ESAB MobileFeed 201 AVS User manual

0558 012 084 20150923 Valid for: serial no.WxxK530XXXX

MobileFeed 201 AVS

US Instruction manual

CA Manuel d'instructions

XL Instrucciones de uso

BR Manual de instruções

Page is loading ...

TABLE OF CONTENTS

0558 012 084 © ESAB AB 2015

1 SAFETY PRECAUTIONS ..................................................................................... 4

2 INTRODUCTION................................................................................................. 10

2.1 Overview ............................................................................................................. 10

2.2 Equipment...........................................................................................................10

3 TECHNICAL DATA ............................................................................................. 10

4 INSTALLATION................................................................................................... 11

4.1 Receiving and handling..................................................................................... 11

4.2 Selection of drive rolls and guide tubes ..........................................................12

4.3 Installing drive rolls and guide tubes...............................................................12

4.4 Installing the welding wire ................................................................................13

4.5 Threading the welding wire...............................................................................14

4.6 Adjusting the brake drag...................................................................................14

4.7 Torch connection ...............................................................................................15

4.8 Supply connections ...........................................................................................16

5 OPERATION ....................................................................................................... 17

5.1 Overview ............................................................................................................. 17

5.2 Connections and control devices.....................................................................18

5.3 Operating procedures........................................................................................21

5.3.1 Operating safety precautions ...........................................................................21

5.3.2 Setting a welding procedure.............................................................................23

5.3.3 Weld data table ................................................................................................23

5.3.4 MobileFeed 201 with CC Power Sources ........................................................24

5.3.5 MobileFeed 201 with CV Power Sources.........................................................24

5.3.6 Shutdown .........................................................................................................25

6 MAINTENANCE.................................................................................................. 25

6.1 Inspection and service ......................................................................................25

6.2 Wire feeder.......................................................................................................... 26

6.3 Solenoid valve replacement..............................................................................26

6.4 Troubleshooting .................................................................................................26

7 ORDERING SPARE PARTS ............................................................................... 27

WIRING DIAGRAM.................................................................................................. 110

WEAR PARTS.......................................................................................................... 111

ORDERING NUMBERS........................................................................................... 112

ACCESSORIES ....................................................................................................... 113

Rights reserved to alter specifications without notice.

1 SAFETY PRECAUTIONS

0558 012 084

- 4 -

1 SAFETY PRECAUTIONS

MEANING OF SYMBOLS

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

DANGER!

Means immediate hazards that, 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!

Read and understand the instruction manual before

installing or operating.

NOTE!

Be sure this information reaches the operator. You can obtain extra copies via

your supplier.

CAUTION!

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

with the principles of operation and safe practices for arc welding equipment, we

urge you to read our booklet, "Precautions and Safe Practices for Arc, 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 before installing or operating

this equipment.

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

manual and accompanying labels and/or insert when installed, operated, maintained and

repaired in accordance with the instruction 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 immediately. Should

such repair or replacement become necessary, the manufacturer recommends that a

telephone or written request for service advice be made to the Authorised Distributor from

whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of

the manufacturer. The user of this equipment shall have the sole responsibility for any

malfunction which results from improper use, faulty maintenance, damage, improper repair or

alteration by anyone other than the manufacturer or a service facility designated by the

manufacturer.

1 SAFETY PRECAUTIONS

0558 012 084

- 5 -

WARNING!

These Safety Precautions are for your protection. They summarise precautionary

information from the references listed in the Additional Safety Information section.

Before performing any installation or operating procedures, be sure to read and

follow the safety precautions listed below as well as all other manuals, material

safety data sheets, labels, etc. Failure to observe the Safety Precautions could

result in injury or death.

PROTECT YOURSELF AND OTHERS

Some welding, cutting and gouging processes are noisy and require

hearing protection. The arc, like the sun, emits ultraviolet (UV) and

other radiation and can injure the 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 fitted with the correct filter and cover plates to protect your eyes, face,

neck and ears from sparks and rays of the arc when operating or observing operations.

Warn bystanders not to look at the arc and not to expose themselves to the rays of the

electric-arc or hot metal.

