mig 2e wire feeder - f15-999/mig... · 1. always provide adequate ventilation in the work area by...
TRANSCRIPT
Be sure this information reaches the operator.You can get extra copies through your supplier.
F15-143-COctober, 2008INSTRUCTION MANUAL
Mig 2EWIRE FEEDER
EFFECTIVE WITH SERIAL NUMBER WK-I930001
This manual provides complete instructions on the Mig 2E Wire Feeder, P/N 34157.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operationand safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practicesfor Arc Welding, Cutting, and Gouging", Form 52-529. Do NOT permit untrained persons to install, operate, ormaintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fullyunderstand these instructions. If you do not fully understand these instructions, contact your supplier forfurther information. Be sure to read the Safety Precautions (Section I) before installing or operating thisequipment.
USER RESPONSIBILITY
i
TABLE OF CONTENTS
SECTION TITLE PAGE PARAGRAPH
1 SAFETY ................................................................................................................................3
2 DESCRIPTION AND SPECIFICATION ...................................................................................72.1 Mig 2E Wire Feeder ................................................................................................72.2 Mig 2E Wire Feeder Option .....................................................................................7
3 EQUIPMENT ...........................................................................................................................9
3.1 General ...................................................................................................................93.2 Companion Equipment and Accessories .................................................................93.3 Accessories.............................................................................................................9
4 INSTALLATION .....................................................................................................................10
4.1 Installation .............................................................................................................10
5 OPERATION .........................................................................................................................115.1 Adjustments and Operation ...................................................................................115.2 Operating Sequence .............................................................................................11
6 SERVICE ..............................................................................................................................126.1 Maintenance .........................................................................................................12
7 REPLACEMENT PARTS .......................................................................................................157.1 General .................................................................................................................15
This equipment will perform in conformity with the description thereof contained in this manual and accompanyinglabels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided.This equipment must be checked periodically. Malfunctioning equipment should not be used. Parts that are broken,missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement becomenecessary, the manufacturer recommends that a telephone or written request for service advice be made to theAuthorized 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. Theuser of this equipment shall have the sole responsibility for any malfunction which results from improper use, faultymaintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facilitydesignated by the manufacturer.
2
3
WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before
performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.
PROTECT YOURSELF AND OTHERS --Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.Training in the proper use of the processes and equip-ment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any workarea, even if welding helmets, face shields, and gogglesare also required.
2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc andnot to expose themselves to the rays of the electric-arcor hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing
5. Protect other personnel from arc rays and hot sparkswith a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and ex-plosions. Therefore:
1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.“
3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.
SAFETY PRECAUTIONS
10/98
5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.
6. After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when neces-sary.
7. For additional information, refer to NFPA Standard 51B,"Fire Prevention in Use of Cutting and Welding Pro-cesses", available from the National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.
1. Be sure the power source frame (chassis) is connectedto the ground system of the input power.
2. Connect the workpiece to a good electrical ground.3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatalshock.
4. Use well-maintained equipment. Replace worn or dam-aged cables.
5. Keep everything dry, including clothing, work area,cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated fromwork and from ground.
7. Do not stand directly on metal or the earth while workingin tight quarters or a damp area; stand on dry boards oran 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 grounding recommendations. Do not mis-take the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —May be dangerous. Electric current flow-ing through any conductor causes lo-calized Electric and Magnetic Fields(EMF). Welding and cutting current cre-ates EMF around welding cables andwelding machines. Therefore:
1. Welders having pacemakers should consult their physi-cian before welding. EMF may interfere with some pace-makers.
2. Exposure to EMF may have other health effects which areunknown.
3. Welders should use the following procedures to minimizeexposure 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 welding power source and cables as far away
from your body as possible.
4
FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can cause asphyxiation.Therefore:
1. Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel,copper, zinc, lead, beryllium, or cadmium unless posi-tive mechanical ventilation is provided. Do not breathefumes from these materials.
2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene, a highly toxicgas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation is notadequate. Stop work and take necessary steps to im-prove ventilation in the work area. Do not continue tooperate 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 orcutting, produces fumes or gases whichcontain chemicals known to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety Code §25249.5 et seq.)
CYLINDER HANDLING -- Cylinders, ifmishandled, can rupture and violentlyrelease gas. Sudden rupture of cylin-der, valve, or relief device can injure orkill. Therefore:
1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition. Followmanufacturer's operating instructions for mounting regu-lator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chainor strap to suitable hand trucks, undercarriages, benches,walls, post, or racks. Never secure cylinders to worktables or fixtures where they may become part of anelectrical circuit.
3. When not in use, keep cylinder valves closed. Havevalve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitablehand trucks. Avoid rough handling of cylinders.
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 inCylinders", which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington,VA 22202.
EQUIPMENT MAINTENANCE -- Faulty orimproperly maintained equipment cancause injury or death. Therefore:
1. Always have qualified personnel perform the installa-tion, troubleshooting, and maintenance work. Do notperform any electrical work unless you are qualified toperform such work.
2. Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.
3. Maintain cables, grounding wire, connections, powercord, and power supply in safe working order. Do notoperate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keepequipment 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 positionand in good repair.
6. Use equipment only for its intended purpose. Do notmodify it in any manner.
ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices for elec-tric arc welding and cutting equipment, askyour supplier for a copy of "Precautions andSafe Practices for Arc Welding, Cutting andGouging", Form 52-529.
The following publications, which are available from theAmerican Welding Society, 550 N.W. LeJuene Road, Mi-ami, 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 Hand-
book.8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have HeldHazardous Substances."
MEANING OF SYMBOLS - As used through-out this manual: Means Attention! Be Alert!Your safety is involved.
Means immediate hazards which, ifnot avoided, will result in immediate,serious personal injury or loss of life.
Means potential hazards which couldresult in personal injury or loss of life.
Means hazards which could result inminor personal injury.
SP98-10
5
a. Éloigner suffisamment tous les matériaux combus-tibles du secteur où l’on exécute des soudures ou descoupes à l’arc, à moins de les recouvrir complètementd’une bâche non-inflammable. Ce type de matériauxcomprend notamment le bois, les vêtements, la sciure,l’essence, le kérosène, les peintures, les solvants, legaz naturel, l’acétylène, le propane et autres sub-stances combustibles semblables.
b. Les étincelles ou les projections de métal incandes-cent peuvent tomber dans des fissures du plancher oudans des ouvertures des murs et y déclencher uneignition lente cachée. Veiller à protéger ces ouverturesdes étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérationsde gougeage ou autres travaux à chaud à la surfacede barils, bidons, réservoirs ou autres contenantsusagés, avant de les avoir nettoyés de toute trace desubstance susceptible de produire des vapeursinflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, ilconvient de disposer d’un matériel d’extinction prêt àservir immédiatement, tel qu’un tuyau d’arrosage, unseau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteurde façon à vous assurer qu’aucune étincelle ou projec-tion de métal incandescent ne risque de provoquerultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arcau plasma exige l’emploi de tensions à viderelativement importantes; or, celles-ci risquent decauser des dommages corporels graves et mêmemortels en cas d’utilisation inadéquate. La gravité duchoc électrique reçu dépend du chemin suivi par lecourant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous ten-sion venir au contact direct de la peau ou devêtements humides. Veillez à porter des gants biensecs.
b. Si vous devez effectuer un travail sur une surfacemétallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secset des chaussures à semelles de caoutchouc et envous tenant sur une planche ou une plate-formesèche.
c. Mettez toujours à la terre le poste de soudage/coupageen le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Nesurchargez jamais le câble. Utilisez toujours unéquipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas enservice. une mise à la masse accidentelle peut eneffet provoquer une surchauffe de l’équipement et undanger d’incendie. Ne pas enrouler ou passer le câbleautour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce enun point aussi proche que possible de la zone detravail. Le branchement des câbles de masse àl’ossature du bâtiment ou en un point éloigné de lazone de travail augmente en effet le risque de pas-sage d’un courant de sortie par des chaînes delevage
PRÉCAUTIONS DE SÉCURITÉAVERTISSEMENT: Ces règles de sécurité ont pour objetd’ assurer votre protection. Veillez à lire et à observer lesprécautions énoncées ci-dessous avant de monter l’équipement ou de commercer à l’utiliser. Tout défautd’observation de ces précautions risque d’entraîner desblessures graves ou mortelles.1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arcélectrique ou du métal incandescent, lors du soudageau plasma ou à l’électrode ou lors du gougeage àl’arc, peuvent s’avérer plus graves que cellesrésultant d’une exposition prolongée au soleil. Aussiconvient-il d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaquesprotectrices et des verres filtrants appropriés afin devous protéger les yeux, le visage, le cou et les oreillesdes étincelles et du rayonnement de l’arc électriquelorsque vous effectuez des soudures ou des coupesou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximitéde façon à ce qu’elles ne regardent pas l’arc et à cequ’elles ne s’exposent pas à son rayonnement, ni àcelui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tuniqueépaisse à manches longues, des pantalons sansrebord, des chaussures à embout d’acier et uncasque de soudage ou une calotte de protection, afind’éviter d’exposer la peau au rayonnement de l’arcélectrique ou du métal incandescent. ll est égalementsouhaitable d’utiliser un tablier ininflammable defaçon à se protéger des étincelles et du rayonnementthermique.
c. Les étincelles ou les projections de métal incandes-cent risquent de se loger dans des manchesretroussées, des bords relevés de pantalons ou dansdes poches. Aussi convient-il de garder boutonnés lecol et les manches et de porter des vêtements sanspoches à l’avant.
