ESAB MobileFeed 200 AVS Manual de usuario

ESAB
Marca
ESAB
Modelo
MobileFeed 200 AVS
Categoría
Sistema de soldadura
Tipo
Manual de usuario
MobileFeed 200 AVS
Portable “OThe Arc” Wire Feeder
Instruction Manual
0558004754 07 / 2008
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!
4
5
SECTION TITLE PAGE
SAFETY PRECAUTIONS ..........................................................................................................................7
SECTION 1 DESCRIPTION .............................................................................................................. 19
1.1 General .........................................................................................................................................................21
1.2 Receiving-Handling .................................................................................................................................21
1.3 Description .................................................................................................................................................21
SECTION 2 INSTALLATION ............................................................................................................ 23
2.1 Drive Rolls ...................................................................................................................................................23
2.2 Welding Wire Speed ................................................................................................................................23
2.3 Torch Connections ...................................................................................................................................24
2.4 Supply Connections ................................................................................................................................24
2.5 Threading the Welding Wire .................................................................................................................25
2.6 Brake Drag Adjustment ..........................................................................................................................25
SECTION 3 OPERATION ................................................................................................................. 27
3.1 Controls .......................................................................................................................................................27
3.1.1 Power Switch .............................................................................................................................................27
3.1.2 Wire Feed Speed (Arc Voltage Control) ............................................................................................27
3.1.3 Wire Feed Speed (Constant Speed) ...................................................................................................27
3.1.4 5 amp Circuit Breaker (CB1) ..................................................................................................................27
3.2 Operating Procedures ............................................................................................................................29
3.2.1 Operating Safety Precautions ..............................................................................................................29
3.3 Setting A Welding Procedure ...............................................................................................................30
3.4 Shutdown ...................................................................................................................................................31
SECTION 4 MAINTENANCE ........................................................................................................... 33
4.1 Maintenance ..............................................................................................................................................33
4.2 Inspection and Service ...........................................................................................................................33
4.2.1 Wire Feeder ................................................................................................................................................33
4.2.2 Solenoid Valve Replacement ...............................................................................................................33
4.2.3 General Replacement .............................................................................................................................33
4.3 Troubleshooting .......................................................................................................................................34
SECTION 5 REPLACEMENT PARTS ................................................................................................ 37
TABLE OF CONTENTS
6
TABLE OF CONTENTS
7
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.
8
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.
9
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"
10
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.
11
SEGURIDAD
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adi-
cional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS--
Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2. Use una careta que tenga el ltro correcto y lente
para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las per-
sonas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chis-
pas calientes con una cortina adecuada no-amable
como división.
6. Use careta protectora además de sus gafas de segu-
ridad cuando esté removiendo escoria o puliendo.
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases amables, solventes,
pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté to-
talmente limpia y libre de substancias que puedan
producir gases inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.
4. Tenga siempre a la mano equipo extintor de fu-
ego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspec-
cione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corri-
ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.
12
SEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condi-
ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mien-
tras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETI-
COS - Son peligrosos. La corriente
eléctrica uye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes proced-
imientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cad-
mio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique sub-
stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico per-
siste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomen-
daciones especícas en la ventilación.
13
SEGURIDAD
5. ADVERTENCIA-- Este producto cuando se uti-
liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de Cali-
fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romp-
erse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adapta-
dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablil-
leros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
1. Siempre tenga personal cualicado para efec-
tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGURI-
DAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
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"
14
SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig-
nican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
15
SÉCURITÉ
1.3 Safety - French
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1. Éloignez susamment tous les matériaux combus-
tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vête-
ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incan-
descent peuvent tomber dans les ssures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre tra-
vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauer et provoquer un in-
cendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec-
tion de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-
telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurez-
vous de lire et de suivre les précautions de sécurité ci-
dessous, dans les manuels, les ches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans la-
téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres ltrants et de
plaques protectrices appropriées an de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas re-
garder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes an de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininammable an de vous proté-
ger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recom-
mandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininammable.
6. Portez des lunettes étanches par dessus vos lunettes
de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
Les per sonnes se trou vant à proximité doivent égale -
ment porter des lunettes étanches par dessus leur
lunettes de sécurité.
16
SÉCURITÉ
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A. Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne re-
spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila-
tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lor-
sque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ven-
tilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom-
magés.
5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte-
électrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe-
ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉ-
TIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-
teur produit des champs électriques
et magnétiques localisés. Le soudage et le cou-
rant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour cer-
tains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des eets néfastes inconnus pour
la santé.
17
SÉCURITÉ
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.
3. Maintenez les câbles, les ls de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez ja-
mais un équipement s'il présente une défectuosité
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.
6. Utilisez l'équipement conformément à son usage
prévu et n'eectuez aucune modication.
