ESAB Solid State Controlled Voltage Sensing Wire Feeder User manual

Brand: ESAB

Model: Solid State Controlled Voltage Sensing Wire Feeder

Category: Welding System

Type: User manual

This manual is also suitable for

HEFTY

II STAINLESS

SEMIAUTOMATIC, SOLID STATE CONTROLLED

VOLTAGE SENSING WIRE FEEDER

For the Following Specs:

•

100052-1

OWNER’S MANUAL Number 430429-456 (Rev AB)

Revised June 5, 2000

THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.

IMPORTANT: Readtheseinstructionsbeforeinstalling, operating, or servicing this system.

INTRODUCTION 1

How To Use This Manual ..................................1-1

Equipment Identification ..................................1-1

Receipt Of Equipment ...................................1-1

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2

DESCRIPTION OF EQUIPMENT 3

General ...........................................3-1

Product Specifications ...................................3-1

Features/Benefits ......................................3-2

Meanings Of Markings And Graphical Symbols ......................3-3

Front Panel Controls And Connections ...........................3-4

Internal Controls And Connections (Component Side) ...................3-5

Internal Controls And Connections (Wire Spool Side) ...................3-6

Description Of Feedhead Assembly ............................3-6

Power Source Compatibility ................................3-7

Available Options ......................................3-8

INSTALLATION 4

Connections .........................................4-1

Installation Of Welding Wire Spool .............................4-1

Adjustment Of Spool Tension ................................4-1

Input And Output Wire Guide Installation ..........................4-1

Selection And Installation Of Feed Rolls ..........................4-1

Welding Gun Compatibility And Installation .........................4-2

Threading Wire Into Feedhead ...............................4-2

OPERATION 5

Prewelding Procedure ...................................5-1

Welding Procedure .....................................5-2

Welding In CC Mode vs. CV Mode .............................5-2

Theory Of Operation ....................................5-2

Adjusting Burnback Time ..................................5-2

Calibrating Wire Feed Speed Meter ............................5-3

Protection And Safety Circuits ...............................5-3

MAINTENANCE 6

Cleaning Of The Unit ....................................6-1

Cleaning Of The Feed Rolls ................................6-1

Feedhead Maintenance ...................................6-1

Contactor Maintenance ...................................6-1

Gas Valve Maintenance ..................................6-1

TROUBLESHOOTING 7

Scope ............................................7-1

Safety ............................................7-1

Troubleshooting Hints ....................................7-1

Troubleshooting Guide ...................................7-2

430429-456

TABLE OF CONTENTS

June 5, 2000 Revised Page 1

PARTS LIST 8

Equipment Identification ..................................8-1

How To Use This Parts List .................................8-1

DIAGRAMS

WARRANTY

430429-456

TABLE OF CONTENTS

Page 2 November 17, 1999

INTRODUCTION

How To Use This Manual:

This Owner’s Manual usually applies to just the

underlined specification or part numbers listed on

the cover. If none are underlined, they are all cov-

ered by this manual.

Throughout this manual, the words WARNING,

CAUTION, and NOTE may appear. Pay particular

attention to the information provided under these

headings. These special annotations are easily rec-

ognized as follows:

WARNING gives information re-

garding possible personal in-

jury. Warnings will be enclosed

in a box such as this.

CAUTION refers to possible equipment

damage. Cautions will be shown in bold

type.

NOTE offers helpful information concern-

ingcertainoperatingprocedures. Noteswill

be shown in italics.

Equipment Identification:

The unit’s identification number (specification or

part number), model, and serial number usually

appear on a nameplate attached to the control

panel. In some cases, the nameplate may be at-

tached to the rear panel. Equipment whichdoes not

have a control panel such as gun and cable assem-

blies is identified only by the specification or part

number printed on the shipping container. Record

these numbers for future reference.

Receipt Of Equipment:

When you receive the equipment, check it against

the invoice to make sure it is complete and inspect

theequipmentforpossibledamageduetoshipping.

If there is any damage, notify the carrier immedi-

ately to file a claim. Furnish complete information

concerning damage claims or shipping errors to

Thermal Arc, Order Department, 2200 Corporate

Drive, Troy, Ohio 45373-1085. Include all equip-

ment identification numbers as described above

along with a full description of the parts in error.

