ESAB Mig 2E WIRE FEEDER User manual

Brand: ESAB

Model: Mig 2E WIRE FEEDER

Category: Welding System

Type: User manual

Be sure this information reaches the operator.

You can get extra copies through your supplier.

F15-143-C

October, 2008

INSTRUCTION MANUAL

Mig 2E

WIRE 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 operation

and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices

for Arc Welding, 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 (Section I) before installing or operating this

equipment.

USER RESPONSIBILITY

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

1 SAFETY ................................................................................................................................3

2 DESCRIPTION AND SPECIFICATION ...................................................................................7

2.1 Mig 2E Wire Feeder ................................................................................................7

2.2 Mig 2E Wire Feeder Option .....................................................................................7

3 EQUIPMENT ...........................................................................................................................9

3.1 General ...................................................................................................................9

3.2 Companion Equipment and Accessories.................................................................9

3.3 Accessories.............................................................................................................9

4 INSTALLATION .....................................................................................................................10

4.1 Installation .............................................................................................................10

5 OPERATION .........................................................................................................................11

5.1 Adjustments and Operation...................................................................................11

5.2 Operating Sequence .............................................................................................11

6 SERVICE ..............................................................................................................................12

6.1 Maintenance .........................................................................................................12

7 REPLACEMENT PARTS.......................................................................................................15

7.1 General .................................................................................................................15

This equipment will perform in conformity with the description thereof contained in this manual and accompanying

labels 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 become

necessary, the manufacturer recommends that a telephone or written request for service advice be made to the

Authorized 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 summarize precaution-

ary information from the references listed in

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 Safety Precautions can result

in injury or death.

PROTECT YOURSELF AND OTHERS

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (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 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 watch the arc and

not to expose themselves to the rays of the electric-arc

or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld-

ing helmet or cap for hair 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 clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot slag

or sparks can also cause fires and ex-

plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable covering. Combustible materials include wood,

cloth, sawdust, liquid and gas fuels, solvents, paints and

coatings, 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 so that there

are no substances on the workpiece which might pro-

duce flammable or toxic vapors. Do not do 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.

SAFETY PRECAUTIONS

10/98

5. Do not use equipment beyond its ratings. For example,

overloaded welding cable can overheat and create a fire

hazard.

6. After completing operations, inspect the work area to

make certain there are no hot sparks or hot metal which

could 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 live

electrical parts and ground can cause

severe injury or death. DO NOT use AC

welding current in damp areas, if move-

ment is confined, or if there is danger of

falling.

1. Be sure the power source frame (chassis) is connected

to 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 fatal

shock.

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 from

work and from ground.

7. Do not stand directly on metal or the earth 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 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 and

welding 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 are

unknown.

3. Welders should use the following procedures to minimize

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 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. Shield-

ing 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 galvanized steel, stainless steel,

copper, zinc, lead, beryllium, or cadmium unless posi-

tive mechanical ventilation is provided. Do not breathe

fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors 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 ventilation is not

adequate. Stop work and take necessary steps to im-

prove 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 which

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.)

CYLINDER HANDLING -- Cylinders, if

mishandled, can rupture and violently

release gas. Sudden rupture of cylin-

der, 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

manufacturer's operating instructions for mounting regu-

lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain

or strap to suitable hand trucks, undercarriages, benches,

walls, 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 con-

nected. Secure and move cylinders by using suitable

hand 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 in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, 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, grounding 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.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for elec-

tric 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, 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 Held

Hazardous Substances."

MEANING OF SYMBOLS - As used through-

out this manual: Means Attention! Be Alert!

Your safety is involved.

Means immediate hazards which, if

not avoided, will result in immediate,

serious personal injury or loss of life.

Means potential hazards which could

result in personal injury or loss of life.

Means hazards which could result in

minor personal injury.

SP98-10

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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 constant

potential (CP) welding power source.

Secondary input from the Power Source can be DC

"+" or DC "-" depending on the requirements of the

wire type being used.

Mig spot welding can be done with the Mig 2E if it is

equipped with optional spot-welding features. Addi-

tion of spot-welding circuitry in no way modifies

capability of the unit for normal mig, or cored wire

welding.