d. Protégez des étincelles et du rayonnement de l’arcélectrique les autres personnes travaillant à proximitéà l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécuritélorsque vous vous trouvez dans un secteur où l’oneffectue des opérations de soudage ou de coupage àl’arc. Utilisez des lunettes de sécurité à écrans ouverres latéraux pour piquer ou meûler le laitier. Lespiquetures incandescentes de laitier peuvent êtreprojetées à des distances considérables. Lespersonnes se trouvant à proximité doivent égalementporter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasmaproduisent un niveau de bruit extrêmement élevé (de100 à 114 dB) et exigent par conséquent l’emploi dedispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections delaitier incandescent ou d’étincelles peuventprovoquer de graves incendies au contact dematériaux combustibles solides, liquides ou gazeux.Aussi faut-il observer les précautions suivantes:
9/97
6
des câbles de grue ou divers chemins électriques.g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement detravail, des câbles, du porte-électrode et du poste desoudage/coupage. Réparez immédiatement toutefuite d’eau.
4. VENTILATION-- La respiration prolongée des fuméesrésultant des opérations de soudage/coupage, àl’intérieur, d’un local clos, peut provoquer des mal-aises et des dommages corporels. Aussi convient-ild’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate del’emplacement de travail en maintenant une ventila-tion naturelle ou à l’aide de moyens mécaniques.N’effectuez jamais de travaux de soudage ou decoupage sur des matériaux de zinc, de plomb, deberyllium ou de cadmium en l’absence de moyensmécaniques de ventilation capables d’empêcherl’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou decoupage à proximité de vapeurs d’hydrocarburechloré résultant d’opérations voisines de dégraissageou de pulvérisation. La chaleur dégagée ou lerayonnement de l’arc peut déclencher la formation dephosgène -- gaz particulièrement toxique -- et d’autresgaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de lagorge constatée au cours de l’utilisation del’équipement dénote un défaut de ventilation. Arrêtez-vous de travailler afin de prendre les mesures néces-saires à l’amélioration de la ventilation. Ne poursuivezpas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisationsoù circule de l’hydrogène. L’armoire de commande estmunie d’un ventilateur destiné à empêcher la forma-tion de poches d’hydrogène, lesquelles présentent undanger d’explosion; ce ventilateur ne fonctionne quesi l’interrupteur correspondant du panneau avant setrouve placé en position ON (Marche). Veillez àmanœuvrer cette commande en vérifiant si lecouvercle est bien en place, de façon à assurerl’efficacité de la ventilation ainsi réalisée. Ne jamaisdébrancher le ventilateur.
e. Les fumées produites par l’opération de soudage oude coupage peuvent s’avérer toxiques. Aussi est-ilnécessaire de disposer en permanence d’un dispositifadéquat de ventilation de type aspirant, afin d’élimi-ner du voisinage de l’opérateur tout dégagement defumée visible.
f. Consultez les recommandations particulières enmatière de ventilation indiquées à l’alinéa 6 de lanorme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipemententretenu de façon défectueuse ou inadéquate risquenon seulement de réaliser un travail de mauvaisequalité mais, chose plus grave encore, d’entraîner
des dommages corporels graves, voire mortels endéclenchant des incendies ou des chocs électriques.Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qua-lifié l’installation, le dépannage et l’entretien du postede soudage et de coupage. N’effectuez aucuneréparation électrique sur l’équipement à moins d’êtrequa-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretienquelconque à l’intérieur du poste de soudage/coupage, avant d’avoir débranché l’alimentationélectrique.
c. Maintenez en bon état de fonctionnement les câbles,le câble de masse, les branchements, le cordond’alimentation et le poste de soudage/coupage.N’utilisez jamais le poste ou l’équipement s’il présenteune défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage etdes équipements accessoires. Gardez-les à l’écartdes sources de charleur, notamment des fours, del’humidité, des flaques d’eau maintenez-les à l’abri destraces d’huile ou de graisse, des atmosphères corro-sives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tousles panneaux de l’armoire de commande en veillant àles garder en bon état.
f. Utilisez le poste de soudage/coupage conformément àson usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVESÀ LA SÉCURITÉ--
Pour obtenir des informations complémentaires sur lesrègles de sécurité à observer pour le montage etl’utilisation d’équipements de soudage et de coupageélectriques et sur les méthodes de travailrecommandées, demandez un exemplaire du livret N°52529 “Precautions and Safe Practices for Arc Weld-ing, Cutting and Gouging” publié par ESAB. Nousconseillons également de consulter les publicationssui-vantes, tenues à votre disposition par l’AmericanWelding Society, 550 N.W. LeJuene Road, Miami, FL32126:
a. “Safety in Welding and Cutting” AWS Z49.1b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.d. “Recommended Safe Practices for Plasma Arc Cut-
ting” AWS-A6. 3.e. “Recommended Safe Practices for Plasma Arc Weld-
ing” AWS-C5. 1.f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
9/97
7
SECTION 2 DESCRIPTION AND SPECIFICATION
2.1 Mig 2E Wire Feeder
The Mig 2E Wire Feeder (Figure 2-1 and Table 2-1)described in this manual is designed for short arc,spray arc mig or cored wire welding with a constantpotential (CP) welding power source.
