ESAB Mig 4HD Ultra PulseWire Feeder User manual

Brand: ESAB

Model: Mig 4HD Ultra PulseWire Feeder

Category: Welding System

Type: User manual

This manual provides instructions for units: P/N 36645, Mig 4HD Wire Feeder

Mig 4HD Ultra PulseWire Feeder

F15-348-C 07 / 2009 Valid serial no. WK-I30001

Instruction Manual

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

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. 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 ser-

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting 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 be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

SECTION TITLE PAGE

SECTION 1 SAFETY PRECAUTION .................................................................................................................................................5

1.1 Safety - English ..................................................................................................................................................................5

1.2 Safety - Spanish .................................................................................................................................................................9

1.3 Safety - French ................................................................................................................................................................13

SECTION 2 DESCRIPTION AND SPECIFICATION ....................................................................................................................17

2.1 Mig 4HD Ultra Pulse Wire Feeder .............................................................................................................................17

2.2 Mig 4HD Wire Feeder Options ..................................................................................................................................17

SECTION 3 EQUIPMENT ....................................................................................................................................................................19

3.1 General ..............................................................................................................................................................................19

3.2 Companion Equipment and Accessories ..............................................................................................................19

3.3 Accessories .......................................................................................................................................................................19

SECTION 4 INSTALLATION ..............................................................................................................................................................21

4.1 Installation .......................................................................................................................................................................11

SECTION 5 OPERATION ....................................................................................................................................................................23

5.1 Adjustments and Operation ......................................................................................................................................23

5.2 Pulsed Mig Operation ..................................................................................................................................................23

5.3 Operating Sequence ....................................................................................................................................................24

5.4 Eects of Slope on Pulse Mig Arc Stability ...........................................................................................................25

5.5 Standard Operation ......................................................................................................................................................25

SECTION 6 MAINTENANCE .............................................................................................................................................................27

6.1 Maintenance ...................................................................................................................................................................27

SECTION 7 REPLACEMENT PARTS ...............................................................................................................................................31

7.0 Replacement Parts ........................................................................................................................................................31

7.1 General ..............................................................................................................................................................................31

7.2 Ordering ............................................................................................................................................................................31

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. 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.

ROTECT 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 equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operat-

ing 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 ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes,

and a welding helmet or cap for hair protection, to

protect against arc rays and hot sparks or hot metal.

A ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, 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-ammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Hea

t from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ammable covering. Combustible materials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

. Hot sparks or hot metal can fall through cracks or

crevices in oors or wall openings and cause a hid-

den smoldering re or res on the oor 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

produce ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a re 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 re. Use re watchers when

necessary.

7. For additional information, refer to NFPA Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protec-

tion Association, 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 movement is conned, or if there is

danger of falling.

SECTION 1 SAFETY PRECAUTIONS

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

nected 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

damaged 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 o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects 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 conned 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, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive 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 ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

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 vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures 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 ames.

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 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

. 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.

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.

Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

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

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, 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.

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2.1 Mig 4HD Ultra Pulse Wire Feeder

The Mig 4HD Ultra Pulse Wire Feeder (Figure 2-1 and Table 2-1) described in this manual is designed for short arc, spray arc

mig, cored wire and pulsed mig welding. This wire feeder is designed for use with SVI-450i.

Secondary input from the Power Source can be DC "+" or DC "-" depending on the requirements of the wire type being

used.

The wire feeder uses a PM wire drive motor designed to feed wires from .023 to 3/32-inches in diameter. Rate of wire feed

(50-750 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 detachable to provide maximum portability of the wire feeder.

The wire feeder is designed to set on at surfaces or mount on a swivel post, if desired, allowing movement as necessary

during torch operations. The standard features of the Mig 4HD Ultra Pulse wire feeder follows:

• 4-roll geared drive stand

• Two drive rolls and two pressure rolls

• Internal gas solenoid

• 60-ft. (18m) control cable w/19-pin amphenol style plug (factory installed)

• 60-ft. (18m) gas hose w/ttings (factory installed)

• "Euro" style torch connection

• "ON" indicator light

• Wire feed speed potentiometer

• Digital meter

• Voltage control potentiometer

• Gas purge switch

• Jog (wire) switch

• Remote power source voltage control (non-pulse mode)

• Pulse/Standard switch

• Pulse Arc trim control (pulse mode)

• Spot welding, burnback, preow and postow control

• Trigger locking capability

A water kit may be purchased (as an optional accessory) for use with the Mig 4HD Ultra Pulse when used with water cooled

torches.