The Mig 2E uses a PM wire drive motor designed to

feed wires from .023 to 5/64-inches in diameter. Rate

of wire feed (50-650 inches per minute) is precisely

controlled by a solid-state, Pulse Width Modulated

(PWM) governor printed circuit board housed in the

control assembly. For operator safety, the torch switch

is energized by 12 volts ac supplied by the control. All

interconnecting cables and hoses are quickly de-

tachable to provide maximum portability of the wire

feeder.

The Mig 2E wire feeder is designed to set on flat surfaces

or mount on a swivel post, if desired, allowing movement

as necessary during torch operations. The standard

features 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 following

option is available from ESAB or your supplier.

• Spot/Burnback/Pre-postflow/Trigger Lock Mod-

ule (P/N 34182). Easy to install kit permits the

operator to set times for spot welding (0-5 sec), wire

burnback (0-0.6 sec), gas preflow (0-5 sec) and gas

postflow (0-7.5 sec). This module also includes

trigger lock which allows the welder to make long

welds 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-phase

Wire 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.

SECTION 2

DESCRIPTION AND SPECIFICATION

FRONT VIEW

PRE GAS FLOW*

POST GAS FLOW*

CONTINUOUS, SPOT,*

TRIGGER LATCH

SPOT WELD TIME*

BURN BACK WELD TIME*

5 A CIRCUIT BREAKER

CONTROL CABLE

GAS

CONNECTION

REEL STAND

WELDING POWER

INPUT STAND

REAR VIEW

Figure 2-1. Mig 2E Wire Feeder

DOOR LATCH

WIRE SPOOL HUB

MIG TORCH

CONNECTOR

RECEPTACLE

WIRE FEED

SPEED CONTROL

POWER "ON"

INDICATOR

REEL STAND

*Included with option module

P/N 34182

SECTION 3 EQUIPMENT

Table 3-1. Drive Roll & Guide Tube Selection

Upper

Wire Type / Lower Pressure Guide

Diameter 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 21166

1/16 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 21165

3/64 in. (1.2mm) 21161 2361 2368 21165

1/16 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 21166

1/16 in. (1.6mm) 21161 2361 2369 21166

1/16 in. (1.6mm)† 37320 37320 21166

5/64 in. (2.0mm) 21162 2361 2369 21166

5/64 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 and

the recommended companion equipment and acces-

sories required to properly operate the Mig 2E. The

optional accessories available through ESAB (or

your ESAB supplier) will also be addressed.

3.2 Companion Equipment and Acces-

sories.

A. Constant potential power source. Use the Mig

2E with power sources such as: 352cv, 353cv,

452cv, 453cv, 652cvcc, 653cvcc, SVI-300i, or

SVI-450i

B. Extension Cables. Multi-conductor cable with

19-pin amphenol plug and receptacle. Used to

extend 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 115

V ac auxiliary and contactor. Includes interface

box and adapter cables for power sources not

equipped with 42 vac control circuitry.

D. ESAB mig welding torch. Torch with contact tip,

wire conduit and outlet guide for wire size/type

to be employed.

E. Shielding gas regulator/flowmeter and fitted hose

to bring gas from flowmeter to wire feeder. Such

as:

Regulator/Flowmeters:

R-5007 Argon/Helium/Nitrogen, P/N 998124.

R-5008 CO

, P/N 998125.

F. Drive Roll and Guide Tube. (Refer to Table 3-

1). The Mig 2E wire feeder comes equipped

with a drive roll and a guide tube for wire sizes

.035 to .045 (0.9 to 1.2 mm). Select other size

drive rolls from Table 3-1 for the wire size and

type to be used.

3.3 Accessories

A. Swivel Post (P/N 34350). Installs into tube on

power sources such as 650cvcc or SVI 450i

cvcc and allows the wire feeder to freely swivel

on post.

B. Swivel Post w/Mounting Bracket (P/N 34075).

Attaches to Inverter Cart (P/N 31700) or other

flat mounting surfaces and allows the wire feeder

to freely swivel on the post.

C. Counterbalance Mini-Boom (P/N 34322). Keeps

torch-cables off the floor and reduces wire feed-

ing problems caused by sharp bends in torch

conduits or cables. Includes boom, swivel post

and 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). Includes

handle with rubber grip and mounting hardware.

F. Wire Reel Adapter (P/N 34323). Use with 60 or

65-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 clear

cover and mounting hardware.