Secondary input from the Power Source can be DC"+" or DC "-" depending on the requirements of thewire type being used.
Mig spot welding can be done with the Mig 2E if it isequipped with optional spot-welding features. Addi-tion of spot-welding circuitry in no way modifiescapability of the unit for normal mig, or cored wirewelding.
The Mig 2E uses a PM wire drive motor designed tofeed wires from .023 to 5/64-inches in diameter. Rateof wire feed (50-650 inches per minute) is preciselycontrolled by a solid-state, Pulse Width Modulated(PWM) governor printed circuit board housed in thecontrol assembly. For operator safety, the torch switchis energized by 12 volts ac supplied by the control. Allinterconnecting cables and hoses are quickly de-tachable to provide maximum portability of the wirefeeder.
The Mig 2E wire feeder is designed to set on flat surfacesor mount on a swivel post, if desired, allowing movementas necessary during torch operations. The standardfeatures of the Mig 2E wire feeder follows:
• 2-roll geared drive stand• One drive roll and one pressure roll• Internal gas solenoid• Ten-foot (3m) control cable w/19-pin amphenol style
plug (factory installed)• Ten-foot (3m) gas hose w/fittings (factory installed)• "Euro" style torch connection• "ON" indicator light• Wire feed speed potentiometer
2.2 Mig 2E Wire Feeder Option. The followingoption is available from ESAB or your supplier.
• Spot/Burnback/Pre-postflow/Trigger Lock Mod-ule (P/N 34182). Easy to install kit permits theoperator to set times for spot welding (0-5 sec), wireburnback (0-0.6 sec), gas preflow (0-5 sec) and gaspostflow (0-7.5 sec). This module also includestrigger lock which allows the welder to make longwelds without continuously depressing the torch trig-ger. Includes module and current detector.
Table 2-1. Mig 2E Specifications
Input Power Required ....................................................... 42 V ac, 5A, 50/60 Hz, 1-phaseWire Feed Speed Range ................................................ 50-650 in./min. (1.3-16.5 m/min.)Wire Sizes Accommodated:
Hard/Soft ............................................................ .023 thru 1/16 in. (0.6 thru 1.6 mm)Flux Cored ......................................................... .035 thru 5/64-in. (0.9 thru 2.0 mm)
Length ........................................................................................................... 21 in. (54 cm)Width9 in. (23 cm)Height* ....................................................................................................... 9.25 in. (24 cm)Weight (approx**) ....................................................................................... 28 lbs (12.7 kg)
*Add 2-3/4-in. (7 cm) for spindle and spindle arm.**8-ft (2.4m) control cable and hose included in specified weight.
8
SECTION 2 DESCRIPTION AND SPECIFICATION
FRONT VIEWPRE GAS FLOW*
POST GAS FLOW*
CONTINUOUS, SPOT,*TRIGGER LATCH
SPOT WELD TIME*
BURN BACK WELD TIME*
5 A CIRCUIT BREAKER
CONTROL CABLE
GASCONNECTION
REEL STAND
WELDING POWERINPUT STAND
REAR VIEW
Figure 2-1. Mig 2E Wire Feeder
DOOR LATCH
WIRE SPOOL HUB
MIG TORCHCONNECTORRECEPTACLE
WIRE FEEDSPEED CONTROL
POWER "ON"INDICATOR
REEL STAND
*Included with option moduleP/N 34182
9
SECTION 3 EQUIPMENT
Table 3-1. Drive Roll & Guide Tube Selection
UpperWire Type / Lower Pressure GuideDiameter Drive Roll Roll Tube
Hard Wires (“V” groove).023 in. (0.6mm) 21155 2361 2368 21163.030 in. (0.8mm) 21155 2361 2368 21164.035 in. (0.9mm)* 21156 2361 2368 21165.040 in. (1.0mm)* 21156 2361 2368 21165.045 in. (1.2mm)* 21156 2361 2368 21165.052 in. (1.4mm) 21157 2361 2368 211661/16 in. (1.6mm) 21157 2361 2368 21166 Soft (aluminum) Wires (“U” groove).030 in. (0.8mm) 21160 2361 2368 21164.035 in. (0.9mm) 21160 2361 2368 211653/64 in. (1.2mm) 21161 2361 2368 211651/16 in. (1.6mm) 21161 2361 2368 21166 Cored Wires (Serrated “V” groove).030 in. (0.8mm) 21160 2361 2369 21164.035 in. (0.9mm) 21160 2361 2369 21165.040 in. (1.0mm) 21161 2361 2369 21165.045 in. (1.2mm) 21161 2361 2369 21165.045 in. (1.2mm)† 37319 37319 21165.052 in. (1.4mm) 21161 2361 2369 21166.052 in. (1.4mm)† 37319 37319 211661/16 in. (1.6mm) 21161 2361 2369 211661/16 in. (1.6mm)† 37320 37320 211665/64 in. (2.0mm) 21162 2361 2369 211665/64 in. (2.0mm)† 37320 37320 21166
* Supplied with Mig 2E wire feeder.† Recommended for use with soft cored wires that are easy to flatten.
