ESAB MobileMaster 2cv Portable Wire Feeder User manual

Brand: ESAB

Model: MobileMaster 2cv Portable Wire Feeder

Category: Welding System

Type: User manual

MobileMaster 2CV

PORTABLE WIRE FEEDER

INSTRUCTION MANUAL

This manual provides complete instructions for the following unit starting with Serial No. WORI822001:

36654 - MobileMaster 2cv (42 VAC)

Be sure this information reaches the operator.

You can get extra copies through your supplier.

F-15-448

July, 1998

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

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

Safe Practices for Arc Welding, Cutting, and Gouging", Form 52-529. Do NOT permit untrained persons to

install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you

have read and fully understand these instructions. If you do not fully understand these instructions, contact

your supplier for further information. Be sure to read the Safety Precautions on pages 3 and 4 before

installing or operating this equipment.

USER RESPONSIBILITY

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

labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided.

This equipment must be checked periodically. Malfunctioning equipment should not be used. Parts that are broken,

missing, plainly worn distorted or contaminated, should be replaced immediately. Should such repair or replacement

become necessary, ESAB recommends that a telephonic or written request for service advice be made to the ESAB

Authorized Distributor from whom purchased or to the nearest ESAB Sales Office.

This equipment or any of its parts should not be altered without the prior written approval of ESAB. 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 ESAB or a a service facility designated by ESAB.

TABLE OF CONTENTS

SECTION TITLE PAGE

SAFETY PRECAUTIONS ................................................................................. 3-4

SECTION 1 DESCRIPTION .................................................................................................... 7

1.1 General ................................................................................................................ 7

1.2 Receiving-Handling .............................................................................................. 7

1.3 Description ........................................................................................................... 7

1.4 Required Equipment ............................................................................................ 7

1.5 Optional Accessories ........................................................................................... 8

1.6 Safety................................................................................................................... 8

SECTION 2 INSTALLATION ................................................................................................... 9

2.1 Drive Rolls ........................................................................................................... 9

2.2 Welding Wire Spool ............................................................................................. 9

2.3 Torch Connections ............................................................................................. 10

2.4 Supply Connections ........................................................................................... 10

2.5 Threading the Welding Wire .............................................................................. 10

2.6 Brake Drag Adjustment ....................................................................................... 11

SECTION 3 OPERATION ...................................................................................................... 12

3.1 Adjustment and Operations................................................................................ 12

3.1.1 Control Setting ................................................................................................... 12

3.1.2 Feeding Wire ..................................................................................................... 12

3.1.3 Shielding Gas Flow Rate .................................................................................... 12

3.1.4 Making the Weld ................................................................................................ 13

3.2 Optional Meter ................................................................................................... 13

3.3 Operating Safety Precautions ............................................................................ 13

3.4 Shutdown ........................................................................................................... 13

SECTION 4 MAINTENANCE ................................................................................................ 14

4.1 Maintenance ...................................................................................................... 14

4.2 Inspection and Service ....................................................................................... 14

4.2.1 42 Volt Wire Feeder and Control Circuits ........................................................... 14

4.2.2 Wire Feeder ....................................................................................................... 14

4.2.3 Drive Roll Pressure Adjustment ......................................................................... 14

4.2.4 Solenoid Valve Replacement ............................................................................. 14

4.2.5 General Replacement ........................................................................................ 14

4.3 Troubleshooting ................................................................................................. 15

SECTION 5 REPLACEMENT PARTS ................................................................................... 18

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary information from the references listed in

Additional Safety Information section. Before

performing any installation or operating procedures, be

sure to read and follow the safety precautions listed below

as well as all other manuals, material safety data sheets,

labels, etc. Failure to observe Safety Precautions can result

in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.

Training in the proper use of the processes and equip-

ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

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

are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from

sparks and rays of the arc when operating or observing

operations. Warn bystanders not to watch the arc and

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

or hot metal.

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

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

ing helmet or cap for hair protection, to protect against

arc rays and hot sparks or hot metal. A flameproof apron

may also be desirable as protection against radiated

heat and sparks.

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

trouser cuffs, or pockets. Sleeves and collars should be

kept buttoned, and open pockets eliminated from the

front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

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

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot slag

or sparks can also cause fires and ex-

plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable covering. Combustible materials include wood,

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

coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden

smoldering fire or fires on the floor below. Make certain

that such openings are protected from hot sparks and

metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might pro-

duce flammable or toxic vapors. Do not do hot work on

closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

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

portable fire extinguisher. Be sure you are trained in its

use.

SAFETY PRECAUTIONS

11/95

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

overloaded welding cable can overheat and create a fire

hazard.