2.2 Wire Feeder Options. The following options are available from ESAB or your supplier.

• Water Kit (P/N 34325). Convenient way of using water cooled torches. Kit consists of inlet/outlet ttings, mounting

hardware, quick action connectors for the torch and 10-ft (3m) water hoses with "B" size water ttings.

• Push-Pull Torch Control Kit (P/N 34327). Easy to install kit allows the use of Mig 41A Push-Pull Torches. Uses 2 pole

plug on front of Mig 4HD Ultra Pulse.

Table 2-1. Mig 4HD Ultra Pulse Specications

Input Power Required ....................................................................4

2 V ac, 5A, 50/60 Hz, 1-phase

Wire Feed Speed Range ............................................................. 50-750 in./min. (1.3-19 m/min.)

Wire Sizes Accommodated:

Hard/Soft ........................................................................023 thru 1/16 in. (0.6 thru 1.6 mm)

Flux Cored .................................................................... .035 thru 3/32-in. (0.9 thru 2.4 mm)

Length ................................................................................................................................. 2

1 in. (54 cm)

Width .......................................................................................................................................9 in. (23 cm)

Height* .............................................................................................................................9.

25 in. (24 cm)

Weight (approx**) ........................................................................................................30 lbs (13.6 kg)

*Add 2-3/4-in. (7 cm) for spindle and spindle arm.

SECTION 2 DESCRIPTION

COVER

DIGITAL VOLTAGE

AND WIRE SPEED

METER

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 4HD Ultra Pulse Wire Feeder

MIG

TORCH

CONNECTOR

RECEPTACLE

DOOR LATCH

WATER OUT

(WATER KIT

INSTALLED)

WATER IN (WATER KIT IN-

STALLED)

POWER "ON"

INDICATOR

WIRE FEED

SPEED AND

VOLTAGE

WIRE SPOOL HUB

VOLTAGE

CONTROL

WIRE FEED

SPEED CONTROL

STANDARD/

PULSE SWITCH

PULSE ARC

TRIM CONTROL

PUSH-PULL

GUN CONTROL

RECEPTACLE

VIEW UNDER TOP COVER

MATERIAL

SELECTOR

CONTROL

JOG/PURGE

SWITCH

SECTION 2 DESCRIPTION

3.1 General.

This section describes the Mig 4HD Ultra Pulse Wire Feeder and the recommended companion equipment and accessories

required to properly operate the Mig 4HD Ultra Pulse. The optional accessories available through ESAB (or your supplier)

will also be addressed.

3.2 Companion Equipment and Accessories.

A. Constant Potential Power Source. Use the Mig 4HD Ultra Pulse with SVI-450i cvcc power source.

B. ESAB Mig Welding Torch. Torch with contact tip, wire conduit and outlet guide for wire size/type to be employed.

A suitable air or water cooled torch may be used with the wire feeder.

When using a water-cooled torch it will be necessary to connect the torch water hose to either a continuous water

supply or to the wire feeder by using an optional water kit (refer to paragraph 2.2).

C. Shielding Gas Regulator/Flowmeter and Fitted Hose to bring gas from owmeter to wire feeder. Such as:

Regulator/Flowmeters:

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

R-5008 CO

, P/N 998125.

D. Drive Roll and Guide Tube. (Refer to Table 1): The Mig 4HD Ultra Pulse wire feeder comes equipped with drive rolls

and a guide tube for aluminum wire sizes 3/64 - 1/16 (1.2 to 1.6 mm). Select other size drive rolls from Table 1 for the

wire size and type to be used.

3.3 Accessories

A. Swivel Post w/Mounting Bracket (P/N 34075). Attaches to Inverter Cart (P/N 31700) or other at mounting surfaces

and allows the wire feeder to freely swivel on the post.