Order both lower drive roll and upper pressure roll.If a Geared Pressure Roll is desired, order P/N 23612397.
3.1 General.
This section describes the Mig 2E Wire Feeder andthe recommended companion equipment and acces-sories required to properly operate the Mig 2E. Theoptional accessories available through ESAB (oryour ESAB supplier) will also be addressed.
3.2 Companion Equipment and Acces-sories.
A. Constant potential power source. Use the Mig2E with power sources such as: 352cv, 353cv,452cv, 453cv, 652cvcc, 653cvcc, SVI-300i, orSVI-450i
B. Extension Cables. Multi-conductor cable with19-pin amphenol plug and receptacle. Used toextend 8-ft (2.4m) cable supplied with wire feeder.
• 30-foot (9.1 m) P/N 34378• 60-foot (18.3 m) P/N 34377
C. 115 V ac to 42 V ac Interface (P/N 34351).Adapts Mig 2E to power sources with only 115V ac auxiliary and contactor. Includes interfacebox and adapter cables for power sources notequipped with 42 vac control circuitry.
D. ESAB mig welding torch. Torch with contact tip,wire conduit and outlet guide for wire size/typeto be employed.
E. Shielding gas regulator/flowmeter and fitted hoseto bring gas from flowmeter to wire feeder. Suchas:
Regulator/Flowmeters:R-5007 Argon/Helium/Nitrogen, P/N 998124.R-5008 CO
2, P/N 998125.
F. Drive Roll and Guide Tube. (Refer to Table 3-1). The Mig 2E wire feeder comes equippedwith a drive roll and a guide tube for wire sizes.035 to .045 (0.9 to 1.2 mm). Select other sizedrive rolls from Table 3-1 for the wire size andtype to be used.
3.3 Accessories
A. Swivel Post (P/N 34350). Installs into tube onpower sources such as 650cvcc or SVI 450icvcc and allows the wire feeder to freely swivelon post.
B. Swivel Post w/Mounting Bracket (P/N 34075).Attaches to Inverter Cart (P/N 31700) or otherflat mounting surfaces and allows the wire feederto freely swivel on the post.
C. Counterbalance Mini-Boom (P/N 34322). Keepstorch-cables off the floor and reduces wire feed-ing problems caused by sharp bends in torchconduits or cables. Includes boom, swivel postand mounting hardware.
D. Boom Hanging Bracket Kit (P/N 34321). In-cludes hanging bracket and mounting hard-ware.
E. Carrying Handle Kit (P/N 34320). Includeshandle with rubber grip and mounting hardware.
F. Wire Reel Adapter (P/N 34323). Use with 60 or65-lbs. (27 or 30 kg) coils.
G. Spool Spacer (P/N 34330). For adapting 10-in(25.4 cm) spools.
H. Spool Cover Kit (P/N 34326). Includes clearcover and mounting hardware.
I. Wire Feeder Wheel Cart (P/N 34324). Cartmakes it easy to roll wire feeder around jobsight. Cart is 5-7/8-in (15 cm) high and includesbase, front swivel caster wheels, rear casterwheels and mounting hardware.
SECTION 4 INSTALLATION
10
4.1 Installation
This wire feeder should NOT be earth or chassisgrounded. The feeder has rubber feet to keep itinsulated. In a boom mounted arrangement, theremust be an insulator between the boom and feederchassis. If not properly insulated and if wire touchesthe chassis, such as "bird nesting", current mayheat the wire and wire may contact circuit compo-nents, causing the PC board to fail.
After checking to be sure you have all required compo-nents and accessories (refer to Section 3), refer toFigure 2-1 for connections.
A. Remove input power from power source or inter-face box.
B. Hose and Electrical Connections. Connect shield-ing gas supply hose. Connect control cable topower source. If power source has been usedwith another type feeder, check to make certainthat no wiring changes have been made whichpermit actuation of contactor by some meansother than power received through the weldingcontrol cable receptacle. Any such modificationsmust be removed before attaching control cable topower source.
C. Wire Spool.
As with any work area, make sure safety glasseswith side shields are worn when handling or chang-ing wire or clipping wire off at the spool or at the endof the torch. Hold onto the wire coming off the spoolwith one hand before clipping. Serious eye injurycan result due to the resilience of the wire whichcan quickly unravel, or a cut wire end which mayshoot across the room.
Install a spool of welding wire on the hub as follows:
1. Unscrew spool nut from hub.2. Place wire spool on hub to rotate clockwise
as wire is unwound; hub pin must engagehole in spool.