I. Wire Feeder Wheel Cart (P/N 34324). Cart

makes it easy to roll wire feeder around job

sight. Cart is 5-7/8-in (15 cm) high and includes

base, front swivel caster wheels, rear caster

wheels and mounting hardware.

SECTION 4 INSTALLATION

4.1 Installation

This wire feeder should NOT be earth or chassis

grounded. The feeder has rubber feet to keep it

insulated. In a boom mounted arrangement, there

must be an insulator between the boom and feeder

chassis. If not properly insulated and if wire touches

the chassis, such as "bird nesting", current may

heat 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 to

Figure 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 to

power source. If power source has been used

with another type feeder, check to make certain

that no wiring changes have been made which

permit actuation of contactor by some means

other than power received through the welding

control cable receptacle. Any such modifications

must be removed before attaching control cable to

power source.

C. Wire Spool.

As with any work area, make sure safety glasses

with side shields are worn when handling or chang-

ing wire or clipping wire off at the spool or at the end

of the torch. Hold onto the wire coming off the spool

with one hand before clipping. Serious eye injury

can result due to the resilience of the wire which

can quickly unravel, or a cut wire end which may

shoot 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 engage

hole in spool.

3. Install spool nut.

D. Drive Rolls. The drive roll has two grooves; the

small groove feeds 0.035 in. diameter wire, the

large groove feeds 0.045 in. wire. The groove

nearest the gear motor feeds the wire. If the

required groove is not correctly positioned, per-

form the following:

1. Release the pressure drive roll lever and lift

the assembly upward.

2. Remove the retaining screw holding the drive

roll 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 from

power source or interface box.

When the control cable is connected to power

source or interface box and the power is on and gun

trigger is depressed, the welding wire becomes

electrically hot, and the wire feed rolls are acti-

vated.

2. Release pressure drive roll assembly and lift

upward. Check that proper wire diameter

groove is in the inner position.

Before threading welding wire through liner, make

sure chisel point and burrs have been removed

from wire end to prevent wire from jamming in

torch or liner.

3. Feed the wire from the spool through the inlet

guide, across the drive roll groove and into

gun outlet guide.

Make sure that the proper "outlet guide tube"

is inserted into the front-panel torch fitting for

the size and type of wire being used.

To ensure proper wire feeding, it is important

that the wire be kept clean and that the drive

rolls be periodically cleaned of any chips or

scale that might be carried into the torch liner

and cause sticking.

4. Lower pressure roll assembly and secure.

Check that the gears mesh. Feed wire through

to torch tip using the torch trigger.

F. Brake Drag Adjustment. Brake disc friction should

provide enough drag to keep the wire spool or core

from spinning freely after wire feed stops. If

adjustment is required, turn adjusting screw (lo-

cated inside hub) clockwise to increase drag,

counterclockwise to decrease it. Drag should be

just low enough to limit wire overrun.

SECTION 5

OPERATION

5.1 Adjustments and Operation

A. Control Setting.

1. Apply power to wire feeder.

2. Set the wire feed rate by adjusting the

WIRE FEED SPEED and VOLTS control

knobs on the front panel.

NOTE: Steps 3 and 4 apply only if spot/burnback/

pre-postflow/trigger lock module option

is installed (P/N 34182).

3. Set the BURNBACK control on the rear

panel to the desired setting (orange: 0-0.6

seconds), depending on the amount of

burnback desired. The higher the setting,

the greater the amount of time that the

contactor is held in to allow the wire to burn

back out of the puddle, after releasing the

torch 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 through

torch and contact tip as directed in Section 4,

simply cut off wire, as required, so that the wire

extends about 1/2-inch beyond the end of the

torch nozzle.

C. Shielding Gas Flow Rate. Depress gas PURGE

switch (located under the feeder cover) and set

desired gas flow rate at the shielding gas regu-

lator-flowmeter. Hold switch in at least 15

seconds to insure adequate purging of gas hose

and torch.

NOTE: Pre and Postflow adjustment applies

only if Spot/Burnback/Pre-Postflow/Trig-

ger Lock Module option is installed (P/N

34182).

Set pre and postflow potentiometers for the

desired preflow interval (range: 0-5 seconds)

and postflow interval (range: 0 to 7.5 seconds).