B. Boom Hanging Bracket Kit (P/N 34321). Includes hanging bracket and mounting hardware.

C. Carrying Handle Kit (P/N 34320). Includes handle with rubber grip and mounting hardware.

D. Wire Reel Adapter (P/N 34323). Use with 60 or 65-lbs. (27 or 30 kg) coils.

E. Spool Spacer (P/N 34330). For adapting 10-in (25.4 cm) spools.

F. Spool Cover Kit (P/N 34326). Includes clear cover and mounting hardware.

G. 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 3 EQUIPMENT

Table 1. Drive Roll & Guide Tube Selection

Lower Upper Outlet Center Inlet

Wire Type / Drive Pressure Guide Guide Guide

Diameter Roll Roll Tube Tube Tube

Hard Wires (“V” groove)*

.023 in. (0.6mm) 21155 2361 2368 21163 34612 34615

.030 in. (0.8mm) 21155 2361 2368 21164 34612 34615

.035 in. (0.9mm) 21156 2361 2368 21165 34612 34615

.040 in. (1.0mm) 21156 2361 2368 21165 34612 34615

.045 in. (1.2mm) 21156 2361 2368 21165 34612 34615

.052 in. (1.4mm) 21157 2361 2368 21166 34612 34615

1/16 in. (1.6mm) 21157 2361 2368 21166 34612 34615

Soft (aluminum) Wires (“U” groove)

.030 in. (0.8mm) 21158 2361 2368 21167



34612 34615

.035 in. (0.9mm) 21158 2361 2368 21168



34612 34615

3/64 in. (1.2mm) 21159 2361 2368 21168



34612 34615

1/16 in. (1.6mm) 21159 2361 2368



34612 34615

Top and Bottom Grooved- Aluminum

.035 in. (0.9mm) 36860 36860 21167 34612 34615

3/64 in. (1.2mm) 36860 36860 21168 34612 34615

1/16 in. (1.6mm) 36861 36861



34612 34615

Cored Wires (Serrated “V” groove)

.030 in. (0.8mm) 21160 2361 2369 21164 34612 34615

.035 in. (0.9mm) 21160 2361 2369 21165 34612 34615

.040 in. (1.0mm) 21161 2361 2369 21165 34612 34615

.045 in. (1.2mm) 21161 2361 2369 21165 34612 34615

.045 in. (1.2mm)† 37319 37319 21165 34612 34615

.052 in. (1.4mm) 21161 2361 2369 21166 34612 34615

.052 in. (1.4mm)† 37319 37319 21166 34612 34615

1/16 in. (1.6mm) 21161 2361 2369 21166 34612 34615

1/16 in. (1.6mm)† 37320 37320 21166 34612 34615

5/64 in. (2.0mm) 21162 2361 2369 21166 34613 34616

5/64 in. (2.0mm)† 37320 37320 21166 34613 34616

† Recommended for use with soft cored wires that are easy to atten.

Order both lower drive roll and upper pressure roll.



Requires Support Tube, P/N 21169.



Call Factory for current recommendation.

* If a geared pressure roll is desired, order P/N 23612397.

SECTION 3 EQUIPMENT

4.1 Installation

After checking to be sure you have all required components and accessories (refer to Section 3), refer to Figure 2-1 for con-

nections.

A. Remove input power from Power Source or Interface Box.

B. Hose and Electrical Connections. Connect shielding gas supply hose. When using a watercooled torch, the water

connections shown in Figure 2-1 must also be made. 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 actua-

tion of contactor by some means other than power received through the welding control cable receptacle. Any such

modications must be removed before attaching control cable to power source.

NOTE: When using the Mig 4HD Ultra Pulse with the SVI-450i power source, the SVI-450i must be modied as fol-

lows:

a. Remove top cover from SVI-450i and locate main control PC board. Change hardware jumpers on PC board as shown

below.

FROM: TO:

b. Locate and remove one end of the ORANGE jumper wire between P3-2 and P2-9. Tape exposed end of the wire or

lug with a blind insulated lug.

C. Wire Spool.

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.

J1 J2 J3

J1 & J3 closed

J2 open

J1 open

J2 & J3 closed

J1 J2 J3

SECTION 4 INSTALLATION

This wire feeder should NOT be earth or chassis grounded. The feeded 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 components, causing the PC board to fail.

CAUTION

As with any work area, make sure safety glasses with side shields are worn when

handling or changing wire or clipping wire o at the spool or at the end of the torch.