3. Install spool nut.
D. Drive Rolls. The drive roll has two grooves; thesmall groove feeds 0.035 in. diameter wire, thelarge groove feeds 0.045 in. wire. The groovenearest the gear motor feeds the wire. If therequired groove is not correctly positioned, per-form the following:
1. Release the pressure drive roll lever and liftthe assembly upward.
2. Remove the retaining screw holding the driveroll to the gear.
3. Reverse the drive roll on the drive roll shaft.4. Replace the screw and tighten.5. Secure the pressure drive roll assembly.
E. Threading Wire.
1. Ensure control cable is disconnected frompower source or interface box.
When the control cable is connected to powersource or interface box and the power is on and guntrigger is depressed, the welding wire becomeselectrically hot, and the wire feed rolls are acti-vated.
2. Release pressure drive roll assembly and liftupward. Check that proper wire diametergroove is in the inner position.
Before threading welding wire through liner, makesure chisel point and burrs have been removedfrom wire end to prevent wire from jamming intorch or liner.
3. Feed the wire from the spool through the inletguide, across the drive roll groove and intogun outlet guide.
Make sure that the proper "outlet guide tube"is inserted into the front-panel torch fitting forthe size and type of wire being used.
To ensure proper wire feeding, it is importantthat the wire be kept clean and that the driverolls be periodically cleaned of any chips orscale that might be carried into the torch linerand cause sticking.
4. Lower pressure roll assembly and secure.Check that the gears mesh. Feed wire throughto torch tip using the torch trigger.
F. Brake Drag Adjustment. Brake disc friction shouldprovide enough drag to keep the wire spool or corefrom spinning freely after wire feed stops. Ifadjustment is required, turn adjusting screw (lo-cated inside hub) clockwise to increase drag,counterclockwise to decrease it. Drag should bejust low enough to limit wire overrun.
SECTION 5 OPERATION
11
5.1 Adjustments and Operation
A. Control Setting.
1. Apply power to wire feeder.
2. Set the wire feed rate by adjusting theWIRE FEED SPEED and VOLTS controlknobs on the front panel.
NOTE: Steps 3 and 4 apply only if spot/burnback/pre-postflow/trigger lock module optionis installed (P/N 34182).
3. Set the BURNBACK control on the rearpanel to the desired setting (orange: 0-0.6seconds), depending on the amount ofburnback desired. The higher the setting,the greater the amount of time that thecontactor is held in to allow the wire to burnback out of the puddle, after releasing thetorch switch.
4. If spot welding is to be performed, set rear-panel switch to "SPOT" position, set spot-welding potentiometer for time period(range: 0 to 5 seconds).
B. Feeding Wire. If wire has been threaded throughtorch and contact tip as directed in Section 4,simply cut off wire, as required, so that the wireextends about 1/2-inch beyond the end of thetorch nozzle.
C. Shielding Gas Flow Rate. Depress gas PURGEswitch (located under the feeder cover) and setdesired gas flow rate at the shielding gas regu-lator-flowmeter. Hold switch in at least 15seconds to insure adequate purging of gas hoseand torch.
NOTE: Pre and Postflow adjustment appliesonly if Spot/Burnback/Pre-Postflow/Trig-ger Lock Module option is installed (P/N34182).
Set pre and postflow potentiometers for thedesired preflow interval (range: 0-5 seconds)and postflow interval (range: 0 to 7.5 seconds).
D. Making the Weld. Start to weld by pressing thetorch switch lever to actuate the torch switch.This closes the welding contactor, and startswire feed and gas flow. Then touch the end ofthe welding wire to the workpiece to establish
the arc. The switch lever must be depressed forthe duration of the weld. Welding action will bestopped and all services discontinued when thelever is released and returns to its original posi-tion. If the torch is withdrawn from the workpieceduring welding, the arc will be interrupted, butshielding gas flow and welding wire feed willcontinue until the switch lever is released.
Do not allow metal-to-metal contact between thewire feeder chassis and a metal surface connectedin any way to a welding ground. With such contact,a poor welding ground connection may create adifference in potential that sends part of the weld-ing current through the safety ground wiring in thecontrol cable and wire feeder, resulting in burnoutof that wiring and/or damage to wire feeder cir-cuitry. If the safety ground burns out, the operatormay be exposed to 115 V shock hazard.
NOTE: If trigger lock-in circuit is selected, thetorch switch can be released as soon asarc has been struck. When weld is com-plete, services are discontinued by clos-ing torch switch again.
5.2 Operating Sequence.
A. Normal.
1. Close torch switch.-- Gas solenoid opens, weld contactor closes,wire feed motor runs.
2. Release torch switch.-- Wire feed motor deenergized, brake cir-cuit effective.-- Burnback circuit deenergized.
3. Burnback circuit times out (delay determinedby setting of Burnback potentiometer).-- Weld contactor opens.-- Gas solenoid valve closes.