6. After completing operations, inspect the work area to

make certain there are no hot sparks or hot metal which

could cause a later fire. Use fire watchers when neces-

sary.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Pro-

cesses", available from the National Fire Protection Asso-

ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live

electrical parts and ground can cause

severe injury or death. DO NOT use AC

welding current in damp areas, if move-

ment is confined, or if there is danger of

falling.

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

to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or

missing connection can expose you or others to a fatal

shock.

4. Use well-maintained equipment. Replace worn or dam-

aged cables.

5. Keep everything dry, including clothing, work area, cables,

torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from

work and from ground.

7. Do not stand directly on metal or the earth while working

in tight quarters or a damp area; stand on dry boards or

an insulating platform and wear rubber-soled shoes.

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

9. Turn off the power before removing your gloves.

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

for specific grounding recommendations. Do not mistake

the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —

May be dangerous. Electric current flow-

ing through any conductor causes lo-

calized Electric and Magnetic Fields

(EMF). Welding and cutting current cre-

ates EMF around welding cables and

welding machines. Therefore:

1. Welders having pacemakers should consult their physi-

cian before welding. EMF may interfere with some pace-

makers.

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

unknown.

3. Welders should use the following procedures to minimize

exposure to EMF:

A. Route the electrode and work cables together. Secure

them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded.

E. Keep welding power source and cables as far away

from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in confined spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by

natural or mechanical means. Do not weld, cut, or gouge

on materials such as galvanized steel, stainless steel,

copper, zinc, lead, beryllium, or cadmium unless 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 irritation

while operating, this is an indication that ventilation is not

adequate. Stop work and take necessary steps to im-

prove ventilation in the work area. Do not continue to

operate if physical discomfort persists.

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

for specific ventilation recommendations.

CYLINDER HANDLING -- Cylinders, if

mishandled, can rupture and violently

release gas. Sudden rupture of cylin-

der, valve, or relief device can injure or

kill. Therefore:

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

pressure reducing regulator designed to operate from

the compressed gas cylinder. Do not use adaptors.

Maintain hoses and fittings in good condition. Follow

manufacturer's operating instructions for mounting regu-

lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain

or strap to suitable hand trucks, undercarriages, benches,

walls, post, or racks. Never secure cylinders to work

tables or fixtures where they may become part of an

electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or im-

properly maintained equipment can cause

injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, troubleshooting, and maintenance work. Do not

perform any electrical work unless you are qualified to

perform such work.

2. Before performing any maintenance work inside a power

source, disconnect the power source from the incoming

electrical power.

3. Maintain cables, grounding wire, connections, power cord,

and power supply in safe working order. Do not operate

any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces, wet

conditions such as water puddles, oil or grease, corrosive

atmospheres and inclement weather.

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

in good repair.

6. Use equipment only for its intended purpose. Do not

modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for elec-

tric arc welding and cutting equipment, ask

your supplier for a copy of "Precautions and

Safe Practices for Arc Welding, Cutting and

Gouging", Form 52-529.

The following publications, which are available from the

American Welding Society, 550 N.W. LeJuene Road, 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 Weld-

ing and Cutting of Containers That Have Held Hazardous

Substances."

This symbol appearing throughout this manual

means Attention! Be Alert! Your safety is

involved.

The following definitions apply to DANGER, WARNING,

CAUTION found throughout this manual:

Used to call attention to immediate haz-

ards which, if not avoided, will result in

immediate, serious personal injury or loss

of life.

Used to call attention to potential haz-

ards which could result in personal injury

or loss of life.

Used to call attention to hazards which

could result in minor personal injury.

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SECTION 1 DESCRIPTION

1.1 GENERAL

This manual has been prepared especially for use in

familiarizing personnel with the design, installation,

operation, maintenance, and troubleshooting of this

equipment. All information presented here-in should be

given careful consideration to assure optimum perfor-

mance of this equipment.

1.2 RECEIVING-HANDLING

Prior to 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 car-

rier. A copy of the bill of lading and freight bill will be

furnished by the carrier on request if occasion to file

claim arises.

1.3 DESCRIPTION

The MobileMaster 2cv Wire Feeder described in this

manual is designed for short arc, spray arc mig or cored

wire welding with a constant potential (CP) welding

power source.

Secondary input from the Power Source can be DC

+ or DC - depending on the requirements of the

wire type being used.

The MobileMaster 2cv uses a PM wire drive motor

designed to feed wires from .023 to 5/64 inches in di-

ameter. Rate of wire feed (50 - 700 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 standard features of the MobileMaster 2cv wire

are as follows:

 2-roll geared drive stand

 One drive roll and one pressure roll

 Internal gas solenoid

 Euro style torch connection

 Power ON/OFF switch

 Wire feed speed potentiometer

 Voltage control potentiometer

 Remote Power source voltage control

1.4 REQUIRED EQUIPMENT

1.4.1 Constant potential power source. Use the

MobileMaster 2cv with power sources such as: 452cv,

SVI-450i cvcc, 652 cvcc.

