A 27 V 220 A
Al / Mg Aluminum Diameter
3/64” 1/16”
150 / 3.8
200 / 5.1
Wire Feed Speed
(inch/min) / (m/min)
250 / 6.35
300 / 7.6
350 / 8.9
400 / 10.2
22 V 100 A 23 V 150 A 23 V 175 V 24 V 190 A 25 V 205 A 25 V 220 A 23 V 200 A 25 V 250 A 27 V 280 A 27 V 290 A 28 V 340 A
5.3.4
MobileFeed 201 with CC Power Sources
1. Select the weld current/arc voltage needed for the wire type and diameter to be welded, see section "Weld data table" in this chapter.
2. Set the power supply current with the knob for setting the current on the front panel of the power source.
3. Set the arc voltage value taken from the weld data table using the knob for setting the voltage on the wire feeder.
4. Set the wire feed speed value taken from the weld data table using the knob for setting the wire feed speed on the wire feeder.
5. Strike an arc and adjust it to the desired wire speed with the knob for setting the wire feed speed.
5.3.5
MobileFeed 201 with CV Power Sources
1. Select the arc voltage/weld current needed for the wire type and diameter to be welded, see section "Weld data table" in this chapter.
2. Set the power supply voltage with the knob for setting the voltage on the power source or use the optional remote voltage control in the wire feeder.
3. Read the wire feed speed at the top of the column in the "Weld data table" for the chosen wire type, diameter, and arc voltage/weld current.
4. Use the "Weld data table" to determine the position of the knob for setting the wire feed speed on the wire feeder.
5. Strike an arc and adjust the arc length as needed with the knob for setting the wire feed speed.
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5 OPERATION
NOTE!
It is NOT RECOMMENDED to use the CV switch setting when using a CC power source. Extreme wire feed speed sensitivity exists that makes it difficult to set a stable welding condition. The arc stability is very dependent on maintaining constant "Tip To Work" (TTW) distance which is almost impossible to control when welding manually. CV setting is only recommended for use with CV power sources.
Typical welding voltages for 5000 Aluminum are between 21 and 25 volts, which limits the wire feed speed of the MobileFeed, especially if trying to weld with 035” diameter 5356 alloy. Welding with wire diameters ≤3/64” and/or below 22 arc volts could cause problems with limited wire feed speed and the inability to achieve a good welding condition.
NOTE!
On many CV power sources, the actual welding arc voltage is less than the “Open Circuit Voltage” (OCV) set on the power source front panel. Therefore, an extra 3 to 6 volts may be added to the power source front panel setting to achieve the actual arc voltage needed or shown in the tables.
5.3.6
Shutdown
1. Release the torch trigger switch to break the arc.
2. When leaving the equipment unattended, always turn off and disconnect all power to the equipment and turn off the shielding gas supply at the source.
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6 MAINTENANCE
6 MAINTENANCE
WARNING!
Make sure that the branch circuit or main disconnect switch is OFF or electrical input circuit fuses are removed from the power source main supply before attempting any inspection or work on the inside of the wire feeder. Placing the power switch on the welding machine in the OFF position does not remove all power from inside of the equipment.
WARNING!
Inspection, troubleshooting, and repair of this equipment should be undertaken by a competent individual having at least general experience in the maintenance and repair of semi-conductor electronic equipment. Maintenance or repair should not be undertaken by anyone without such qualifications.
6.1
Inspection and service
Keep equipment in clean and safe operating condition, free of oil, grease, liquid and metallic particles which can cause short-circuits.
Regularly check cylinder valves, regulators, hoses and gas connections for leaks with soap solution.
Check for and tighten loose hardware including electrical connections. Loose power connections overheat during welding.
Immediately replace all worn or damaged power cables and connectors. Check for frayed and cracked insulation, particularly in areas where conductors enter equipment.
The electrode wire and all metal parts in contact with it are electrically energized while welding. Inspect these parts periodically for defective insulation and other electrical hazards.
WARNING!
If uninsulated cable and parts are not replaced, an arc caused by a bared cable or part touching a grounded surface may damage unprotected eyes or start a fire.
Body contact with a bared cable, connector or uncovered conductor can shock, possibly fatally.
Keep power cables dry, free of oil and grease and protected at all times from damage by hot metal and sparks.
Clean dirt and metal particles from drive roll groove weekly; replace roll if badly worn.
6.2
Wire feeder
When soft wire is fed, the drive rolls may pick up metal from the wire surface. Accumulation on the rolls may score the wire with resulting unwanted friction and incorrect feeding.
Inspect the rolls regularly and clean them with a fine-wire power brush. Avoid roughening, or removing the hardness of groove surfaces in grooved rolls. Any roughening may score the wire, just as the accumulation being removed may do.
6.3
Solenoid valve replacement
If there is no gas flow through the wire feeder, the gas solenoid valve may be clogged or electrically malfunctioning and it should be replaced. When replacing the gas solenoid valve, the inlet (with the word IN) must face the rear of the unit.
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6 MAINTENANCE
6.4
Troubleshooting
If the welding equipment does not work correctly, inspect as follows: 1. With all power controls in position on and other operating controls at required settings, visually check all power cables and connections for evidence of overheating or sparking.
WARNING!
To avoid shock, do not touch the electrode wire or parts in contact with it, or uninsulated cable or connections.
2. Check all gas hoses, connections, flowmeters and regulators for possible sources of leakage, breakdown or intermittent failure.
3. Isolate trouble to one part of the welding installation: primary power supply, power source, wire feeder or wire guide train (casing, drive rolls, liners and contact tip). If this inspection indicates trouble in the wire feeder, refer to the wiring diagram.
WARNING!