Move the equipment to the installation site before

uncrating the unit. Use care to avoid damaging the

equipment when using bars, hammers, etc., to un-

crate the unit.

Additional copies of this manual may be pur-

chased by contacting Thermal Arc at the address

given above. Include the Owner’s Manual number

and equipment identification numbers.

430429-456

INTRODUCTION

November 17, 1999 1-1

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430429-456

INTRODUCTION

1-2 November 17, 1999

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER

WEARERSKEEPAWAY UNTIL CONSULTINGYOURDOCTOR. DO NOTLOSETHESEINSTRUCTIONS.READOPERATING/INSTRUC-

TION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does

not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and

trainingbefore using thisequipment. Anyonenot having extensive training inwelding and cutting practices shouldnot attempt toweld.Certain

of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.

Safe practices are outlined in the American National Standard Z49.1 entitled:

SAFETY IN WELDING AND CUTTING. This publication and

other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

ELECTRIC SHOCK can kill.

Touchingliveelectrical partscan causefatal shocks

or severe burns. The electrode and work circuit is

electricallylive wheneverthe output ison. Theinput

power circuit and machine internal circuits are also

livewhenpowerison.Insemiautomaticorautomatic

wire welding, the wire, wire reel, drive roll housing,

and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself fromwork and groundusing dryinsulating mats

or covers.

4. Disconnect input power or stop engine before installing or serv-

icing this equipment. Lock input power disconnect switch open,

or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to

equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water

to coolit or lay it down on the ground or the worksurface. Do not

touch holders connected to two welding machines at the same

time or touch other people with the holder or electrode.

8. Do notuseworn,damaged, undersized,orpoorly splicedcables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground)

circuit.

12. Useonlywell-maintainedequipment.Repairorreplacedamaged

parts at once.

13. In confined spaces or damp locations, do not use a welder with

AC output unless it is equipped with a voltage reducer. Use

equipment with DC output.

14. Wear a safety harness to prevent falling if working above floor

level.

15. Keep all panels and covers securely in place.

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

Arc rays from the welding process produce intense

heat and strong ultraviolet rays that can burn eyes

and skin. Noise from some processes can damage

hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see

ANSI Z49.1 listed in Safety Standards) to protect your face and

eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from flash

and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant

material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

ARC WELDING can be hazardous.

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.

Welding or Cutting

Operation

Torch soldering

Torch brazing

Oxygen cutting

Light

Medium

Heavy

Gas welding

Light

Medium

Heavy

Shielded metal-arc welding

(stick) electrodes

Welding or Cutting

Operation

Gas metal-arc welding (MIG)

Non-ferrous base metal

Ferrous base metal

Gastungstenarc welding(TIG)

Atomic hydrogen welding

Carbon arc welding

Plasma arc welding

Carbon arc air gouging

Light

Heavy

Plasma arc cutting

Light

Medium

Heavy

Electrode Size

Metal Thickness

or Welding Current

—

Under 1 in., 25 mm

1 to 6 in., 25-150 mm

Over 6 in., 150 mm

Under 1/8 in., 3 mm

1/8 to 1/2 in., 3-12 mm

Over 1/2 in., 12 mm

Under 5/32 in., 4 mm

5/32 to 1/4 in., 4 to 6.4 mm

Over 1/4 in., 6.4 mm

Electrode Size

Metal Thickness

or Welding Current

All

Under 300 Amp

300 to 400 Amp

Over 400 Amp

Filter

Shade

No.

3or4

4or5

5or6

4or5

5or6

6or8

Filter

Shade

No.

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

May 8, 1996 2-1

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The

flying sparks and hot metal, weld spatter, hot work-

piece, and hot equipment cancause fires and burns.

Accidental contact of electrode or welding wire to

metal objects can cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc.

If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition

can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

11. Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

FLYING SPARKS AND HOT METAL can

cause injury.

Chipping and grinding cause flying metal. As welds

cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields rec-

ommended.

2. Wear proper body protection to protect skin.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gasunder high pres-

sure. If damaged, a cylinder can explode. Since gas

cylinders are normally part of the welding process,

be sure to treat them carefully.