1.4.2 Control Cables. Multi-conductor cable with 19-

pin amphenol plug and receptacle.

 25-foot (7.6m) P/N 36663

 50-foot (15.3m) P/N 36664

 100-foot (30.6m) P/N 36659

1.4.3 115 V ac to 42 V ac Interface (P/N 34351). Adapts

to power sources with only 115 V ac auxiliary and

contactor. Includes interface box and adapter cables

for power sources not equipped with 42 vac control

circuitry.

1.4.4 MT-200cc or MT-400cc Mig Welding Torch.

Torch with contact tip, wire conduit and outlet guide for

wire size/type to be employed. A suitable air cooled

torch with a Euro-style connector (cc) may be used

with the wire feeder.

1.4.5 Shielding gas regulator/flowmeter and fitted

hose to bring gas from flowmeter to wire feeder. Such

as:

Regulator/Flowmeters:

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

R-5008 CO

, P/N 998125.

1.4.6 Drive Roll and Guide Tube. (Refer to Table 2.1):

The wire feeder comes equipped with a drive roll and a

guide tube for wire sizes .035 to .045 (0.9 to 1.2mm).

TABLE 1-1. SPECIFICATIONS

Input Power Required ...................................................................................42 V ac, 5A, 50/60 Hz, 1-phase

Wire Feed Speed Range ............................................................................. 50-700 in./min. (1.3--18 m/min.)

Wire Sizes Accommodated:

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

Flux Cored ....................................................................................... .035 thru 5/64 in. (0.9 thru 2.0mm)

Length ................................................................................................................................ 26.9 in. (683mm)

Width.................................................................................................................................... 9.5 in. (241mm)

Height* ............................................................................................................................... 14.0 in. (356mm)

Weight ..................................................................................................................................... 26-lbs. (12kg)

The MobileMaster 2cv will fit through a 16 (406mm) dia. Hole.

Select other size drive rolls from Table 1 for the wire

size and type to be used.

1.5 OPTIONAL ACCESSORIES

1.5.1 Argon Flowmeter Kit, P/N 36658; CO

Flow-

meter Kit, P/N 37365 - These kits include an adjust-

able flowmeter with a protective guard and mounting

hardware for mounting to rear of MobileMaster unit.

1.5.2 Digital Meter Kit, P/N 23540446 - This LCD

meter is simple to mount and displays welding voltage

while welding or preset and actual wire feed speed.

1.5.3 Gas Pre/Postflow with Burnback Kit, P/N

36661 - This kit provides adjustment for shielding gas

preflow and postflow times. Adjustable burnback stops

the wire feed before the arc is stopped to keep the wire

from sticking to the weld.

1.5.4 Burnback Control Kit, P/N 36657 - This kit has

adjustable burnback control for stopping the wire feed

before the arc stops.

1.5.5Crater Control Kit, P/N 36660 - This kit provides

separate settings of wire feed speed and voltage for

crater fill control.

1.5.6 Spool Adaptor, 8-in. Spool, P/N 17511

Spool Adaptor, 10-in. Spool, P/N 34330

Coil Adaptor, 14-lb. Coil, P/N 37337

Required if using wire from a 8 or 10-in. spool or 14-lb.

(6.4 kg) coil.

1.6 SAFETY

Before the equipment is put into operation, the safety

section at the front of this manual should be read com-

pletely. This will help avoid possible injury due to mis-

use or improper welding applications.

SECTION 1 DESCRIPTION

SECTION 2 INSTALLATION

2.1 DRIVE ROLLS

The unit is supplied ready to feed 0.035 and 0.045 (0.9

and 1.6mm) diameter hard wires. (Other drive rolls are

available to feed other sizes of hard wire, soft wire, and

cored wire. See Table 2.1.) The drive roll has two grooves;

the small groove feeds 0.035 diameter wire, the large

groove feeds 0.045 diameter wire. The groove nearest

the gear motor feeds the wire. If the required groove is

not in that position or a different drive roll is required:

A. Release the pressure roll assembly lever and lift

the assembly upward.

B. Remove the screw holding the drive roll to the gear

motor shaft.

C. Remove the drive roll and reverse or replace with

the required size for the wire chosen.

D. Secure the screw removed in B and tighten.

E. Secure the pressure roll assembly.

2.2 WELDING WIRE SPOOL

Install a spool of welding wire on the hub as follows:

A. Unscrew the spool nut from the hub.

B. Place the wire spool on the hub to rotate clock-

wise as the wire is unwound; hub pin must engage

the hole in the wire spool.

