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Instruction manual
0558 012 634 GB 20160229
Valid for: serial no. WxxK533xxxx
MobileFeed 301 AVS
TABLE OF CONTENTS
0558 012 634 © ESAB AB 2016
1
SAFETY ......................................................................................................... 4
1.1 Overview ................................................................................................... 4
2
INTRODUCTION............................................................................................ 7
2.1 Overview ................................................................................................... 7
2.2 Equipment ................................................................................................. 7
3
TECHNICAL DATA ........................................................................................ 8
4
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
5
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
6
MAINTENANCE............................................................................................. 24
6.1 Inspection and service............................................................................. 24
6.2 Wire feeder ................................................................................................ 24
6.3 Solenoid valve replacement .................................................................... 24
6.4 Troubleshooting ....................................................................................... 25
7
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
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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" (432×210×534mm)
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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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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