ESAB Mig 4HD Wire Feeder User manual

Category
Welding System
Type
User manual
This manual provides instructions for units: P/N 34154, Mig 4HD Wire Feeder
Mig 4HD Wire Feeder
F15-142-H 08/2010 Vaild serial no. WK-I930001
Instruction Manual
2
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!
3
TABLE OF CONTENTS
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 Wire Feeder ...................................................................................................................................................17
2.2 Mig 4HD Wire Feeder Options ..................................................................................................................................18
SECTION 3 EQUIPMENT ....................................................................................................................................................................21
3.1 General ..............................................................................................................................................................................21
3.2 Companion Equipment and Accessories ..............................................................................................................21
3.3 Accessories .......................................................................................................................................................................21
SECTION 4 INSTALLATION ..............................................................................................................................................................23
4.1 Installation .......................................................................................................................................................................23
SECTION 5 OPERATION ....................................................................................................................................................................25
5.1 Adjustments and Operation ......................................................................................................................................25
5.2 Operating Sequence ....................................................................................................................................................26
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
4
TABLE OF CONTENTS
5
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 precau-
tions 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 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 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 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 -- Heat 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.
2. 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.
6
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.
7
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.
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
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"
8
SECTION 1 SAFETY PRECAUTIONS
5. AWS C5.5 - "Recommended Practices for Gas Tung-
sten Arc Welding“
6. 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.
17
Table 2-1. Mig 4HD Specications
Input Power Required ....................................................................42 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 ................................................................................................................................. 21 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.
**8-ft (2.4m) control cable and hose included in specied weight.
2.1 Mig 4HD Wire Feeder
The Mig 4HD Wire Feeder (Figure 2-1 and Table 2-1) 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.
Mig spot welding can be done with the Mig 4HD if it is equipped with optional spot-welding features. Addition of spot-
welding circuitry in no way modies capability of the unit for normal mig or cored wire welding.
The Mig 4HD 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 Mig 4HD 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 wire feeder follows:
4-roll geared drive stand
Two drive rolls and two pressure rolls
Internal gas solenoid
8-foot (2.4m) control cable w/19-pin amphenol style plug (factory installed)
8-foot (2.4m) gas hose w/ttings (factory installed)
"Euro" style torch connection
"ON" indicator light
Wire feed speed potentiometer
Voltage control potentiometer
Gas purge switch
Jog (wire) switch
Remote power source voltage control
A water kit may be purchased (as an optional accessory) for use with the Mig 4HD when used with water cooled torches.
SECTION 2 DESCRIPTION
18
2.2 Mig 4HD Wire Feeder Options
The following options are available from ESAB or your supplier.
Spot/Burnback/Pre-postow/Trigger Lock Module (P/N 34182). Easy to install kit permits the operator to set
times for spot welding (0-5 sec), wire burnback (0-0.6 sec), gas preow (0-1.5 sec) and gas postow (0-7.5 sec). This
module also includes trigger lock which allows the welder to make long welds without continuously depressing the
torch trigger. Includes module and current detector.
Digital Meter/Preset Module (P/N 34180). Easy to install kit provides a digital display of wire feed speed (set ipm
or m/min) and voltage. This option also enables the welder to preset wire feed speed and power source voltage.
Dual Schedule Kit w/Remote Receptacle (P/N 34181). Easy to install kit includes controls for setting a second set
of welding conditions (wire feed speed and voltage). The welder can select Schedule A or Schedule B on a switch
(provided with kit) located on the front panel of wire feeder or select remotely using an optional Remote Pendant
Control or use an optional torch mounted Remote Schedule Selector Switch.
Remote Pendant Control (P/N 34328). (Requires Dual Schedule Kit) Provides a third schedule with remote control
of wire feed speed and power source voltage. Schedule selection (A, B, or C) switch also included.
Remote Schedule Selector Switch (P/N 34329). (Requires Dual Schedule Kit) Torch mounted, two position switch
provides remote schedule selection (A or B).
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.
SECTION 2 DESCRIPTION
19
COVER
PUSH-PULL
GUN CONTROL
RECEPTACLE
WIRE FEED
SPEED CONTROL
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 Wire Feeder
MIG
TORCH
CONNECTOR