B. Spot Weld.
1. Close torch switch.-- Gas solenoid, weld contactor, wire feedmotor energized.-- Spotweld timing circuit energized.
2. Spotweld circuit times out (interval estab-lished by setting of spotweld potentiometer).-- Wire feed motor deenergized, brake cir-cuit effective.-- Burnback circuit energized.
SECTION 5 OPERATION
12
3. Burnback circuit times out (interval estab-lished by setting of burnback potentiometer).-- Weld contactor opens.
4. Release torch switch.-- Gas solenoid valve closes.
C. Pre-flow/Post-Flow. Same as "NORMAL" exceptthat when torch switch is closed, only gas solenoidvalve is immediately energized. Contactor andwire feed motor are energized only after intervalestablished by setting of preflow potentiometer.When torch switch is opened, gas solenoid valve
remains energized until interval established bysetting of postflow potentiometer has elapsed.
D. Trigger Latch. Same as "NORMAL" except thatclosing of torch switch energizes the lock-incircuit, so torch switch lever can be releasedafter the arc is initiated. At end of weld, momen-tary closing of the torch switch initiates thesequence that normally follows opening of thatswitch. Trigger latch can only be set during timearc is established.
SECTION 6 SERVICE
A. 42 Volt Wire Feeder and Control Circuits.
If it should become necessary to replace the 10amp wire feeder circuit breaker or any other circuitbreaker/fuse in the welding machine, ensure thatthe proper size is used as a replacement.
The 42-volt circuit is protected by a 10 amp circuitbreaker located at the rear of the wire feeder.Failure of this circuit breaker will shut off thecontactor, shielding gas, and wire feeder.
B. Wire Feeder. As soft wire is fed, the drive rollsmay pick up metal from the wire surface. Accu-mulation on the rolls may score the wire withresulting unwanted friction and improper feeding.
Inspect the rolls regularly and clean them with afine-wire power brush. Avoid roughening, orremoving the hardness of groove surfaces ingrooved rolls. Any roughening may score thewire, just as the accumulation being removed maydo.
6.1 Maintenance.
If this equipment does not operate properly, stopwork immediately and investigate the cause of themalfunction. Maintenance work must be performedby an experienced person, and electrical work by atrained electrician. Do not permit untrained per-sons to inspect, clean, or repair this equipment.Use only recommended replacement parts.
Little maintenance is required to keep the wire feeder intop operating condition. It is important, however, thatmoving parts such as feed and pressure rolls, wire feedmotor, etc., be kept clean and free of dust or dirt.Cleaning is best accomplished by regularly blowing offthese parts with dry compressed air. This should bedone once for every eight hours of operating time, moreoften if necessary.
13
D-3
4190
-A
Figu
re 6
-1. S
chem
atic
Dia
gram
- M
ig 2
E W
ire F
eede
r
14
D-3
4153
-B
Fig
ure
6-1
. Wir
ing
Dia
gra
m -
Mig
2E
Wir
e F
eed
er
15
SECTION 7 REPLACEMENT PARTS
7.1 General.
Replacement Parts are illustrated on the followingfigures. When ordering replacement parts, order bypart number and part name, as illustrated on the figure.DO NOT ORDER BY PART NUMBER ALONE.
Always provide the series or serial number of the unit onwhich the parts will be used. The serial number isstamped on the unit nameplate.
Replacement parts may be ordered from your distribu-tor. Be sure to indicate any special shipping instructionswhen ordering replacement parts.
Refer to the Communications Guide on the last page ofthis manual for a list of customer service phone num-bers.
16
SECTION 7 REPLACEMENT PARTS
POWER
0
2
1V
3
4 5 6
7
8
9
10
WIRE FEEDSPEED
Figure 7-1. Mig 2E Wire Feeder (Front View)
10
8,7,6
4
5
2
1
ItemNo.
QtyReq .
P artNo . D escrip tion
C kt.S ym bo l
12
456789
111111111111
32112GY9529249529292361235023610528236106961373062332113GY67687620620181373061113792157
PA NE L, C ONTROLTORC H A D A P TOR A S S Y. inc ludes:C ONNE C TION TUB EP OW E R LUGHOUS ING A D A P TOR, S TRA IGHTA D A P TOR, B LOC K A S S E M B LYLATC H, D OORFRONT PA NE LINS ULATOR, 10 M IL , NOM E X 2X 2.5P OTE NTIOM E TE R, 10KK NOBLIGHT, P ILOT
J2
R1
P L1
17
SECTION 7 REPLACEMENT PARTS
Figure 7-2. Mig 2E Wire Feeder (Right Side, Cover Removed)
4
1
(DRIVE STAND REMOVEDFOR CLARITY)
3
7
6
6
4
2
ItemNo.
QtyReq.