C. Screw the spool nut into the hub.

NOTE: If using wire from an 8 or 10-in. spool or from a

14-lb. coil, install proper adaptor (see 1.5.6).

Table 2-1. Drive Roll & Guide Tube Selection

Upper

Wire Type / Lower Pressure Guide

Diameter Drive Roll Roll Tube

Hard Wires (V groove)

.023 in. (0.6mm) 21155 2361 2397 21163

.030 in. (0.8mm) 21155 2361 2397 21164

.035 in. (0.9mm) 21156 2361 2397 21165

.040 in. (1.0mm) 21156 2361 2397 21165

.045 in. (1.2mm) 21156 2361 2397 21165

.052 in. (1.4mm) 21157 2361 2397 21166

1/16 in. (1.6mm) 21157 2361 2397 21166

Soft (aluminum) Wires (U groove)

.035 in. (0.9mm) 21158 2361 2397 21167**

3/64 in. (1.2mm) 21159 2361 2397 21168**

1/16 in. (1.6mm) 21159 2361 2397 Not Reqd

Cored Wires (Serrated V groove)

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

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

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

.045 in. (1.2mm)* 21161 2361 2369 21165

.045 in. (1.2mm) 37319 37319 21165

.052 in. (1.4mm)* 21161 2361 2369 21166

.052 in. (1.4mm) 37319 37319 21166

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

1/16 in. (1.6mm) 37320 37320 21166

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

5/64 in. (2.0mm) 37320 37320 21166

* Supplied with MobileMaster wire feeder.

 Recommended for use with soft cored wires that are easy to flatten.

Order both lower drive roll and upper pressure roll.

** Requires Support Tube 21169.

Figure 2.1 - Inside View of MobileMaster 2cv

WIRE

SPOOL HUB

WELDING CABLE

CONNECTION

PRESSURE

ROLL

TORCH

CONNECTION

DRIVE

ROLL

GUIDE TUBE

LOCATION for OPTIONAL PRE/

POSTFLOW OR BURNBACK KIT

LOCATION for OPTIONAL

CRATER CONTROL KIT

SECTION 2 INSTALLATION

B. Connect a second welding cable to the opposite

polarity output connection on the power source and

to the work piece.

C. Connect control cable (see 1.4.2) to MobileMaster

2cv and to power source.

D. If using with gas shielded wire, connect the inlet

gas hose to the gas inlet connections on the rear

of the feeder.

1. Make sure all hose and cable connections are

tight.

2. Turn power source ON.

3. Turn the wire feeder ON and close the torch

trigger.

Unless starting to weld, do not allow the welding

wire to touch a grounded metal surface. The weld-

ing wire becomes electrically hot when the weld-

ing power source is turned on and the contactor is

closed. Keep fingers clear of the drive rolls; they

will start turning when the torch trigger is pressed.

4. Inspect all gas connections for leaks.

5. If using gas shielded wires, adjust the gas flow-

meter to the desired flow rate.

6. Turn power source and wire feeder OFF.

2.5 THREADING THE WELDING WIRE

When the wire feeder is connected to the power

source and the power source is turned on, the wire

feeder is energized when the wire feeder is turned

on. Closing the torch trigger will cause the weld-

ing wire to become electrically hot, and will cause

the drive rolls to turn. Keep fingers clear!

2.3 TORCH CONNECTIONS

The torch adaptor on the MobileMaster connects di-

rectly to the wire feeder wire drive assembly, the weld-

ing power, torch trigger connections and shielding gas

supply. Line up the respective pins on the torch con-

nector with the wire feeder adaptor, push on firmly and

hand tighten the locking collar.

Make sure the torch chosen is of the proper rating

for the welding current to be used, has the proper

size and type of liner, the proper contact tip and

the proper guide tube.

2.4 SUPPLY CONNECTIONS (See Figure 2.2)

Before making any connections between the wire

feeder and the welding power source, turn off

power to the welding power source and the wire

feeder.

A. Connect the proper polarity output welding cable

from the power source; positive terminal for gas

shielded wires, or negative for most gasless self-

shielded cored wires, to the weld cable lug

connection extending from the rear of the

MobileMaster 2cv feeder.

Be sure to properly insulate this connection

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 shock, possibly fatally.

Figure 2.2 - Typical Set-up of MobileMaster 2cv

- (or +) + (or -)

CONTROL CABLE ASSEMBLY

(See 1.4.2)

SECTION 2 INSTALLATION

A. Turn OFF the power source and the wire feeder.

B. Release the pressure roll assembly lever and

check for the proper drive roll and groove posi-

tion.

Before threading welding wire through the casing,

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 casing or liner.