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

high-topped shoes and a welding helmet or cap for protection, to protect against arc rays

and hot sparks or hot metal. A flameproof apron may also be desirable as protection

against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and

collars should be kept buttoned and open pockets eliminated from the front of the

clothing.

5. Protect other personnel from arc rays and hot sparks using a suitable nonflammable

partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be

hot and can fly for long distances. Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS

The heat from flames and arcs can start fires. Hot slag or sparks can

also cause fires and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials

with a protective nonflammable covering. Combustible materials include wood, cloth,

sawdust, liquid and gas fuels, solvents, paints and coating paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and

cause a hidden smoldering fire or fires on the floor below. Make certain that such

openings are protected from hot sparks and metal.

3. Do not weld, cut or perform other hot work until the workpiece has been completely

cleaned, to ensure there are no substances on the workpiece which might produce

flammable or toxic vapors. Do not perform hot work on closed containers. They may

explode.

4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water

pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.

1 SAFETY PRECAUTIONS

0558 012 084

- 6 -

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can

overheat and create a fire hazard.

6. After completing work, inspect the work area to make sure there are no hot sparks or hot

metal that could cause a fire later. Use fire 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 Protection Association,

Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK

Contact between live electrical parts and earth can cause severe injury

or death. DO NOT use AC welding current in damp areas, if movement

is confined, or if there is danger of falling. Therefore:

1. Be sure the power source frame (chassis) is connected to the earth system of the input

power.

2. Connect the workpiece to a good electrical earth.

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 the workpiece and from earth.

7. Do not stand directly on metal or the ground while working in tight quarters or a damp

area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power, before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding

recommendations. Do not mistake the work lead for a earth cable.

ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor

causes localised Electric and Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables and welding

machines. Therefore:

1. Welders with pacemakers fitted should consult their doctor before welding. EMF may

interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimise 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 the welding power source and cables as far away from your body as possible.

1 SAFETY PRECAUTIONS

0558 012 084

- 7 -

FUMES AND GASES

Fumes and gases, can cause discomfort or harm, particularly in

confined spaces. Do not breathe fumes and gases. Shielding 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 galvanised steel, stainless steel, copper,

zinc, lead beryllium or cadmium unless positive mechanical ventilation is provided. Do

not breathe in the fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc can react with

chlorinated hydrocarbon vapours to form phosgene, a highly toxic gas and other irritant

gases.

3. If you develop momentary eye, nose or throat irritation while operating, this is an

indication that the ventilation is not adequate. Stop work and take the necessary steps to

improve ventilation in the work area. Do not continue to operate if physical discomfort

persists.

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

recommendations.

5. WARNING: This product, when used for welding or cutting, produces fumes or gases

which contain chemicals known to the State of California to cause birth defects and in

some cases cancer (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING

Cylinders, if mishandled, can rupture and violently release gas.

Sudden rupture of 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 fittings in good condition. Follow the manufacturer's operating instructions for

mounting a regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position, by chain or strap, to suitable hand trucks,

undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or

fixtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if

regulator is not connected. Secure and move cylinders by using suitable hand trucks.

4. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of

Compressed Gases in Cylinders," which is available from Compressed Gas Association,

1235 Jefferson Davis Highway, Arlington, VA 22202.

MOVING PARTS

Moving parts, such as fans, rotors and belts can cause injury.

Therefore:

1. Keep all doors, panels and covers closed and securely in place.

2. Have only qualified people remove covers for maintenance and troubleshooting as

necessary

3. Keep hands, hair, loose clothing and tools away from moving parts.

1 SAFETY PRECAUTIONS

0558 012 084

- 8 -

WARNING!

EQUIPMENT MAINTENANCE

Faulty or improperly maintained equipment can cause injury or death.

Therefore:

1. Always have qualified personnel perform the installation, troubleshooting and

maintenance work. Do not perform any electrical work unless you are

qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect

the power source from the incoming electrical power.

3. Maintain cables, earthing wire, connections, power cord and power supply in

safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from

heat sources such as furnaces, wet conditions such as water puddles, oil or

grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

CAUTION!