RECEPTACLE
DOOR LATCH
WATER OUT (WATER KIT INSTALLED)
WATER IN (WATER KIT INSTALLED)
VOLTS
POWER "ON"
INDICATOR
WIRE FEED
SPEED AND
VOLTAGE*
*Included with option module P/N 34180
**Included with option module P/N 34182
W I R E S P O O L
HUB
SECTION 2 DESCRIPTION
21
3.1 General
This section describes the Mig 4HD Wire Feeder and the recommended companion equipment and accessories required to
properly operate the Mig 4HD. 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 with power sources such as: 353cv, 452cvcc, 453cvcc, SVI-450i cvcc,
652 cvcc and 653cvcc.
B. Extension Cables. Multi-conductor cable with 19-pin amphenol plug and receptacle. Used to extend 8-ft (2.4m) cable
supplied with wire feeder.
30-foot (9.1 m) P/N 34378
60-foot (18.3 m) P/N 34377
C. 115 V ac to 42 V ac Interface (P/N 34351). Adapts Mig 4HD 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.
D. 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 Mig 4HD 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).
E. Shielding gas regulator/owmeter and tted hose to bring gas from owmeter to wire feeder. Such as:
Regulator/Flowmeters:
R-5007 Argon/Helium/Nitrogen, P/N 998124.
R-5008 CO
2
, P/N 998125.
F. Drive Roll and Guide Tube. (Refer to Table 2.2): The Mig 4HD wire feeder comes equipped with drive rolls and a guide
tube for wire sizes .035 to .045 (0.9 to 1.2 mm). Select other size drive rolls from Table 1 for the wire size and type to
be used.
3.3 Accessories
A. Swivel Post (P/N 36172). Installs into tube on power sources such as 652 cvcc or 452 cvcc and allows the wire feeder
to freely swivel on post.
B. 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.
C. Boom Hanging Bracket Kit (P/N 34321). Includes hanging bracket and mounting hardware.
D. Carrying Handle Kit (P/N 34320). Includes handle with rubber grip and mounting hardware.
E. Wire Reel Adapter (P/N 34323). Use with 60 or 65-lbs. (27 or 30 kg) coils.
F. Spool Spacer (P/N 34330). For adapting 10-in (25.4 cm) spools.
G. Spool Cover Kit (P/N 34326). Includes clear cover and mounting hardware.
H. 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
22
† 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
Wire Type /
Diameter
Lower
Drive Roll
Upper
Pressure
Roll
Outlet
Guide
Tube
Center
Guide
Tube
Inlet
Guide
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)**
.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
Table 2.2. Drive Roll & Guide Tube Selection
23
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 water-cooled torch, the water
connections shown in Figure 2-1 must also be made.Connect control cable to power source. If the power source has
been used with another type feeder, check to make certain that no wiring changes have been made which permit
actuation 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.
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.
D. Drive Rolls. The drive roll has two grooves; the small groove feeds 0.035 in. diameter wire, the large groove feeds
0.045 in. 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 retaining 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.
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
4.1 Installation
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
24
E. Threading Wire.
1. Ensure control cable is disconnected from Power Source or interface box
.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
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
25
5.1 Adjustments and Operation
A. Control Setting.
1. Apply power to wire feeder.
2. Set the wire feed rate by adjusting the WIRE FEED SPEED and VOLTS control knobs on the front panel.
NOTE: Steps 3 and 4 apply only if spot/burnback/pre-postow/trigger lock module option is installed (P/N 34182).
3. 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.
4. 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. 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.
C. 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.
NOTE: Pre and Postow adjustment applies only if Spot/Burnback/Pre-Postow/Trigger Lock Module option is installed
(P/N 34182).
Set pre and postow potentiometers for the desired preow interval (range: 0-5 seconds) and postow interval (range:
0 to 7.5 seconds).
D. 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 workpiece
during welding, the arc will be interrupted, but shielding gas ow and welding wire feed will continue until the switch
lever is released.
NOTE: If trigger lock-in circuit is selected, the torch switch can be released as soon as arc has been struck. When weld
is complete, services are discontinued by closing torch switch again.
WARNING
SECTION 5 OPERATION
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, resulting
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.
26
SECTION 5 OPERATION
5.2 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 deenergized.
3. Burnback circuit times out (delay determined by setting of Burnback potentiometer).
-- Weld contactor opens.
-- Gas solenoid valve closes.
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. Trigger latch can only be set during time arc is established.
27
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.
SECTION 6 MAINTENANCE
CAUTION
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.
31
SECTION 7 REPLACEMENT PARTS
7.1 General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
To ensure 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 ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
7.2 Ordering
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
Note
7.0 Replacement Parts
32
1
5
6
7
2,3,4
9
Figure 7-1. Mig 4HD Wire Feeder (Front View)
2,3,4
8
10
Item
No.
Qty
Req.
Part
No. Description
Ckt.
Symbol
1
2
3
4
5
6
7
8
9
10
1
2
2
2
1
1
1
1
1
1
1
1
1
1
32110GY
13730611
2062018
676876
952924
23610528
23610696
952929
23612350
13730623
32111GY
951261
13792157
34141GY
PANEL, CONTROL
KNOB
POTENTIOMETER, 10K
INSULATOR, 10 MIL, NOMEX 2X2.5
TORCH ADAPTOR ASSY Includes:
HOUSING ADAPTOR, STRAIGHT
ADAPTOR, BLOCK ASSEMBLY
CONNECTION TUBE
POWER LUG
LATCH, DOOR
PANEL, FRONT
RECEPTACLE, 2-POLE
LIGHT, PILOT
COVER, OPTION, UPPER FRONT
R1, R2
J1
PL1
SECTION 7 REPLACEMENT PARTS
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ESAB Mig 4HD Wire Feeder User manual

Category
Welding System
Type
User manual

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