C. Feed the wire from the spool through the inlet guide

along the drive roll groove and into the torch inlet

guide.

D. Lower the pressure roll assembly and adjust the

drive roll pressure to assure no wire slippage, but

not too tight to create excess pressure.

E. Turn ON the power source and the wire feeder.

Close the torch trigger to feed wire through the

torch.

2.6 BRAKE DRAG ADJUSTMENT

Brake disc friction should provide enough drag to keep

the wire spool from spinning freely after the wire feed

stops. If adjustment is required, turn the adjusting screw

clockwise to increase drag, counterclockwise to de-

crease drag. Drag should be just enough to limit wire

overrun.

SECTION 3 OPERATION

3.1 ADJUSTMENTS AND OPERATIONS

3.1.1 CONTROL SETTING

1. Set voltage control on the power source to the

appropriate setting. Set to remote for control

from the wire feeder.

2. Apply power to wire feeder.

3. Set the wire feed rate and voltage by adjusting

the WIRE FEED SPEED and VOLTS control

knobs on the front panel.

4. If optional pre/postflow/burnback Kit (36661)

is installed, set the BURNBACK control to the

desired setting (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.

3.1.2 FEEDING WIRE

If wire has been threaded through torch and con-

tact tip as directed in Section 2.5, simply cut off

wire, as required, so that the wire extends about

1/2-inch beyond the end of the torch nozzle.

3.1.3 SHIELDING GAS FLOW RATE

Release drive roll pressure arm. Depress gas torch

switch and set desired gas flow rate at the shield-

ing gas regulator-flowmeter. Hold switch in at least

15 seconds to insure adequate purging of gas hose

and torch. Secure the drive roll pressure arm.

If installed, set pre and postflow potentiometers for

the desired preflow interval (range: 0 to 1.5 sec-

onds) and postflow interval (range: 0 to 7.5 sec-

onds).

3.1.4 MAKING THE WELD

Start to weld by pressing the torch switch lever to

actuate the torch switch. This closes the welding

contactor, and starts wire feed and gas flow. Then

touch the end of the welding wire to the workpiece

to establish the arc. The switch lever must be de-

pressed for the duration of the weld. Welding ac-

tion will be stopped and all services discontinued

when the lever is released and returns to its origi-

nal position. If the torch is withdrawn from the work-

piece during welding, the arc will be interrupted,

but shielding gas flow and welding wire feed will

continue until the switch lever is released.

If the optional Crater Control Kit (36660) is installed,

and crater control switch is in the AUTO position,

the wire feeder will change to crater condition after

releasing torch switch from normal welding and

continue to weld until the torch switch is depressed

again to terminate the weld.

3.2 OPTIONAL METER

The optional meter allows for monitoring the arc volt-

age or wire feed speed while welding.

Figure 3.1 - Controls and Connections, MobileMaster 2cvcc

5A CB

OPT. METER KIT

POWER ON-OFF

SWITCH

WIRE SPEED

CONTROL

TORCH

CONNECTION

WELDING CABLE

CONNECTION

(Figure 2.1)

SHIELD GAS

CONNECTION

VOLTAGE

CONTROL

19-PIN RECEPTACLE

3.3 OPERATING SAFETY PRECAUTIONS

Comply with all ventilation, fire and other safety require-

ments for arc welding as established in the SAFETY

Section at the front of this manual.

A. 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 hel-

met. The helmet filter plate should be shade num-

ber 11 (nonferrous) or 12 (ferrous). All those view-

ing the arc should use helmets with filter plates, as

well as flash goggles. Nearby personnel should

wear flash goggles.

B. The radiant energy of the arc can be decomposed

by chlorinated solvent vapors, such as

trichloroethane and perchlorethylene, to form phos-

gene, even when these vapors are present in low

concentrations. DO NOT weld where chlorinated

solvents are present in atmospheres in or around

the arc.

C. DO NOT touch the electrode, contact tip or metal

parts in contact with them 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.

D. 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 ap-

proved oxygen measuring instrument. The con-

fined 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.

E. Never operate the equipment at currents greater

than the rated ampere capacity. Overheating will

occur.

SECTION 3 OPERATION

F. 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.

G. Whenever the equipment is left unattended, turn

all control and power supply switches and gas sup-

plied OFF and open the main line switch.

H. Wear dark substantial clothing to protect exposed

skin from arcburn, sparks and flying hot metal.

I. Turn off welding power before adjusting or replac-

ing electrodes.

When the power switch is ON, and torch trigger is

depressed, 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 wire to touch

a grounded metal surface as it will cause an arc

flash. Keep clear of feed rolls and drive gears.

Prior to welding, it is imperative that proper pro-

tective clothing (welding coat and gloves) and eye

protection (glasses and/or welding helmet) be put

on. Failure to comply may result in serious injury.