INFORMATIONS SUPPLÉMENTAIRES RELA-
TIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precau-
tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recomman-
dées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
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. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques consid-
éres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
MANIPULATION DES CYLINDRES --
La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles-
sures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas bran-
ché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre dis-
position par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe-
ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
18
SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
Signie un danger qui peut entraîner des blessures
corporelles mineures.
DANGER
AVERTISSEMENT
ATTENTION
19
• Arc voltage feeder capable of use with Constant
Current (CC) or Constant Voltage (CV) units
• Available with “CC” torch connection
• 4 roll drive stand
• Secondary contactor
• Built for harsh environments such as construction
sites, pipe lines, shipyards, oshore, general
fabrication, mobile welding rigs and more
• Totally enclosed, impact-resistant case protects
welding wire from dirt, metal grit, moisture and other
contaminants.
• Molded plastic case will stand extreme abuse like hot
slag, grinding sparks, corrosive chemicals, knocks,
bumps, drops and more
• Operates with reverse polarity (wire DC +) or straight
polarity (wire DC-)
• Permanent magnet drive motor with PWM drive, solid
state control - provides powerful, dependable wire
feeding and controlled wire acceleration for smooth
arc starts and chatterfree solenoid operation
• Electronic Dynamic Braking
• Safety features include insulated case, low voltage
torch trigger circuit and overload protection
• Meets lEC-974-1 specications.
Ordering Information
Each MobileFeed wire feeder includes gas solenoid and
dual groove feed rolls.
MobileFeed 200 AVS LC40 ............................. 0558004709
Includes .045 - 1/16 in. (1.2 - 1.6 mm) serrated groove drive rolls.
MobileFeed 200 AVS OKC CE ........................0558005796
Includes .035 - .045 in. (0.9 - 1.2 mm) V groove drive rolls.
Note:
0558004709 has LC40 type cable connector
and
0558005796 has OKC type cable connector.
Specications
MobileFeed 200 AVS
Wire Speed Range* ......................................50 - 800 ipm (1.3 - 20.3 m/min)
* actual speed range will depend on the arc voltage
Wire Diameter Capacity .................................. .030 - 5/64 in. (0.8 - 2.0 mm)
Primary Input** (open circuit voltage or arc voltage)
Minimum..................................................................................................16.5vdc
Maximum ......................................................................... 100vdc (113v peak)
** not for use with AC power
Weight .............................................................................................26 lbs (11.8 kg)
MobileFeed 200 AVS Feeder
(AVS = Arc Voltage Sensing)
Common to MobileFeed 200 AVS
Standard - 2-in (5.1 cm) ID spindle hub
8 in. OD (20.3 cm) spools - no adaptor required
Physical Dimensions
Case W x H x L ....................................................................6.75” x 14.00” x 18.50”
.................................................................................(171mm x 356mm x 470mm)
MobileFeed feeders will t through 14.25 in. (362mm) diameter hole.
Required Accessories
Drive Rolls & Guide Tubes ............................ see table on next page
SECTION 1 DESCRIPTION
20
Shock mounts and
a exible base provide
“give” to the case enabling
the wire feeder to survive a drop,
even fully loaded
Wire drive system uses
dual groove feed rolls.
Controls are located on
a recessed front panel to
protect dial and switch
Built-in, insulated quick connector - no
extra gas hoses or switch cables hanging
from the feeder
Voltage pickup cable is
included with
MobileFeed 200 AVS
SECTION 1 DESCRIPTION
Clamp
Two lower drive rolls are required for four roll drive systems.
+
Use at, plain pressure roll(s) (P/N 0455 907 001) supplied with wire feeder.
Drive Rolls and Guide Tubes for: MobileFeed 200 AVS
Outlet Guide Tube
Center
Guide
Wire Diameter Desc.
+
Roll Qty EURO Qty Qty Inlet Guide Qty
.030 in. (0.8 mm) V-Groove 0369 557 002 2 0558001077 1 0558001757 1 0558001758 1
.040 in. (1.0 mm) V-Groove 0369 557 002 2 0558001078 1 0558001757 1 0558001758 1
.040 in. (1.0 mm) V-Groove 0369 557 003* 2 0558001078 1 0558001757 1 0558001758 1
.045 in. (1.2 mm) V-Groove 0369 557 003* 2 0558001078 1 0558001757 1 0558001758 1
.045 in. (1.2 mm) V-Groove X2 0369 557 010 2 0558001078 1 0558001757 1 0558001758 1
.052 in. (1.4 mm) V-Groove 0369 557 013 2 0558001079 1 0558001757 1 0558001758 1
.062 in. (1.6 mm) V-Groove 0369 557 013 2 0558001079 1 0558001757 1 0558001758 1
.030 in. (0.8 mm) K-Cored 21160 2 0558001077 1 0558001757 1 0558001758 1
.035 in. (0.9 mm) K-Cored 21160 2 0558001078 1 0558001757 1 0558001758 1
.045 in. (1.2 mm) K-Cored 21161 2 0558001079 1 0558001757 1 0558001758 1
.052 in. (1.4 mm) K-Cored 21161 2 0558001079 1 0558001757 1 0558001758 1
1/16 in. (1.6 mm) K-Cored 21161 2 0558001079 1 0558001757 1 0558001758 1
5/64 in. (2.0 mm) K-Cored 21162 2 0558001079 1 0558001757 1 0558001758 1
3/64 in. (1.2 mm) U-Soft 21159 2 0558001898 1 0558001895 1 0558001758 1
1/16 in. (1.6 mm) U-Soft 21159 2 0558001898 1 0558001895 1 0558001758 1
*As delivered on 0558005796, 0558005728 and 0558005832
21
TABLE 1-1 SPECIFICATIONS
Wire Feed Speed 50 - 800 in./min. (1.3 - 20.3 m/min.)
