ESAB MobileFeed 301 AVS User manual

Brand: ESAB

Model: MobileFeed 301 AVS

Category: Welding System

Type: User manual

ESAB MobileFeed 301 AVS is a portable wire feeder powered entirely on the arc voltage from a constant current (CC) or constant voltage (CV) welding power source. It can weld with hard, soft, and cored electrodes (gas shielded or self-shielded) from 0.030” (0.8mm) through 5/64” (1.98mm) diameter with a wire feed speed from 50 to 750 in/min (1.3 - 19.0 m/min). The feeder components are enclosed in a rugged case for portability and durability and it comes with a voltage pickup cable with a clamp. The MobileFeed 301 AVS is designed for use in a variety of welding applications, including: -MIG (Metal Inert Gas) welding

Instruction manual

0558 012 634 GB 20160229

Valid for: serial no. WxxK533xxxx

MobileFeed 301 AVS

TABLE OF CONTENTS

0558 012 634 © ESAB AB 2016

SAFETY ......................................................................................................... 4

1.1 Overview ................................................................................................... 4

INTRODUCTION............................................................................................ 7

2.1 Overview ................................................................................................... 7

2.2 Equipment ................................................................................................. 7

TECHNICAL DATA ........................................................................................ 8

INSTALLATION.............................................................................................. 9

4.1 Recieving and handling ........................................................................... 9

4.2 Selection of drive rolls and guide tubes ................................................ 9

4.3 Installing drive rolls and guide tubes ..................................................... 10

4.4 Installing the welding wire....................................................................... 10

4.5 Threading the welding wire ..................................................................... 11

4.6 Adjusting the brake drag ......................................................................... 11

4.7 Torch connection...................................................................................... 12

4.8 Supply connections ................................................................................. 13

OPERATION .................................................................................................. 15

5.1 Overview ................................................................................................... 15

5.2 Connections and control devices ........................................................... 16

5.3 Operating procedures .............................................................................. 19

5.3.1 Operating safety precautions ................................................................. 19

5.3.2 Setting a welding procedure................................................................... 20

5.3.3 Weld data table....................................................................................... 21

5.3.4 MobileFeed 301 with CC Power Sources............................................... 22

5.3.5 MobileFeed 301 with CV Power Sources ............................................... 22

5.3.6 Shutdown ............................................................................................... 23

MAINTENANCE............................................................................................. 24

6.1 Inspection and service............................................................................. 24

6.2 Wire feeder ................................................................................................ 24

6.3 Solenoid valve replacement .................................................................... 24

6.4 Troubleshooting ....................................................................................... 25

ORDERING SPARE PARTS .......................................................................... 26

WIRING DIAGRAM............................................................................................... 27

WEAR PARTS CE PRODUCTS ........................................................................... 28

ORDERING NUMBERS........................................................................................ 31

ACCESSORIES .................................................................................................... 32

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

1.1 Overview

MEANING OF SYMBOLS

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, 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.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and

Material Safety Data Sheets (MSDSs).

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 can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed 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

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

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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 may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions

when welding and cutting. Ask for your employer's safety practices which should

be based on manufacturers' hazard data.

ELECTRIC SHOCK - Can kill

• Install and earth the unit in accordance with applicable standards

• Do not touch live electrical parts or electrodes with bare skin, wet gloves

or wet clothing

• Insulate yourself from earth and the workpiece

• Ensure your working stance is safe

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone and the general area

ARC RAYS - Can injure eyes and burn skin.

• Protect your eyes and body. Use the correct welding screen and filter

lens and wear protective clothing

• Protect bystanders with suitable screens or curtains

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable materials nearby

NOISE - Excessive noise can damage hearing

• Protect your ears. Use earmuffs or other hearing protection. Protect your

ears. Use earmuffs or other hearing protection

• Warn bystanders of the risk

MALFUNCTION - Call for expert assistance in the event of malfunction.

Read and understand the instruction manual before installing or operating.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

1 SAFETY

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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 those locations, due to conducted as well

as radiated disturbances.

NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of 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.

2 INTRODUCTION

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2 INTRODUCTION

2.1 Overview

The MobileFeed 301 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 301

AVS is available with two connections, EURO and TWECO. A remote 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” (0.8mm) through 5/64” (1.98mm) 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 301 AVS is supplied with:

• Instruction manual

• Voltage pickup cable with clamp

3 TECHNICAL DATA

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3 TECHNICAL DATA

NOTE!