Do not terminate the arc by removing the torch from

the weld area. Release the torch trigger to stop

welding before removing the torch.

Failure to shut OFF shield gas in a confined space

may result in a build-up of fumes, displacing oxy-

gen.

3.4 SHUTDOWN

A. Release torch trigger and break the arc.

B. When leaving the Equipment unattended, always

shut OFF and disconnect all power to the Equip-

ment and shut off the shielding gas supply at

source.

SECTION 4 MAINTENANCE

4.1 MAINTENANCE

Be sure the branch circuit or main disconnect

switch is OFF or electrical input circuit fuses are

removed from the power source main supply be-

fore attempting any inspection or work on the in-

side of the wire feeder. Placing the power switch

on the welding machine in the OFF position does

not remove all power from inside of the equipment.

Inspection, troubleshooting, and repair of this

equipment should be undertaken by a competent

individual having at least general experience in the

maintenance and repair of semi-conductor elec-

tronic equipment. Maintenance or repair should not

be undertaken by anyone not having such qualifi-

cations.

Shut OFF shielding gas supply at source.

To aid in checking and servicing, use Schematic, Fig-

ure 4.1.

4.2 INSPECTION AND SERVICE

Keep equipment in clean and safe operating condition,

free of oil, grease, and (in electrical parts) liquid and

metallic particles which can cause short-circuits.

Regularly check cylinder valves, regulators, hoses, and

gas connections for leaks with soap solution.

Check for and tighten loose hardware including elec-

trical connections. Loose power connections overheat

during welding.

Immediately replace all worn or damaged power cables

and connectors. Check for frayed and cracked insula-

tion, particularly in areas where conductors enter Equip-

ment.

The electrode wire and all metal parts in contact with it

are electrically energized while welding. Inspect these

parts periodically for defective insulation and other elec-

trical hazards.

If uninsulated cable and parts are not replaced, an

arc caused by a bared cable or part touching a

grounded surface may damage unprotected eyes

or start a fire. Body contact with a bared cable,

connector, or uncovered conductor can shock,

possibly fatally.

Keep power cables dry, free of oil and grease, and pro-

tected at all times from damage by hot metal and

sparks.

Clean dirt and metal particles from drive roll groove

weekly; replace roll if badly worn.

4.2.1 42 VOLT WIRE FEEDER AND CONTROL CIR-

CUITS

The 42-volt circuit is protected by a 5 amp circuit

breaker located on the front panel of the wire feeder.

Failure of this circuit breaker will shut off the contactor,

shielding gas, and wire feeder.

If it should become necessary to replace the 5 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.

4.2.2 WIRE FEEDER

When 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 im-

proper feeding.

Inspect the rolls regularly and clean them with a fine-

wire power brush. Avoid roughening, or removing the

hardness, of groove surfaces in grooved rolls. Any

roughening may score the wire, just as the accumula-

tion being removed may do.

4.2.3 DRIVE ROLL PRESSURE ADJUSTMENT

Adjust the drive roll pressure knob until no wire slip-

page occurs. DO NOT OVERTIGHTEN - EXCESSIVE

PRESSURE CAN CAUSE WIRE FEEDING PROB-

LEMS.

4.2.4 SOLENOID VALVE REPLACEMENT

If there is no gas flow through the wire feeder, the gas

solenoid valve 13792051 (42V) may be clogged or elec-

trically malfunctioning and it should be replaced. When

replacing the gas solenoid valve, the inlet (with the word

IN) must face the rear of the unit.

4.2.5 GENERAL REPLACEMENT

The exploded views in the Parts Section indicate gen-

erally, in numbered parts sequence, the disassembly

of the wire drive and feeder parts.

Reassemble in reverse order.

4.3 TROUBLESHOOTING

If welding equipment doesnt work right despite com-

pliance with check list, inspect as follows:

A. With all power controls ON and other operating

controls at required settings, visually check all

power cables and connections for evidence of over-

heating or sparking.

To avoid shock, do not touch electrode wire or parts

in contact with it, or uninsulated cable or connec-

tions.

B. Check all gas hoses and connections, flowmeters,

and regulators for possible sources of leakage,

breakdown, or intermittent failure.

SECTION 4 MAINTENANCE

C. Isolate trouble to one part of the welding installa-

tion: primary power supply, power source, wire

feeder, or wire guide train (casing, drive rolls, lin-

ers, and contact tip). If this inspection indicates

trouble in the wire feeder, use schematic diagram,

Figure 4.1.

Many troubleshooting situations require that the

power remain on and that power terminals in the

equipment carry voltage. Exercise extreme caution

when working on live equipment. Avoid contact

with electrical components, except when testing

with an appropriate instrument.

Do not make any repairs to equipment unless you

are fully qualified, as described in the maintenance

section.

Page is loading ...

5.1 GENERAL

Always provide the series or serial number of the unit

on which the parts will be used. The serial number is

stamped on the unit nameplate.

5.2 ORDERING

To assure proper operation, it is recommended that

only genuine ESAB parts and products be used with

this equipment. The use of non-ESAB parts may void

your warranty.

Replacement parts may be ordered from your distribu-

tor or from:

ESAB Welding & Cutting Products

Attn: Customer Service Dept.

P.O. Box 100545

Ebenezer Road

Florence, SC 29501-0545

Be sure to indicate any special shipping instructions

when ordering replacement parts.

To order parts by phone, contact ESAB at 1-843-664-

5540 or 4460. Orders may also be faxed to 1-800-634-

7548. Be sure to indicate any special shipping instruc-

tions when ordering replacements parts.

Refer to the Communication Guide located on the last

page of this manual for a list of customer service phone

numbers.

SECTION 5 REPLACEMENT PARTS

Figure 5.1 - MobileMaster 2cv, Front/Right Side View

36654

Item Qty Part Description CKT.

No. Req. No. Desig.

1 1 952680 CASE MOLDED

2 2 13730632 POT. LIN 10K 2W R1, 2

3 2 13730611 KNOB

4 1 32292 PANEL CONTROL SILKSCREENED

5 1 34141BK COVER OPTION UPPER FRONT

6 1 952626 HANDLE FOLDING 2 POS.

7 2 37334 NUT HANDLE W/SHOULDER

8 1 2062161 CIRCUIT BREAKER 5 AMP CB1

10 1 13732469 SWITCH TOGGLE SPST 2 POS 20A 125V S1

11 1 951474 SWITCH SEAL BLACK

12 1 37333 HOLDER GUN

13 1 23610528 HOUSING

14 1 23610696 ADAPTOR BLOCK ASSY J5

15 1 23612590 CONNECTION TUBE

6, 7

2, 3

10, 11

Page is loading ...

Figure 5.2 - MobileMaster 2 cvcc, Right Inside View

Item Qty Part Description CKT.

No. Req. No. Desig.

31 1 952684 LATCH LIFT/TURN

32 1 37378BK TAB LATCH

33 1 64309431 WASHER .250

34 1 952627 PLATE BACKING LATCH

35 1 954760 LABEL WARNING ROLL PINCH HAZARD

36 1 37327 HINGE LIVING (18 - RIVET PLASTIC EXPANSION 952686)

37 1 58V58 ADAPTOR B/IGF X 1/4 NPTM

38 1 44251100 ELBOW PIPE 90° 1/4 BRS

39 1 2232017 NIPPLE 1/4 NPTM X 1/4 ID HOSE

40 1 31463 CONTROL BOARD ASSY PCB1

41 1 SPOOL HUB ASSY (See Figure 5.4)

42 1 37254BK SUPPORT WIRE REEL

43 1 951530 MOTOR KSV 5035/388 M1

44 1 37258 PLATE BLANKING UPPER (Removed to show inside)

45 1 37257 PLATE BLANKING LOWER (Removed to show inside)

46 1 23612627 DRIVE STAND ASSY (See Figure 5.3)

47 1 34198 PLATE SHIM (Behind Drive Stand)

48 1 954698 LABEL WARNING GEAR PINCH HAZARD

49 1 21166 GUIDE TUBE .052 - 1/16 (See Table 2.1)

50 2 952687 STUD RUBBER PLATE MOUNT (Under Item 42)

51 1 13792051 VALVE SOLENOID SOL1

52 1 951174 CLAMP 1 EAR 10.0

53 1 952860 CLAMP 1 EAR 12.8 w/insert

54 1 950762 RECEPT. PANEL MT 19 PIN SOLDER TYPE (on rear panel) P1

55 1 950626 CLAMP 1 EAR 13.3 w/insert

56 1 993717 TRANSFORMER 117V T1

57 1 13730469 RECT. 35A 400V BR1

SECTION 5 REPLACEMENT PARTS

Figure 5.3 - 2 Roll Drive Stand

Item

No. Qty

Part

No. Description

23612627

23612626

23612387

23612475

23612385

23612470

23612472

23612386

23612460

23612473

23612461

23612383

23612398

23612478

23612479

23612480

23612384

23612462

23612662

23612663

2 ROLL GEARED WIRE DRIVE SYSTEM, CONSISTS OF:

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

AXLE, PRESSURE ROLL

PRESSURE ARM

CIRCLIP, PRESSURE ROLL

PIVOT PIN

CIRCLIP

PRESSURE ROLL, SMOOTH (see Table 2.1)

GEARED ADAPTOR, PRESSURE ROLL

PRESSURE DEVICE ASSY.

LOCATING PIN

INLET GUIDE

DRIVE ROLL, (see Table 2.1)

GEARED ADAPTOR DRIVE ROLL

FEED ROLL RETAINING SCREW

FEED PLATE

FEED ROLL KEY

MOTOR SHAFT SNAP RING (Not Shown)

LOCATING SCREW

SCREW

SPACER TUBE (Pressure Arm)

SPRING PRESSURE ARM

73, 76

SECTION 5 REPLACEMENT PARTS

Figure 5.4 - Wire Spool Hub Assembly

Item

No.

Qty

Req.

Part

No. Description

Ckt.

Symbol

92040101

23600010

64304125

23600952

23606237

23600255

36756

23600982

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

NUT, PLASTIC

WASHER, FLAT 3/8"

WASHER

HUB REEL

BRAKE DISC

"D" SHAFT

SPRING

SECTION 5 REPLACEMENT PARTS

As of Feb. 4, 1998

QTY

RECOMMENDED SPARES LISTING NO. OF UNITS TO MAINTAIN

ITEM PER FOR TWO YEARS RUNNING 1 10 25 50-+

NUMBER AY DESCRIPTION UNIT UNITS UNITS UNITS

36756 1 REEL HUB, D SHAFT 1 3 5

31463 1 PCB MOBILEMASTER 2CV 1 3 5

13732469 1 TOGGLE SWITCH SPST 2POS 1 3 5

951474 1 SWITCH SEAL 1 2 6 10

951530 1 MOTOR TYP KSV 503-2DR 1 3 5

13792051 1 SOLENOID VALVE, 42V 1 2 3

13730469 1 RECT *** *** *35A 1 2 4

13730611 2 KNOB 1 2 4 8

13730632 2 POT LIN *10.0K 1 3 5

2062161 1 CIRC. BREAKER 5 AMP 1 2 5 10

23600010 1 PLASTIC NUT 2 5 10

23600255 1 BRAKE DISC 2 5 10

23600952 1 WASHER D-TYPE 2 5 10

23600982 1 SPRING, BRAKE 2 5 10

23606237 1 REEL HUB 2 5 10

23610696 1 EURO ADAPTER BLOCK 1 2 3

23612383 *1 GEARED ADAPTER, DRIVE ROLL 2 5 10

23612384 *2 LOCATING SCREW, DRIVE ROLL 2 4 10 20

23612385 *1 CIRCLIP, AXLE, PRESSURE ROLL 1 3 5

23612386 *1 GEARED ADAPTER, PRESSURE ROLL 2 5 10

23612387 *1 AXLE, PRESSURE ROLL 1 3 5

23612398 *1 RETAINING SCREW, DRIVE ROLL 1 2 5 10

23612460 *1 PRESSURE DEVICE WITH SCALE 1 3 5

23612462 *5 SCREW 1 5 13 25

23612470 *1 LOCATING PIN, PRESSURE DEVICE 1 3 5

23612472 *2 CIRCLIP, LOCATING PIN, PRESSURE ARM 2 5 10

23612473 *1 LOCATING PIN, PRESSURE ARM 1 3 5

23612475 *1 PRESSURE ARM 1 3 5

23612478 *1 FEED PLATE 1 3 5

23612479 1 FEED ROLL KEY 1 3 5

23612590 1 CONNECTION TUBE ASSY. 2 4 8

23612626 *1 PRESSURE ARM GEARED COMPLETE, R. H. 2 5 10

23612627 1 DRIVE STAND ASSY (SEE NOTE-*) 1 2 3

23612662 *1 SPACER TUBE, PRESSURE ARM 1 3 5

23612663 *1 SPRING, PRESSURE ARM, 2DR STAND 1 3 5

92040101 1 SCREW R.H. SLOTTED 3/8-16 X 0.75" 1 2 5 10

AS REQD. 1 DRIVE ROLL (21161 SUPPLIED STANDARD) AS REQUIRED

AS REQD. 1 INLET GUIDE (21166 SUPPLIED STANDARD) AS REQUIRED

AS REQD. 1 PRESSURE ROLL (23612397 SUPPLIED STANDARD) AS REQUIRED

*-DENOTES ITEM IS PART OF 23612627 DRIVE STAND KIT

MobileMaster 2cv

F-15-448 7/98 Printed in U.S.A.

ESAB MobileMaster 2cv Portable Wire Feeder User manual

Brand: ESAB

Model: MobileMaster 2cv Portable Wire Feeder

Category: Welding System

Type: User manual

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ESAB MobileMaster 2cv Portable Wire Feeder User manual

ESAB MobileMaster 2cv Portable Wire Feeder User manual

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