D. Making the Weld. Start to weld by pressing the

torch switch lever to actuate the torch switch.

This closes the welding contactor, and starts

wire feed and gas flow. Then touch the end of

the welding wire to the workpiece to establish

the arc. The switch lever must be depressed for

the duration of the weld. Welding action will be

stopped and all services discontinued when the

lever is released and returns to its original posi-

tion. If the torch is withdrawn from the workpiece

during welding, the arc will be interrupted, but

shielding gas flow and welding wire feed will

continue until the switch lever is released.

Do not allow metal-to-metal contact between the

wire feeder chassis and a metal surface connected

in any way to a welding ground. With such contact,

a poor welding ground connection may create a

difference in potential that sends part of the weld-

ing current through the safety ground wiring in the

control cable and wire feeder, resulting in burnout

of that wiring and/or damage to wire feeder cir-

cuitry. If the safety ground burns out, the operator

may be exposed to 115 V shock hazard.

NOTE: If trigger lock-in circuit is selected, the

torch switch can be released as soon as

arc 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 determined

by setting of Burnback potentiometer).

-- Weld contactor opens.

-- Gas solenoid valve closes.

B. Spot Weld.

1. Close torch switch.

-- Gas solenoid, weld contactor, wire feed

motor 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

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" except

that when torch switch is closed, only gas solenoid

valve is immediately energized. Contactor and

wire feed motor are energized only after interval

established by setting of preflow potentiometer.

When torch switch is opened, gas solenoid valve

remains energized until interval established by

setting of postflow potentiometer has elapsed.

D. Trigger Latch. Same as "NORMAL" except that

closing of torch switch energizes the lock-in

circuit, so torch switch lever can be released

after the arc is initiated. At end of weld, momen-

tary closing of the torch switch initiates the

sequence that normally follows opening of that

switch. Trigger latch can only be set during time

arc is established.

SECTION 6

SERVICE

A. 42 Volt Wire Feeder and Control Circuits.

If it should become necessary to replace the 10

amp wire feeder circuit breaker or any other circuit

breaker/fuse in the welding machine, ensure that

the proper size is used as a replacement.

The 42-volt circuit is protected by a 10 amp circuit

breaker located at the rear of the wire feeder.

Failure of this circuit breaker will shut off the

contactor, shielding gas, and wire feeder.

B. Wire Feeder. As soft wire is fed, the drive rolls

may pick up metal from the wire surface. Accu-

mulation on the rolls may score the wire with

resulting unwanted friction and improper 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.

6.1 Maintenance.

If this equipment does not operate properly, stop

work immediately and investigate the cause of the

malfunction. Maintenance work must be performed

by an experienced person, and electrical work by a

trained 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 in

top operating condition. It is important, however, that

moving parts such as feed and pressure rolls, wire feed

motor, etc., be kept clean and free of dust or dirt.

Cleaning is best accomplished by regularly blowing off

these parts with dry compressed air. This should be

done once for every eight hours of operating time, more

often if necessary.

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SECTION 7 REPLACEMENT PARTS

7.1 General.

Replacement Parts are illustrated on the following

figures. When ordering replacement parts, order by

part 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 on

which the parts will be used. The serial number is

stamped on the unit nameplate.

Replacement parts may be ordered from your distribu-

tor. Be sure to indicate any special shipping instructions

when ordering replacement parts.

Refer to the Communications Guide on the last page of

this manual for a list of customer service phone num-

bers.

SECTION 7

REPLACEMENT PARTS

POWER

WIRE FEED

SPEED

Figure 7-1. Mig 2E Wire Feeder (Front View)

8,7,6

Item

No.

Qty

Req.

Part

No. Description

Ckt.

Symbol

32112GY

952924

952929

23612350

23610528

23610696

13730623

32113GY

676876

2062018

13730611

13792157

PANEL, CONTROL

TORCH ADAPTOR ASSY. includes:

CONNECTION TUBE

POWER LUG

HOUSING ADAPTOR, STRAIGHT

ADAPTOR, BLOCK ASSEMBLY

LATCH, DOOR

FRONT PANEL

INSULATOR, 10 MIL, NOMEX 2X2.5

POTENTIOMETER, 10K

KNOB

LIGHT, PILOT

PL1

SECTION 7 REPLACEMENT PARTS

Figure 7-2. Mig 2E Wire Feeder (Right Side, Cover Removed)

(DRIVE STAND REMOVED

FOR CLARITY)

Item

No.