1. Protectcompressedgascylindersfromexcessiveheat,mechani-

cal shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining

themtoastationarysupportorequipmentcylinderracktoprevent

falling or tipping.

3. Keep cylinders awayfrom anywelding orother electricalcircuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and

associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is

in use or connected for use.

8. Readand follow instructions oncompressed gascylinders, asso-

ciated equipment, and CGA publication P-1 listed in Safety

Standards.

ENGINES can be hazardous.

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away

from any building air intakes.

FUMES AND GASES can be hazardous

to your health.

Weldingproducesfumesandgases.Breathingthese

fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manu-

facturer’s instruction for metals, consumables, coatings, and

cleaners.

5. Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Shielding gases used for

welding can displace air causing injury or death. Be sure the

breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying

operations. The heat and raysof the arc canreact with vapors to

form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the

weld area, the area is well ventilated, and if necessary, while

wearing an air-supplied respirator. The coatings and any metals

containing these elements can give off toxic fumes if welded.

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

2-2 May 8, 1996

STEAM AND PRESSURIZED HOT

COOLANT can burn face, eyes, and

skin.

The coolant inthe radiatorcan bevery hotand under

pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to

cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

PRINCIPAL SAFETY STANDARDS

Safety inWelding andCutting, ANSIStandard Z49.1,fromAmerican

Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safetyand Health Standards, OSHA29 CFR1910, fromSuperinten-

dent of Documents, U.S. Government Printing Office, Washington,

D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and

CuttingofContainersThatHaveHeldHazardousSubstances,Ameri-

can Welding Society Standard AWS F4.1, from American Welding

Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-1, from Compressed Gas Association, 1235 Jefferson Davis High-

way, Suite 501, Arlington, VA 22202.

Code forSafety inWelding andCutting, CSAStandardW117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Pro-

tection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

SPARKS can cause BATTERY GASES

TO EXPLODE; BATTERY ACID can

burn eyes and skin.

Batteriescontainacidandgenerateexplosivegases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

MOVING PARTS can cause injury.

Moving parts,such as fans,rotors, and beltscan cut

fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely

in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for mainte-

nance and troubleshooting as necessary.

4. To preventaccidentalstartingduring servicing,disconnectnega-

tive (-) battery cable from battery.

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

parts.

6. Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

ENGINE FUEL can cause fire or

explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do notaddfuelwhile smokingorif unitisnear anysparksor open

flames.

3. Allow engine to cool before fueling. If possible, check and add

fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel isspilled, clean up before starting engine.

NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment,

Biological Effects

of Power Frequency Electric & Magnetic Fields — Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May

1989): “... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and

people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of

this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to

offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures:

About Pacemakers:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away from body as

practical.

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 Sec. 25249.5 et seq.)

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

May 8, 1996 2-3

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ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

2-4 May 8, 1996

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DES PIECES EN MOUVEMENT PEU-

VENT CAUSER DES BLESSURES.

Despiècesen mouvement,telsdesventilateurs,des

rotors et des courroies peuvent couper doigts et

mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les

protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système,arrêtez lemoteur.

3. Seules des personnes qualifiées doivent démonter des protec-

teurs ou des capots pour faire l’entretien ou le dépannage

nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien,

débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mou-

vement; elles peuvent aussi accrocher des vêtements amples

et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes

après des travaux d’entretien et avant de faire démarrer le

moteur.

DESETINCELLESPEUVENT FAIREEX-

PLOSER UN ACCUMULATEUR;

L’ELECTROLYTE D’UN ACCUMU-

LATEUR PEUT BRULER LA PEAU ET

LES YEUX.

Les accumulateurs contiennent de l’électrolyte

acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-

lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des

câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un

accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger

un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

LA VAPEUR ET LE LIQUIDE DE RE-

FROIDISSEMENT BRULANT SOUS

PRESSION PEUVENT BRULER LA

PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut

être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas

refroidi.

2. Mettez desgants etposez un torchonsur le bouchonpour l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le

bouchon.