The MobileFeed 301 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 301 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 14 V DC

Welding 45 V DC (when welding)

Maximum 100 V DC (113 V peak)

Standard spindle hub 2” (50 mm) ID

Standard spool 8” (200 mm) OD, 12" (300 mm) OD

Maximum welding current 320 A at 60 % duty cycle

250 A at 100 % duty cycle

Maximum gas inlet pressure 75 psi (5.2 Bar)

Wire diameters

Hard .030” (0.8 mm), .035” (0.9 mm),

.045” (1.2 mm), .052” (1.4 mm),

1/16” (1.6 mm)

Soft .035” (0.9 mm), 3/64” (1.2 mm),

1/16” (1.6 mm)

Cored .030” (0.8 mm), .035” (0.9 mm),

.045” (1.2 mm), .052” (1.4mm),

1/16” (1.6 mm), 5/64” (2.0 mm)

Motor type DC permanent magnet pre-lubricated, enclosed

Brake type (wire) Drag

Control Solid state

Feed system Push

On-Off switch Standard

Ramp start Standard

Height × Width × Length 17.0" × 8.3" × 21.0" (432×210×534mm)

Weight (with contactor, without spool) 33 lbs (15 kg)

Enclosure class 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 is intended for indoor and outdoor use; however, should not be

operated in precipitation.

4 INSTALLATION

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4 INSTALLATION

4.1 Recieving 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.

If the unit is unstable in upright position (A), as when the torch or spool is disconnected or

when there is a risk that the unit might be pulled by the torch during operation, the unit must

be secured. Alternatively it can be operated in horizontal position (B) if conditions permit.

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 work piece 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 INSTALLATION

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4.3 Installing drive rolls and guide tubes

CAUTION!

Turn off the power source and the wire feeder.

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.

4 INSTALLATION

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1. Remove the spool retainer nut (1).

2. Put the wire spool (2) on the hub to rotate counterclockwise as the wire is unwounded.

The hub pin must engage the hole in the wire spool.

3. Install the spool retainer nut (1).

4.5 Threading the welding wire

CAUTION!

Before threading the wire, make sure 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 goove 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.

4 INSTALLATION

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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 that wire is slightly slack when wire feed stops.

1. To increase the braking torque, use an 5/16" (8 mm) allen key and turn the drag

adjusting screw (1) clockwise.

2. To reduce the braking torque, use an 5/16" (8 mm) allen key and turn the drag

adjusting screw (1) 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 adaptor 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 adaptor and push on firmly.

2. Hand tighten the locking collar on the Euro connector.

4 INSTALLATION

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4.8 Supply connections

CAUTION!

Turn off the power source and the wire feeder.

The MobileFeed 301 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 301 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 injury, possibly

fatally.

2. Connect a second welding cable (2) between the opposite polarity output connection

on the power source and the work piece.

3. Connect the wire feeder work lead/voltage pick-up cable clip (3) to the work piece.

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.

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.

4 INSTALLATION

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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.

5 OPERATION

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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 handle intended for transportation. Never pull

the equipment by the welding torch.

CAUTION!

Before threading the wire, make sure 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.

WARNING!

Risk of crushing when replacing the wire bobbin! Do not use safety gloves when

inserting the welding wire between the feed rollers.

WARNING!

Do not operate the feeder with the enclosure open.

5 OPERATION

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5.2 Connections and control devices

1. Knob for setting the wire

feed speed

5. Display for wire feed

speed/voltage

9. Shield gas connection

2. Knob for setting the

voltage

6. Trigger lock switch 10. Welding cable

connection

3. Torch connection 7. Power switch 11. Power source remote

voltage control

connection

4. Work lead (Voltage

pick-up)

8. Torch switch connector

(TWECO/NAS versions

only)

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.

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.

5 OPERATION

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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 work piece. The power source must be turned on

with the contactor closed.

5 OPERATION

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1. Main fuse, 10 A 3. Jog/purge switch

2. Circuit breaker, 7 A 4. CC/CV switch

Circuit breaker, 7 A

This resettable 7 A 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 the 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 the wire has been threaded through torch 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 torch

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 for constant voltage power sources. The selected mode also has

impact on the functions of the wire feeder as shown below:

Mode Display Knob for setting the wire feed speed

CC Wire feed speed and arc voltage

shown

Controls the arc voltage / Wire speed

feed increase with increased voltage

CV Wire feed speed shown Controls the welding current

5 OPERATION

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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

up 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.

5 OPERATION

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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 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 grunded 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) are put on. Failure

to comply may reult 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 shield gas in confined space may result in a build-up of fumes,

displacing oxygen.

5.3.2 Setting a welding procedure

Quick set-up procedure

1. For Constant Voltage (CV) Power Source; Set the desired arc voltage on the power

source.

2. For 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 guidance.

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.

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ESAB MobileFeed 301 AVS User manual

Brand: ESAB

Model: MobileFeed 301 AVS

Category: Welding System

Type: User manual

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ESAB MobileFeed 301 AVS User manual

ESAB MobileFeed 301 AVS User manual

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