Qty

Req.

Part

No. Description

Ckt.

Symbol

37712GY

951531

674156

21156

952939

13730583

950823

21165

REEL STAND

FOOT MOUNTING

ADAPTER, POWER CABLE, MOLDED

FEED ROLL, .035-.045

DRIVE STAND, 2-ROLL (See Fig. 7-6)

BUSHING, TERMINAL

SNAP BUSHING

GUIDE TUBE .035 - .045

TB1

TP1, TP2

SECTION 7

REPLACEMENT PARTS

Figure 7-3. Mig 2E Wire Feeder (Top View, Cover Removed)

SEE DETAIL A

SEE FIGURE 7-4

DETAIL A

Item

No.

Qty

Req.

Part

No. Description

Ckt.

Symbol

10'

34136GY

951530

951174

952860

993717

13792051

13730469

31463

951528

997887

136Z08

35N22

BASE

MOTOR, WIRE FEED

CLAMP, 1 EAR #10 US

CLAMP, 1 EAR #12.8 GER

TRANSFORMER, CONTROL

VALVE, SOLENOID

RECTIFIER BRIDGE

PC BOARD

CONTROL CABLE ASSY, 10 COND. 19-PIN CONN.

HOSE, WATER

NUT, HOSE

NIPPLE, HOSE

SOL1

BR1

PCB1

SECTION 7 REPLACEMENT PARTS

Figure 7-4. Mig 2E Wire Feeder Wire Spool Hub Assembly

Item

No.

Qty

Req.

Part

No. Description

Ckt.

Symbol

92040101

23600010

92056007

23600952

23606237

23600255

36756

23600982

63300136

64302037

SCREW R.H.M. 3/8-16X.75

NUT, PLASTIC

WASHER, FLAT 3/8"

WASHER D-TYPE

HUB REEL

BRAKE DISC

"D" SHAFT

SPRING

NUT HEX 3/8-16

WASHER LOCK 3/8

SECTION 7

REPLACEMENT PARTS

TOP VIEW

SIDE VIEW

END VIEW

Figure 7-5. Mig 2E Wire Feeder External Views

Item

No.

Qty

Req.

Part

No. Description

Ckt.

Symbol

2091514

34142YL

34140GY

2062161

98W85

950823

13730222

954698

LABEL, WARNING

COVER, TOP

COVER, OPTION, BAFFLE

CIRCUIT BREAKER, 5A

STRAIN RELIEF .875 M.H.

SNAP BUSHING

LABEL WARNING PINCH HAZARD

(Inside Cover)

CB1

SECTION 7 REPLACEMENT PARTS

Figure 7-6. Mig 2-Roll Drive Stand

Item

No.

Qty

Req.

Part

No. Description

952939

952704

23612477

23612475

23612474

23612625

23612472

23612368

23612476

23612460

23612473

23612461

21156

952

944

952925

23612478

34608

952945

952926

23612462

23612662

23612663

2 ROLL WIRE DRIVE SYSTEM, CONSISTS OF:

PRESSURE ARM ASSY., (incls. 2, 3, 4, 7, 8)

AXLE, PRESSURE ROLL

PRESSURE ARM

AXLE NUT

PIVOT PIN

CIRCLIP

PRESSURE ROLL, SMOOTH

SPACER

PRESSURE DEVICE ASSY.

LOCATING PIN

INLET GUIDE

DRIVE ROLL, .035" - .045" (See Table 3-1)

ADAPTOR DRIVE ROLL

FEED ROLL THUMB SCREW

FEED PLATE

WASHER RETAINING SCREW

FEED ROLL SPACER

THUMB SCREW M6X16

SCREW, MOTOR MOUNTING

SPACER TUBE (Pressure Arm)

SPRING PRESSURE ARM

1,3

2,4

7,8

10,6

12,13

Page is loading ...

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 Delivery

Order 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) 446-5693

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST

Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548

Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: (843)664-4428 / Fax: (843) 679-5864

Training 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 Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

ESAB Mig 2E WIRE FEEDER User manual

Brand: ESAB

Model: Mig 2E WIRE FEEDER

Category: Welding System

Type: User manual

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