PRINCIPALES NORMES DE SECURITE

SafetyinWeldingandCutting,normeANSIZ49.1,AmericanWelding

Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and

CuttingofContainersThatHaveHeldHazardousSubstances,norme

AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd.,

Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1,

Compressed Gas Association, 1235 Jefferson Davis Highway, Suite

501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 Asso-

ciation canadienne de normalisation, Standards Sales, 276 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Pro-

tection, norme ANSI Z87.1, American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC

Instruction 830002

2-4 8-V-96

DESCRIPTION OF EQUIPMENT

General:

The HEFTY II STAINLESS is a portable, solid state

controlled,voltage sensingwire feeder that operates on

arc voltage andcanbe usedwith mostconstantvoltage

(CV)andconstantcurrent(CC)DC-typepowersources.

Theonlyconnectionrequiredbetweenthepowersource

and the wire feeder is the welding cable.

The unique design of this wire feeder allows op-

eration in a constant wire feed speed mode when

used with CV power sources, and in a voltage

sensing wire feed speed mode (wire feed speed

varies with respect to arc voltage) when used with

CC power sources.

The stainless steel case totally encloses the solid

state control circuitry, welding wire, and wire drive

system. A hinged, latched door allows quick and

easy access to the welding wire and feedhead

assembly that features quick change, gear-driven

feed rolls and a hand operated knob for clamping

the welding gun into the feedhead.

The HEFTY II STAINLESS comes with an abun-

dance of standard features, which include: (1)

on/off rocker switch, (2) wire feed speed control

knob, (3) inch/purge switch, (4) carrying handle, (5)

contactor, (6) gas valve, (7) CC/CV mode switch,

(8) inputcircuit breaker for complete system protec-

tion, (9) electronic controlled protection circuitry to

protect against an undervoltage, an overvoltage, a

voltage spike, a shorted or locked motor, a shorted

contactor coil, and a shorted gas valve, (10) elec-

troniccontrolleddynamicbrake,(11)electroniccon-

trolled current limit to motor, (12) electronic

controlledstart circuitfor improvedarc starting, (13)

low voltage gun trigger circuit for operator safety,

and (14) a feed roll kit for 0.035 and 0.045 size filler

wire.

The HEFTY II STAINLESS has been designed to

comply with CSA NRTL/C and NEMA EW 3 stand-

ards.

Product Specifications:

Input Voltage Range ..........................15 - 100 VDC

Input Frequency..................................... 0 Hz (DC)

Maximum Input Current.............................. 8 Amps

Wire Speed Range

(Dependent On Arc Voltage).......... 50 - 700 IPM

..................................................... (1.3 - 17.8 MPM)

Wire Sizes ........................................ 0.024 - 5/64"

......................................................... (0.6 - 2.0 mm)

Maximum Wire Spool Capacity...... 12" (304.8 mm)

....................................................... 30Lbs.(13.6kg)

Feed Rolls............................. 2 (Both Gear Driven)

Welding Current (I)........... 330A at 60% Duty Cycle

Welding Gun Diameter....................... 5/8" Nominal

Maximum Shielding Gas Inlet Pressure....... 75 PSI

Weight (Less Wire)...................... 38 Lbs. (17.2 kg)

Approvals.......................................... CSA NRTL/C

........................................................... NEMA EW 3

Figure 3-1 Dimensional Information

430429-456

DESCRIPTION OF EQUIPMENT

June 5, 2000 Revised 3-1

Features/Benefits:

1. Operates On Arc Voltage

A. Can be used with most constant current (CC) or con-

stant voltage (CV) DC-type power sources

B. No control cables required

2. Voltage Sensing Control Circuit With

CC/CV Switch

A. Allowsvoltagesensingwirefeedspeedoperationwhen

used with CC power sources

B. Allows constant wire feed speed operation when used

with CV power sources

3. Solid State Circuitry

A. Improves wire speed accuracy

B. Compensates for motor load variations

C. Providescurrentlimittocontactor,gasvalve,andmotor

4. Polarity Insensitive

A. Operates on either straight or reverse polarity

5. Electronic Controlled Start Circuit

A. Enhances arc starting performance with CC power

sources

6. Electronic Brake

A. Solid state control of an electronic brake offers quick

stopping of the motor to prevent wire overrun

7. Standard Contactor

A. Allowstheweldingwiretoremainelectrically“cold”until

the gun switch trigger is depressed

B. Increases operator safety

8. Standard Gas Valve

A. Controls the “on/off” flow of shielding gas

9. Powerful, Permanent Magnet DC Drive

Motor

A. Accommodates thefast speeddemandsof smalldiameter

wire

B. Accommodates the lowspeed, high torquedemandsof

large diameter wire

10. Replaceable Motor Brushes

A. Provides economical means of extending motor life

11. Needle Bearing Construction On Motor

Output Shaft

A. Reduces friction and extends bearing life over a

sleeving bearing

12. Input Circuit Breaker

A. Ensures complete system protection

13. Electronic Controlled Protection Circuitry

A. Protects electronics from undervoltage, overvoltage,

and voltage spikes.

B. Protects electronics from a shorted or locked motor

C. Protects electronics from a shorted contactor coil

D. Protects electronics from a shorted gas valve coil

14. Stainless Steel Case

A. Provides strength in a small, portable, light weight

package

B. Allows easy access for difficult to reach jobs

15. Standard Inch/Purge Switch

A. Allows “cold” inching of wire at set wire feed speed

B. Allows purging of gas without running wire

16. Carrying Handle

A. Promotes portability

17. Quick Change Feed Rolls

A. Allows operator to change feed rolls without the use of

tools

B. Both feed rolls are gear driven for better feeding of wire

18. Gun Clamp Knob

A. Allows operator to secure welding gun without the use

of tools

19. Feed Roll Pressure Release

A. Allows operator to adjust feed roll pressure without the

use of tools

B. Allows operator to change feed rolls or wire while

retaining preset feed roll pressure

430429-456

DESCRIPTION OF EQUIPMENT

3-2 November 17, 1999

Meanings Of Markings And Graphical Symbols:

Signifies an OFF position

Signifies an ON position

Signifies voltage input

Signifies a wire feed function

Signifies a voltage or voltage control

Signifies amperage

Signifies cycles per second

Signifies a welding gun

Signifies the feeding of wire towards the work piece with output voltage off

Signifies a purging of gas

Signifies a constant voltage characteristic

Signifies a constant current (drooping) characteristic

Signifies a circuit breaker in an electrical circuit

Signifies welding current

Signifies duty cycle

430429-456

DESCRIPTION OF EQUIPMENT

June 5, 2000 Revised 3-3

Front Panel Controls And

Connections:

See Figure 3-2 for details.

1. WELDING GUN CABLE CONNECTION - The

welding gun cable is connected to the wire feeder

at this point. Connections must be tight; otherwise,

arcing or overheating could result.

2. WIRE FEED SPEED CONTROL - This knob

controls the wire feed speed. The wire feed speed

control can be adjusted during setup or actual weld-

ing.

3. ARC VOLTAGE CONTROL (OPTIONAL) -

This knob controls the arc voltage from the power

source. The arc voltage control can be adjusted

during setup or actual welding.

NOTE: The power source must be in the

remote position for this function to work.

4. ARC VOLTAGE METER (OPTIONAL) - The

arc voltagemeter displays the actualvoltage output

of the power source.

5. WIRE FEED SPEED METER (OPTIONAL) -

Thewirefeedspeedmeterdisplaystheactualwirefeed

speed output of the wire feeder.

6. POWER ON/OFF SWITCH - This switch con-

trols input power only to the wire feeder and not to

the power source.

Signifies a percentage

Signifies an analog meter function

Figure 3-2 Front Panel Controls And Connections

430429-456

DESCRIPTION OF EQUIPMENT

3-4 November 17, 1999

Internal Controls And

Connections (Component Side):

See Figure 3-3 for details.

7. CC/CV MODE SWITCH - The CC position pro-

vides a voltage sensing wire feed speed mode of

operation for use with constant current (CC) power

sources. The CV position provides a constant wire

feed speed mode of operation for use with constant

voltage (CV) power sources.

NOTE: This switch does not select a CC or

CV mode of operation. The mode of opera-

tionissetbythe type ofpowersourcebeing

used.