Hold onto the wire coming o 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.

WARNING

2. Release pressure drive roll assembly and lift upward. Check that proper wire diameter groove is in the inner posi-

tion.

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 gun tting 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 gun liner and cause sticking.

4. Lower pressure roll assembly and secure. Check that the gears mesh. Feed wire through to gun tip using the JOG

switch located under the feeder cover.

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 (located inside hub) clockwise to increase

drag, counterclockwise to decrease it. Drag should be just low enough to limit wire overrun.

SECTION 4 INSTALLATION

D. Drive Rolls. The drive roll has two grooves; the small groove feeds 3/64" (1.2 mm) diameter wire, the large groove

feeds 1/16" (1.6 mm) aluminum wire. The groove nearest the gear motor feeds the wire. If the required groove is not

correctly positioned, perform the following:

1. Release the pressure drive roll levers and lift the assemblies upward.

2. Remove shoulder screw holding each drive roll to the gear.

3. Reverse the drive roll on the drive roll shaft.

4. Replace the screws 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 activated.

WARNING

Before threading welding wire through liner, make sure chisel point and burrs have

been removed from wire end to prevent wire from jamming in gun or liner.

CAUTION

5.1 Adjustments and Operation

5.2 Pulsed Mig Operation

A. Mig 4HD Ultra Pulse

1. Open top cover of Mig 4HD Ultra pulse and set the MATERIAL SELECTOR dial to the wire type and wire diameter

that is being used on the wire feeder.

2. Be sure to use one of the shielding gases that is listed on the Material Selection Table. (see Table 5.1 or wire

compartment of feeder. Close and lock top cover.

3. Place the PULSE/STANDARD toggle switch to the PULSE position.

4. Set the ARC TRIM potentiometer to the “0” or center position.

The ARC TRIM can be used to ne tune the performance by slowly turning the dial counterclockwise to shorten

the arc or clockwise to lengthen the arc.

5. Set the WIRE FEED SPEED dial to a wire feed rate that is within the range listed on the Material Selection

Table.

6. 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.

7. 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. SVI 450i power source set-up.

1. Set up 450i power source for Mig welding as described in instruction manual, F-15-071.

2. Set the SLOPE switch to the STEEP position.

Set the CONTROL switch to the REMOTE position.

C. Feeding Wire. If wire has been threaded through torch and contact tip as directed in Section 4, simply cut o wire,

as required, so that the wire extends about 1/2-inch beyond the end of the torch nozzle.

D. Shielding Gas Flow Rate. Depress gas PURGE switch (located under the feeder cover) and set desired gas ow rate

at the shielding gas regulator-owmeter. Hold switch in at least 15 seconds to insure adequate purging of gas hose

and torch.

Set pre and postow potentiometers for the desired preow interval (range: 0-1 seconds) and postow interval (range:

0 to 7.5 seconds).

SECTION 5 OPERATION

Table 5.1 - Material Selection

Wire Approximate

Material Diameter Wire Speed Range Shielding Gas

Steel .035 85-600 95 AR - 5 CO

.045 55-450 98 AR - 2 CO

AR - CO

- 0

Stainless .035 100-600 98 AR - 2 O

Steel .045 60-400 HE - AR - CO

Aluminum 3/64 120-500 Argon

5XXX 1/16 100-300 Argon-Helium

Aluminum 3/64 120-500 Argon

4XXX 1/16 100-300 Argon-Helium

NOTE: If trigger latch is selected, the torch switch can be released as soon as arc has been struck. When weld is com-

plete, services are discontinued by closing torch switch again.

I. Process control.

1. Use a tip-to-work distance of 5/8" to 3/4". This refers to the distance between the end of the Mig torch contact tip and

the plate or weld puddle.

2. For the best arc stability, keep the arc on the front edge of the molten puddle.

3. The ARC TRIM on the Mig 4HD Ultra Pulse feeder can be used to ne tune the arc performance by slowly turning the

dial counterclockwise to shorten the arc or clockwise to lengthen the arc. If the arc is “uttering” or dicult to control

then shorten the arc by turning the dial counter clockwise.

5.3 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 circuit eective.

-- Burnback circuit energized.