ADDITIONAL SAFETY INFORMATION

For more information on safe practices for electric arc welding and cutting

equipment, ask your supplier for a copy of "Precautions and Safe Practices

for Arc Welding, Cutting and Gouging," Form 52-529.

The following publications, which are available from the American Welding

Society, 550 N.W. LeJuene Road, 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"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding"

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc welding"

7. AWS SP - "Safe practices" - Reprint, Welding Handbook

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 Attention! Be Alert!

1 SAFETY PRECAUTIONS

0558 012 084

- 9 -

DANGER!

Means immediate hazards that, 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.

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

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

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

○ its operation

○ the location of emergency stops

○ its function

○ the relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is 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 equpment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

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 extinquishing equipment must be clearly marked and close at hand

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

operation

2 INTRODUCTION

0558 012 084

- 10 -

CAUTION!

Read and understand the instruction manual before

installing or operating.

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 such locations, due to conducted as

well as radiated disturbances.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

2.1 Overview

The MobileFeed 201 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 201

AVS is available with two connections, EURO and TWECO. A remote voltage control 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” (0.8 mm) to 5/64” (1.98 mm) 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 201 AVS is supplied with:

• Instruction manual

• Voltage pickup cable with clamp

3 TECHNICAL DATA

NOTE!

The MobileFeed 201 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 201 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 14.0 V DC

4 INSTALLATION

0558 012 084

- 11 -

MobileFeed 201 AVS

Maximum 100 V DC (113 V peak)

Standard spindle hub 2” (5.1 cm) ID

Standard spool 8” (20.3 cm) 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 14.50" × 7.375" × 18.50"

(368.3 × 187.3 × 470 mm)

Weight (with contactor, without spool) 28 lbs (12.7 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

4.1 Receiving 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.

4 INSTALLATION

0558 012 084

- 12 -

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 workpiece 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.

4.3 Installing drive rolls and guide tubes

CAUTION!

Turn off the power source and the wire feeder.

4 INSTALLATION

0558 012 084

- 13 -

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

0558 012 084

- 14 -

1. Remove the spool retainer (1).

2. Put the wire spool (2) on the hub to rotate counterclockwise as the wire unwinds. The

hub pin must engage the hole in the wire spool.

3. Install the spool retainer (1) and hand tighten it.

4.5 Threading the welding wire

CAUTION!

Before threading the wire, make sure that 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 groove 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

0558 012 084

- 15 -

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 the wire is slightly slack when the wire feed stops.

1. Remove the spool retainer (1) by turning it counterclockwise.

2. To increase the braking torque, use a 1 1/16" (27 mm) wrench and turn the drag

adjusting nut (2) clockwise.

3. To reduce the braking torque, use a 1 1/16" (27 mm) wrench and turn the drag adjusting

nut (2) 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 adapter 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 adapter and push it on firmly.

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

4 INSTALLATION

0558 012 084

- 16 -

4.8 Supply connections

CAUTION!

Turn off the power source and the wire feeder.

The MobileFeed 201 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 201 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, possibly fatal injury.

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

the power source and the workpiece.

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

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.

5 OPERATION

0558 012 084

- 17 -

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.

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

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 the handle intended for transportation. Never

pull the equipment by the welding torch.

CAUTION!

Before threading the wire, make sure that the chisel point and burrs have been

removed from the end of the wire to prevent the wire from jamming in the torch

liner.

5 OPERATION

0558 012 084

- 18 -

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.

5.2 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)

5 OPERATION

0558 012 084

- 19 -

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.

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 workpiece. The power source must be turned on

with the contactor closed.

5 OPERATION

0558 012 084

- 20 -

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

2. Circuit breaker, 5 A 4. CC/CV switch

Circuit breaker, 5 A

This resettable 5-amp 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 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 the 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 is used for constant voltage power sources. The selected mode

also affects 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

0558 012 084

- 21 -

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

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.

Page is loading ...

ESAB MobileFeed 201 AVS User manual

ESAB MobileFeed 201 AVS User manual

in other languages

Related papers

Other documents