8. INPUT CIRCUIT BREAKER - This circuit

breakerprovidescompletesystemprotectionforthe

wire feeder in the case of a fault or overload condi-

tion.

9. 12 VDC DRIVER PCB - The 12 VDC driver

printed circuit board (PCB) is primarily responsible

for controlling the contactor and gas valve.

10. MOTOR CONTROL PCB - The motor control

printed circuit board (PCB) is primarily responsible

for controlling the output speed of the motor.

11. CONTACTOR - The contactor controls the

“on/off” flow of weld current from the power source.

When the contactor is open, the welding wire is

electrically“cold.” Whenthecontactorisclosed,the

welding wire is electrically “hot.”

CAUTION: The contactor is rated for

330 amps of weld current at a 60% duty

cycle. Exceeding the current or duty cy-

cle ratings will damage or shorten the

life of the contactor.

12. GAS VALVE - The gas valve controls the

“on/off” flow of shielding gas through the welding

gun.

Figure 3-3 Internal Controls And Connections

(Component Side)

430429-456

DESCRIPTION OF EQUIPMENT

June 5, 2000 Revised 3-5

Internal Controls And

Connections (Wire Spool Side):

See Figure 3-4 for details.

13. WELD CABLE CONNECTION - Thisis where

the weld cable from the power source connects to

the wire feeder. Connections must be tight; other-

wise, arcing or overheating could result.

NOTE: The mating connector for the weld

cable connection has been supplied with

the unit and is located in the owner’s man-

ual bag.

14. GAS VALVE INLET - This iswhere the shield-

ing gas hose (if used) is connected to the wire

feeder.

15. HUB TENSION BOLT - The hub tension bolt

is used to adjust the wire spool tension which acts

as a mechanical brake to assist in the stopping of

the welding wire at the completion of a weld.

16. INCH/PURGE SWITCH -Depressing theinch

portion of the switch will feed wire at a speed set by

the wire feed speed control. The wire will not be

electrically “hot” when using the inch switch. De-

pressing the purge portion of the switch will allow

shielding gas to flow out of the welding gun without

feeding wire.

17. GUN SWITCH RECEPTACLE - The gun

switch receptacle accepts the welding gun control

wires. The gun switch receptacle is where a gun

switch closure is inputted to the wire feeder.

18. VOLTAGE SENSING LEAD - This lead

serves as an input power connection point for the

wire feeder and must be connected to the work

piece for proper operation. If the voltage sensing

lead from the wire feeder and the weld cable from

the power source are not connected to the work

piece, the wire feeder will not work.

Description Of Feedhead

Assembly:

See Figure 3-5 for details.

19. LOWER RETAINING KNOB - This knob is

usedtosecure the drive feedroll.Removethisknob

to change the drive feed roll.

20. INPUT WIRE GUIDE - This guide is required

to direct the welding wire from the wire spool to the

drive feed roll.

21. INPUT GUIDE LOCKSCREW - Tighten this

screw to secure the input wire guide.

22. SPRING TENSION KNOB - Use the spring

tension knob to adjust the amount of force the

bearing feed roll exerts on the welding wire.

23. UPPER RETAINING KNOB - This knob is

used to secure the bearing feed roll. Remove this

knob to change the bearing feed roll.

24. OUTPUT GUIDE LOCKSCREW - Tighten

this screw to secure the output wire guide.

Figure 3-4 Internal Controls And Connections

(Wire Spool Side)

430429-456

DESCRIPTION OF EQUIPMENT

3-6 November 17, 1999

25. GUN CLAMP KNOB - Tighten this knob to

secure the welding gun to the wire feeder.

26. OUTPUT WIRE GUIDE - This guide is re-

quired to direct the welding wire from the drive feed

roll to the welding gun cable.

Power Source Compatibility:

Since the HEFTY II STAINLESS operates on arc

voltage, it will work with most constant current (CC)

or constant voltage (CV) DC-type power sources.

When connected to a HEFTY II STAINLESS, the

maximum allowed open circuit voltage (OCV) of the

power source is 100 VDC. Open circuit voltages

exceeding 100 VDC will damage or shorten the life

of the unit.