3. Burnback circuit times out (delay determined by setting of Burnback potentiometer).

-- Weld contactor opens.

-- Gas solenoid valve closes.

SECTION 5 OPERATION

E. Use output work cables that are as short as possible. Do not loop or coil the work cables. Excessive lengths or coiled

cables will result in unstable conditions.

F. Proper connection of the work cables to the work is essential for high quality results. Undersized ground clamps, poor

connects, frayed cables, cable splices or clamps attached to rusting or dirty surfaces will result in unstable condi-

tions.

G. Turn the power source “ON” and initiate the welding process by closing the torch trigger.

H. 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 ow. 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 position. If the torch is withdrawn from the work-

piece during welding, the arc will be interrupted, but shielding gas ow and welding wire feed will continue until the

switch lever is released.

WARNING

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 dierence in potential that sends part of the welding

current through the safety ground wiring in the control cable and wire feeder, result-

ing in burnout of that wiring and/or damage to wire feeder circuitry. If the safety

ground burns out, the operator may be exposed to 115 V shock hazard.

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 established by setting of spotweld potentiometer).

-- Wire feed motor deenergized, brake circuit eective.

-- Burnback circuit energized.

3. Burnback circuit times out (interval established by setting of burnback potentiometer).

-- Weld contactor opens.

4. Release torch switch.

-- Gas solenoid valve closes.

C. Pre-ow/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 preow poten-

tiometer. When torch switch is opened, gas solenoid valve remains energized until interval established by setting of

postow 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, momentary closing of the torch switch initiates the sequence

that normally follows opening of that switch.

5.4 Eects of SLOPE on Pulse MIG Arc Stability

Many uncontrollable variables can aect the arc stability of pulse MIG welding. Some examples are:

Long welding cables

High resistance cables and connections

Dierences in shielding gas compositions

Dierences in weld wire chemistry

Water vs. air cooled torches

Base metal surface condition

When these conditions are present, the pulse arc stability is sometimes less than desirable. The arc will “crackle” and produce

higher than normal spatter levels. This occurs due to higher resistances in the welding circuit causing lower than normal

pulse peak currents. The power source SLOPE setting can help overcome these types of situations.

The initial Mig 4HD Ultra Pulse feeder setup should always start with the STEEP slope setting on the power source front

panel. The synergic relationships designed into the Ultra Pulse control are dependent on the STEEP slope setting But, if low

pulse peak currents are suspected, the MEDIUM slope setting can be used to boost the pulse peak current and, in most cases,

remedy the “crackling” pulse arc instability. When using the MEDIUM slope, the synergic relationship of pulse frequency (arc

length) to wire feed speed may not “track” as designed. This means, when the wire feed speed is changed the ARC TRIM

potentiometer will also have to be adjusted. This is normal with changes in the programmed slope setting.

5.5 Standard Operation

The Mig 4HD Ultra Pulse wire feeder provides for both standard welding and pulsed Mig welding. When the STANDARD/

PULSE switch is in the STANDARD position the wire feeder and power source are ready for standard nonpulsed Mig, Tig or

Stick welding.

For standard Mig welding the wire feed speed and power source output (voltage) are independent. Set the wire feed speed

on the wire feeder and the voltage on the front panel of the power source. Voltage can also be set on the wire feeder VOLTS

potentiometer providing that the power source CONTROL switch is in the REMOTE position.

SECTION 5 OPERATION

SECTION 6 MAINTENANCE

6.1 Maintenance.

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 o these parts with dry compressed air. This should be done once for every eight hours of operating

time, more often if necessary.

A. 42 Volt Wire Feeder and Control Circuits.

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 o 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. Accumulation on the rolls may

score the wire with resulting unwanted friction and improper feeding.

Inspect the rolls regularly and clean them with a ne-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.

CAUTION

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 persons to

inspect, clean, or repair this equipment. Use only recommended replacement parts.

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.

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Figure 6-2. Wiring Diagram - Mig 4HD Ultra Pulse Wire Feeder (Sheet 1 of 2)

D-36672-A

SECTION 6 MAINTENANCE

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ESAB Mig 4HD Ultra PulseWire Feeder User manual

Brand: ESAB

Model: Mig 4HD Ultra PulseWire Feeder

Category: Welding System

Type: User manual

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