Many troubleshooting situations require that the power remain on and that power terminals in the equipment carry voltage. Exercise extreme caution when working on “live” equipment. Avoid contact with electrical components, except when testing with an appropriate instrument.
CAUTION!
Do not make any repairs to equipment unless you are fully qualified, as described in the maintenance section.
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7 ORDERING SPARE PARTS
7 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.
The MobileFeed 201 AVS is designed and tested in accordance with international standard IEC/EN 60974-5 and IEC/EN 60974-10, Canadian standard CAN/CSA-E60974-5 and US standard ANSI/IEC 60974-5. Upon completion of service or repair work, it is the responsibility of the person(s) performing the work to ensure that the product still complies with the requirements of the above standards.
Spare parts may be ordered through your nearest ESAB dealer, see the back cover of this document. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.
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WIRING DIAGRAM
WIRING DIAGRAM
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WEAR PARTS
WEAR PARTS
V-groove Wire diameter inch (mm)
.030 (0.8) .035 (1.0) .045 (1.2) .052 (1.4) .062 (1.6)
V-groove X2 Wire diameter inch (mm) +Roll Qty 2
21155 21156 21156 21157 21157
Outlet Guide Tube, Euro Qty 1
0558 001 077 0558 001 078 0558 001 078 0558 001 079 0558 001 079
Center Guide Qty 1
0558 001 757 0558 001 757 0558 001 757 0558 001 757 0558 001 757
Inlet Guide Qty 1
0558 001 758 0558 001 758 0558 001 758 0558 001 758 0558 001 758 .045 (1.2)
K-Cored Wire diameter inch (mm)
.030 (0.8) .035 (0.9) .045 (1.2) .052 (1.4) 1/16 (1.6) 5/64 (2.0)
U-Soft +Roll Qty 2
0369 557 010
+Roll Qty 1
21160 21160 21161 21161 21161 21162
Outlet Guide Tube, Euro Qty 1
0558 001 078
Outlet Guide Tube, Euro Qty 1
0558 001 077 0558 001 078 0558 001 079 0558 001 079 0558 001 079 0558 001 079
Center Guide Qty 1
0558 001 757
Center Guide Qty 1
0558 001 757 0558 001 757 0558 001 757 0558 001 757 0558 001 757 0558 001 757
Inlet Guide Qty 1
0558 001 758
Inlet Guide Qty 1
0558 001 758 0558 001 758 0558 001 758 0558 001 758 0558 001 758 0558 001 758
Wire diameter inch (mm)
3/64 (1.2) 1/16 (1.6)
+Roll Qty 1
21159 21159
Outlet Guide Tube, Euro Qty 1
0558 001 898 0558 001 898
Center Guide Qty 1
0558 001 895 0558 001 895 + Use flat, plain pressure roll(s), PN 23612368, supplied with wire feeder.
Inlet Guide Qty 1
0558 001 758 0558 001 758 0558 012 084
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© ESAB AB 2015
ORDERING NUMBERS
ORDERING NUMBERS
Each MobileFeed wire feeder includes gas solenoid and dual groove feed rolls.
Ordering Number Denomination
0558 101 910 0558 101 911 0558 102 194 MobileFeed 201 AVS w/meter MobileFeed 201 AVS w/meter-REM V MobileFeed 201 AVS w/meter TWECO
Notes
CSA CSA CSA Technical documentation is available on the Internet at:
www.esab.com.
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ACCESSORIES
ACCESSORIES
Each MobileFeed wire feeder has 3 remote control cable lengths that can be used with ESAB Warrior series power sources. Requires remote option in feeder.
0558 102 197 0558 102 198 0558 102 199 13735631 13792513 81F25 81F26 81F27 19043
Cable Remote MF201/301 25 ft Cable Remote MF201/301 50 ft Cable Remote MF201/301 100 ft OKC50 Connectors, OKC female connector, 1/0 - 4/0 cable OKC50 Connectors, OKC male connector, 1/0 - 4/0 cable LC40 cable connector set (male/female), 1/0 - 3/0 LC40 male cable connector, 1/0 - 3/0 LC40 female cable connector, 1/0 - 3/0 Gas meter (measures gas flow at the gun)
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ACCESSORIES 0558 012 084
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© ESAB AB 2015
ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES
A B C D E F G H CUSTOMER SERVICE QUESTIONS:
Telephone: (800) 362-7080 / Fax: (800) 634-7548
Order Entry Product Availability Pricing Order Information
Hours: 8.00 AM to 7:00 PM EST
Returns ENGINEERING SERVICE:
Telephone: (834) 664-4416 / Fax: (800) 446-5693
Warranty Returns Authorized Repair Stations
Hours: 7.30 AM to 5:00 PM EST
Welding Equipment Troubleshooting TECHNICAL SERVICE:
Telephone: (800) ESAB-123 / Fax: (843) 664-4452
Part Numbers Technical Applications Specifications LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status WELDING EQUIPMENT TRAINING:
Telephone: (843) 664-4428 / Fax: (843) 679-5864
Training School Information and Registrations WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 / Fax:
TECHNICAL ASST. CONSUMABLES:
Telephone: (800) 933-7070 / Fax: Hours: 8.00 AM to 5:00 PM EST
Equipment Recommendations
Hours: 7.30 AM to 4:00 PM EST Hours: 7.30 AM to 3:30 PM EST Hours: 7.30 AM to 4:00 PM EST Hours: 7.30 AM to 4:00 PM EST Hours: 7.30 AM to 5:00 PM EST IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123 Fax: (843) 664-4452 Hours: 7:30 AM to 5:00 PM EST or visit us on the web at http://www.esabna.com
The ESAB web site offers: Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback & Support
ESAB Welding & Cutting Products PO BOX 100545, Florence SC 29501-0545
© ESAB AB 2015
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