Maximum open circuit voltage 100 vdc (113 vdc peak)
Wire diameters Hard: .030” (0.8mm), .035” (0.9mm), .045” (1.2mm), .052” (1.4mm), 1/16” (1.6mm)
Soft: .035” (0.9mm), 3/64” (1.2mm), 1/16” (1.6mm)
Cored: .030” (0.8mm), .035” (0.9mm), .045” (1.2mm), .052” (1.4mm), 1/16” (1.6mm), 5/64” (2.0mm)
Wire package 8” (203mm) diameter spool
Motor type DC permanent magnet pre-lubricated, totally enclosed
Brake type (wire) Drag
Control Solid State
Feed System Push
On-O Switch Standard
Run in start Automatic if required.
Height 14.00” (356mm)
Width 6.75” (171mm)
Length 18.50” (470mm)
Weight (with contactor, without spool) 26 lbs. (11.8Kg)
1.1 GENERAL
This manual has been prepared especially for use in famil-
iarizing 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 performance of this
equipment.
1.2 RECEIVING-HANDLING
Prior to installing this equipment, clean all packing mate-
rial 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 led by the purchaser with the carrier. A copy of
the bill of lading and freight bill will be furnished by the
carrier on request if occasion to le claim arises.
The MobileFeed 200 AVS will t through a 14.25” (362mm) dia. hole.
1.3 DESCRIPTION
The MobileFeed 200 AVS is a portable wire feeder designed
for maximum versatility. The unit is powered entirely on
the arc voltage from a constant current or constant volt-
age welding power source. All models include a secondary
contactor for added operator safety.
The unit is designed for use with hard, soft, and cored
electrodes (gas shielded or self-shielded) from 0.030”
(0.8mm) through 5/64” (1.98mm) diameter with wire feed
speed from 50 to 800 IPM (1.8-20.3 m/mm). The feeder
components are totally enclosed in a rugged case for
optimum mobility.
NOTE
The MobileFeed 200 AVS is not recommended for
short circuiting transfer using constant current power
sources due to the limited short circuit current avail-
able on constant current power sources.
SECTION 1 DESCRIPTION
22
SECTION 1 DESCRIPTION
23
Drive Roll Detail
WIRE
SPOOL HUB
SECTION 2 INSTALLATION
PRESSURE
ROLL
DRIVE
ROLL
PRESSURE
ROLL ASSEMBLY
LEVER
KNURLED
SCREW
PRESSURE
ROLL
ASSEMBLY
SPOOL
RETAINER
Spindle Detail
2.1 DRIVE ROLLS AND GUIDE TUBES
The drive rolls have two grooves. The unit is supplied
ready to feed 0.045”, .052” or 1/16” (1.2 to 1.6mm) diam-
eter cored wires or .035 - .045 (0.9 - 1.2mm) hard wires
depending on the part number ordered. (Other drive rolls
are available to feed other sizes of hard wire, soft wire,
and cored wire. See Drive Roll and Guide Tube Selection
Chart and Table 1-1)
A. Release the pressure roll assembly lever and lift the
Pressure Roll Assembly upward.
B. Remove the knurled screw holding the drive roll to
the gear adaptor.
C. Check and install proper guide tubes.
D. Reverse or replace drive rolls with the required size
designation which is imprinted on the side of the roll
facing out.
E. Replace the screw removed in Step B and tighten.
F. Thread the wire and secure the pressure roll assem-
bly.
2.2 WELDING WIRE INSTALLATION
Install a spool of welding wire on the hub as follows:
A. Turn the red spool retainer in the hub as shown in
picture below.
B. Place the wire spool on the hub to rotate counter-
clockwise as the wire is unwound; hub pin must
engage the hole in the wire spool.
C. Turn the red spool retainer in the hub to lock the
retaining tabs.