NOTE: Because of the high open circuit

voltage associated with most CC power

sources, it is recommended to place the

HEFTY

STAINLESS power switch in the

OFF position when not welding. This pro-

cedurewillprolongthelifeofelectricalcom-

ponentsconnectedtothepowerinputlines.

When using the HEFTY II STAINLESS, there

must be at least 15 VDC between the output termi-

nals of the power source during standby and while

welding. Otherwise, the unit will not have enough

input voltage to operate properly.

A contactor is a standard component of the

HEFTY II STAINLESS and allows the welding wire

to remain electrically “cold” until the gun switch

trigger is depressed. This contactor is rated for 330

amps of welding current at a 60% duty cycle. If the

weld current or duty cycle rating is exceeded, the

contactor will be damaged or its life shortened.

Figure 3-5 Feedhead Assembly

430429-456

DESCRIPTION OF EQUIPMENT

June 5, 2000 Revised 3-7

Available Options:

Thefollowing options areavailablefor use withthe

HEFTY II STAINLESS. Some options are kits while

others are individual items.

1. Spool Adapter - 10# 375585

2. Spool Adapter - 15# 375864-1

3. Coil Adapter - 14# 375942A

4. Feed Roll Kits

(See Diagrams Chapter) 171435-x

5. Control Pot Shaft Friction Lock 402663

6. Flowmeter Kit 870258

7. Tweco Gun Adapter 870144

8. Remote Voltage Control Kits

14 Pin Amphenol, 100’ 870259-1

19 Pin Amphenol, 100’ 870259-2

9. Dinse Connector Coversion Kit 870257

10. Wire Feed Speed

and Arc Voltage Meters 870260

430429-456

DESCRIPTION OF EQUIPMENT

3-8 November 17, 1999

INSTALLATION

Connections:

See the System Outline drawing (170091) in the

Diagrams chapter of this manual for details.

CAUTION: Make sure all connections

are tight; otherwise, arcing or overheat-

ing could result.

1. Connect a weld cable from the power source to

the weld cable connection of the wire feeder.

2. Connect a weld cable from the power source to

the work connection.

3. Connect the voltage sensing lead from the wire

feeder to the work connection.

WARNING: ELECTRIC SHOCK

CAN KILL! DO NOT touch the

metal portions of the voltage

sensing lead when the power

source output is on.

4. Make the proper gas line connection from the

gas supply to the wire feeder gas valve (if gas will

be used).

5. Attach the welding gun to the wire feeder.

6. Connect the welding gun switch leads to the

wirefeeder gun switch receptacle locatedinsidethe

case of the wire feeder.

Installation Of Welding Wire

Spool:

See Figures 3-4 and 3-5.

NOTE:Thewirespoolhubsuppliedwiththe

unit is provided for mounting a 30 pound

spool of wire. Optional adapters are avail-

ableallowinga10or15pound spool of wire

or a 14 pound coil of wire to be used.

1. Remove the wire spool hub nut by turning

counterclockwise.

2. Slide the spool of wire over the wire spool hub,

makingsurethatthealignmentpinonthehubenters

the hole in the backside of the wire spool.

3. Replace the wire spool hub nut and turn clock-

wise to a snug position.

NOTE: Install the welding wire spool so the

wire feeds from the bottom of the spool into

the input wire guide.

Adjustment Of Spool Tension:

Adjust the wire spool tension so the wire will feed

freely into the input wire guide. However, the spool

of welding wire must not “coast” when wire feeding

stops. To adjust the wire spool tension, tighten or

loosen the hub tension bolt accordingly(See Figure

3-4).

NOTE:Excessive tighteningofthehubten-

sion bolt will result in a shorter motor life.

Input And Output Wire Guide

Installation:

Refer to Figure 3-5.

Install the input wire guide (the longer one) by

loosening the input guide lockscrew and inserting

the guide into the hole in the feedhead assembly.

The recessed end of the guide should be towards

the wire spool. Adjust the guide so that it is clear of

the feed rolls and tighten the input guide lockscrew.

Install the output wire guide (with the conical end

towards the feed rolls) in the same manner as the

input guide. The conical end of the guide should be

as close to the feed rolls as practical. Tighten the

output guide lockscrew.