PartNo. Description
Ckt.Symbol
12345678
14111211
37712GY951531674156211569529391373058395082321165
REEL STANDFOOT MOUNTINGADAPTER, POWER CABLE, MOLDEDFEED ROLL, .035-.045DRIVE STAND, 2-ROLL (See Fig. 7-6)BUSHING, TERMINALSNAP BUSHINGGUIDE TUBE .035 - .045
TB1
TP1, TP2
8
18
SECTION 7 REPLACEMENT PARTS
Figure 7-3. Mig 2E Wire Feeder (Top View, Cover Removed)
2
38 SEE DETAIL A 110
SEE FIGURE 7-4
12
DETAIL A
13
14
1716
6
ItemNo.
QtyReq.
PartNo. Description
Ckt.Symbol
123468101213141617
111211111
10'11
34136GY951530951174952860993717137920511373046931463951528997887136Z0835N22
BASEMOTOR, WIRE FEEDCLAMP, 1 EAR #10 USCLAMP, 1 EAR #12.8 GERTRANSFORMER, CONTROLVALVE, SOLENOIDRECTIFIER BRIDGEPC BOARDCONTROL CABLE ASSY, 10 COND. 19-PIN CONN.HOSE, WATERNUT, HOSENIPPLE, HOSE
M1
T1SOL1BR1
PCB1
4
19
SECTION 7 REPLACEMENT PARTS
Figure 7-4. Mig 2E Wire Feeder Wire Spool Hub Assembly
7 1 28
6 5 4 3
ItemNo.
QtyReq.
PartNo. Description
Ckt.Symbol
12345678910
2121111111
92040101236000109205600723600952236062372360025536756236009826330013664302037
SCREW R.H.M. 3/8-16X.75NUT, PLASTICWASHER, FLAT 3/8"WASHER D-TYPEHUB REELBRAKE DISC"D" SHAFTSPRINGNUT HEX 3/8-16WASHER LOCK 3/8
3
9
10
20
SECTION 7 REPLACEMENT PARTS
TOP VIEW
SIDE VIEW
END VIEW
3
4
1
7
2
6
5
Figure 7-5. Mig 2E Wire Feeder External Views
ItemNo.
QtyReq.
PartNo. Description
Ckt.Symbol
12345678
11111111
209151434142YL34140GY206216198W8595082313730222954698
LABEL, WARNINGCOVER, TOPCOVER, OPTION, BAFFLECIRCUIT BREAKER, 5ASTRAIN RELIEF .875 M.H.SNAP BUSHINGSNAP BUSHINGLABEL WARNING PINCH HAZARD(Inside Cover)
CB1
8
21
SECTION 7 REPLACEMENT PARTS
Figure 7-6. Mig 2-Roll Drive Stand
ItemNo.
QtyReq.
PartNo. Description
123456789101112131415161718192021
1111111121111111112311
95293995270423612477236124752361247423612625236124722361236823612476236124602361247323612461211569529449529252361247834608952945952926236124622361266223612663
2 ROLL WIRE DRIVE SYSTEM, CONSISTS OF:PRESSURE ARM ASSY., (incls. 2, 3, 4, 7, 8)AXLE, PRESSURE ROLLPRESSURE ARMAXLE NUTPIVOT PINCIRCLIPPRESSURE ROLL, SMOOTHSPACERPRESSURE DEVICE ASSY.LOCATING PININLET GUIDEDRIVE ROLL, .035" - .045" (See Table 3-1)ADAPTOR DRIVE ROLLFEED ROLL THUMB SCREWFEED PLATEWASHER RETAINING SCREWFEED ROLL SPACERTHUMB SCREW M6X16SCREW, MOTOR MOUNTINGSPACER TUBE (Pressure Arm)SPRING PRESSURE ARM
1,32,4
5
7,8
9
10,6
11
12,13
1516
2120
14
18
19
22
SECTION 7 REPLACEMENT PARTS
23
SECTION 7 REPLACEMENT PARTS
INSTRUCTION MANUAL CHANGES
The "A" edition (3/98) corrected some text errors, reformatted Section I, Table 1, and changed the Reel Stand, Feed Roll, Base, Guide Tube,Top Cover and Option Cover.
The "B" edition (8/99) changed the Water Hose, Drive Stand, Reel Stand, D-Shaft and the Torch Adaptor is now offered completely assembled.
The "C" edition (10/08) updated wiring diagram with revised information per ECN# 083192.
F15-143-C 10 / 08 PRINTED IN U.S.A.
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
A. CUSTOMER SERVICE QUESTIONS:Order Entry Product Availability Pricing DeliveryOrder Changes Saleable Goods Returns Shipping Information
Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548
Central Distribution Center Telephone: (800)783-5360 / Fax: (800) 783-5362
Western Distribution Center Telephone: (800) 235-4012/ Fax: (888) 586-4670
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM ESTWarranty Returns Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM ESTPerformance Features Technical Specifications Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:Telephone: (843)664-4428 / Fax: (843) 679-5864Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
ESAB Welding & Cutting Products, Florence, SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES