ESAB Voltage Error Troubleshooting instruction
- Category
- Welding System
- Type
- Troubleshooting instruction
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DATE: June 4, 2003 BULLETIN NO:M_03_011
TITLE/ PRODUCT NAME: Voltage Error with Digital Meter Kit
Installation on MobileMaster IV “Off the arc” Wire Feeder
RATING:
_
_ DIRECTIVE _X_ ALERT
(Action is Required) (Potential Problem)
_
X_ INFORMATION _X_ PRODUCT IMPROVEMENT
(Action is Optional) (Enhanced Product)
_
X_ General Distribution _ _ Business Confidential
(Unrestricted) (Restricted Distribution)
PRODUCT SERIES/ MODEL: Digital Meter Kit (PN – 23540446) and MobileMaster Feeder
MobileMaster IV CC (Euro) 0558001333
MobileMaster IV NAS 0558001334
MobileMaster IV CC (Euro) w/Meters 0558001802
MobileMaster IV NAS w/Meters 0558001801
SERIAL NO: All
SUMMARY: Recent changes made to the MobileMaster to improve reliability and weld performance on
power sources with low OCV, has affected the accuracy of the arc voltage reading when the digital
meter kit is installed into the MobileMaster. The arc voltage will read from 4 to 8 volts lower than the
actual arc voltage at the gun. The following wiring changes to the MobileMaster will correct the volt
meter error and improve accuracy to within +/- 1 volt.
OPERATIONAL IMPACT: Welding performance is not affected by this change but the feeder will be
able to operate at lower open circuit voltages (OCV) thereby extending the wire feed speed operating
range.
ACTION:
• Locate the two bridge rectifiers (BR1 & BR2) mounted to the inside panel of the
MobileMaster IV cvcc PCB compartment.
• Cut the tie-wraps on the wiring harness and remove the yellow jumper wire connected
between the bridge rectifiers from the double spaded connectors on each bridge.
• Move the 2
nd
yellow wire from the front bridge (BR-2) to the rear bridge (BR-1) where the
jumper was just removed and reconnect capacitor and MOV.
• Insert a new wire from the empty terminal of the contactor assembly to the empty terminal of
the Front bridge (BR-2). Route the new wire behind the spool post and gas solenoid,
through the hole on the bottom side of the PCB compartment to the bridge.
• Reassemble unit and weld test. Volt meter should now read within 1 volt accuracy of the
actual arc voltage.
CONTACT:
ESAB Welding & Cutting Products
Product & Service Information Group
843-664-4416 Phone
843-664-5539 FAX
Bridge
Rectifiers
Jumper Ends
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1
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2
ESAB Voltage Error Troubleshooting instruction
- Category
- Welding System
- Type
- Troubleshooting instruction
- This manual is also suitable for
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