NOTE: Before tightening the input and out-

put guide lockscrews, install the drive feed

roll to help in the alignment of the wire

guides.

Selection And Installation Of

Feed Rolls:

NOTE: See feed roll kit drawing (supplied

in the Diagrams chapter) to order feed roll

kits. Kit includes a bearing roll, a drive roll,

an input wire guide, and an output wire

guide for a specific wire type and size.

For installation of feed rolls, refer to Figure 3-3.

Forselection of feedroll styles,refer to Figure 4-1.

430429-456

INSTALLATION

November 17, 1999 4-1

Style 1 feed rolls consist of a flat, smooth bearing

roll and a double, smooth, vee grooved drive roll.

They feed .024 - .068" hard and tubular wire.

Style 2 feed rolls consist of a flat, knurled bearing

roll and a double, smooth, vee grooved drive roll.

They feed .030 - .045" hard and tubular wire.

Style 3 feed rolls consist of a double, knurled, vee

grooved bearing roll and a double, knurled, vee

grooved drive roll. They feed .045 - 5/64" hard and

tubular wire.

Style 4 feed rolls consist of double, cog bearing

and drive rolls. They feed .045 - .068" tubular wire.

Style 5 feed rolls consist of double, U-grooved

bearing and drive rolls. They feed .035 - 3/64" soft

wire.

NOTE: All grooved feed rolls have their

wire size or range stamped on the side of

the roll. On rolls with different size grooves,

the outer (visible when installed) stamped

wire size indicates the groove in use.

Bearing feed rolls are installed by unscrewing the

upper retaining knob and removing the idler gear.

Thebearingfeedrollretainingknobisthenremoved

from the idler gear, and the bearing feed roll is

placed over the lobes on the idler gear. The bearing

feed roll retaining knob is replaced, and this assem-

bly is returned and secured with the upper retaining

knob.

Drivefeed rollsare installedby removingthe lower

retaining knob, placing the drive feed roll over the

lobes on the drive gear, and securing with the lower

retaining knob.

NOTE: Installation of all styles of feedrolls

for this feeder is identical.

Welding Gun Compatibility And

Installation:

Refer to Figures 3-4 and 3-5.

The HEFTY II STAINLESS wire feeder is de-

signed to be used with most welding guns. In some

cases, a special adapter may be required.

To install the welding gun, simply loosen the gun

clamp knob and insert the welding gun into the

feedhead until it stops. Tighten the gun clamp knob

and connect the welding gun control wires to the

gun switch receptacle.

NOTE: Before inserting the welding gun

into the feedhead, make sure the gun

clamp does not extend into the feedhead;

otherwise,the welding gun cannot beprop-

erly inserted.

Threading Wire Into Feedhead:

Refer to Figure 3-5.

WARNING: ELECTRIC SHOCK

CAN KILL! Make certain the

power source and wire feeder

are turned OFF. Do not turn the

power ON until told to do so in

these instructions.

CAUTION: Use care when handling the

spooled wire as the wire tends to “un-

ravel” when loosened from the spool.

Grasp the end of the wire firmly, and

don’t let it get away from you. Make sure

that the end of the wire is straight and

free of burrs.

1. Placeendoftheweldingwireintotheinputwire

guide. Feed it through the guide and over the drive

roll groove closest to the feedhead casting.

2. Passthewirethroughtheoutputwireguideand

into the welding gun assembly.

3. Lock in position with the spring tension knob.

To adjust the amount of force the bearing feed roll

exerts on the welding wire, turn the spring tension

knob clockwise for increased force or counterclock-

wise for decreased force.

NOTE: Iftheforceappliedtothewireistoo

great, the welding wire will “bird nest” in the

feedhead and not feed properly.

4. Turn the welding machine and wire feeder

ON,andsetthewirefeedspeedcontroltomidrange

(See Figure 3-2). Remove contact tube from weld-

ing gun. See Gun Manual. Press the gun switch or

INCH switch until wire feeds out past the gun noz-

zle. Place contact tube over the wire and screw into

place and tighten. Cut wire off at about 1/4 inch (6

mm) from the nozzle.

430429-456

INSTALLATION

4-2 November 17, 1999

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