24
Figure 2.2 - Typical Set-up of MobileFeed 200 AVS
- (or +) + (or -)
SECTION 2 INSTALLATION
MOBILEFEED
POWER
SOURCE
WELDING CABLES
WORK LEAD
TORCH
WORK
Be sure to properly insulate this connection before
applying power to the power source. Uninsulated
cable and parts can arc when contacting a ground-
ed surface. The arc may damage eyes or start a re.
Body contact with an uninsulated weld cable con-
nector, or uncovered conductor can shock, possibly
fatally.
B. Connect a second welding cable (work lead) between
the opposite polarity output connection on the power
source and the work piece.
C. Connect the wire feeder work lead (voltage pick-up)
alligator clip to the work piece.
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” and close the contactor if
power source is equipped with an output contac-
tor control switch. Open circuit voltage must be
present to operate the wire feeder.
3. Turn wire feeder power switch “ON”.
4. Inspect all gas connections for leaks.
Unless starting to weld, do not allow the welding wire
to touch a grounded metal surface. The welding wire
becomes electrically hot when the secondary contactor
is closed. Keep ngers clear of the drive rolls; they will
start turning when the torch trigger is pressed.
5. If using gas shielded wires, adjust the gas ow-
meter to the desired ow rate by closing the gun
trigger switch.
6. Turn power source and wire feeder OFF when not
in use.
2.3 TORCH CONNECTIONS
The torch adaptor on the MobileFeed connects directly
to the wire feeder wire drive assembly, power and shield-
ing gas supply. Line up the torch connector with the wire
feeder adaptor, push on rmly and hand tighten the lock-
ing collar on the Euro Connector.
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
Before making any connections between the wire
feeder and the welding power source, turn o power
to the welding power source and the wire feeder.
The MobileFeed 200 AVS can be used with either DCEP
or DCEN polarity without modications.
A. Connect the welding cable from the power source;
positive terminal for gas shielded ux cored or sol-
id wires, or negative for most gasless self-shielded
cored wires, to the weld cable lug connection ex-
tending from the rear of the MobileFeed 200 AVS
feeder.
WARNING
WARNING
WARNING
CAUTION
25
SECTION 2 INSTALLATION
2.5 THREADING THE WELDING WIRE
When the wire feeder is connected to the power source,
the work lead from the power source is connected to
the work piece and the power source is energized,
closing the torch trigger will cause the welding wire to
become electrically hot and will cause the drive rolls
to turn. Keep ngers clear!
A. Turn OFF the power source and the wire feeder.
B. Release the pressure roll assembly lever and check
for the proper drive roll, groove position and wire
guides.
Before threading welding wire, 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 liner.
C. Feed the wire from the spool through the inlet guide
along the drive roll groove and into the outlet guide
tube.
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.
CAUTION
WARNING
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.
The brake hub is adjusted when delivered, if readjustment
is required, follow the instructions below. Adjust the brake
hub so that wire is slightly slack when wire feed stops.
Adjusting the braking torque:
Turn red handle to the unlocked position and pull •
straight out to remove.
Using a 0.31” (7.9mm) Allen wrench, turn the Nyloc •
screw clockwise to increase the braking torque.
Using a 0.31” (7.9mm) Allen wrench, turn the Ny-•
loc screw counterclockwise to reduce the braking
torque.
RED
HANDLE
NYLOC
SCREW
26
SECTION 2 INSTALLATION
27
Figure 3.1 - Controls and Connections, MobileFeed 200 AVS
POWER ON-OFF
SWITCH
WIRE SPEED
CONTROL
WORK LEAD
TORCH
CONNECTION
WELDING CABLE
CONNECTION
SHIELD GAS
CONNECTION
SECTION 3 OPERATION
3.1 CONTROLS
3.1.1 POWER SWITCH
The ON-OFF switch on the front of the wire feeder case
energizes the wire feeder when the feeder is connected
to the power source and the work piece, and the power
source is turned ON with the contactor closed.
3.1.2 WIRE FEED SPEED (ARC VOLTAGE CONTROL)
The wire feed speed is controlled by the wire feed speed
dial on the front of the wire feeder case. When connected
to a constant voltage (cv) type power source, the wire
feed speed dial controls the welding current. Turning
the dial clockwise increases welding current; turning it
counterclockwise decreases welding current.
When connected to a constant current (cc) type power
source, the wire feed speed dial controls the arc voltage.
Turning the wire feed speed dial clockwise decreases arc
voltage; turning it counterclockwise increases arc voltage.
The actual wire feed speed for any given setting varies
with the arc voltage. Increasing arc voltage causes an
increase in wire feed speed.
The MobileFeed 200 AVS wire feeder is equipped with
automatic “Slow wire run-in”. If the wire feeder senses
that the power source output voltage is in excess of 33
volts, the “run-in” wire speed automatically decreases for a
xed period of time (250ms) to improve arc starts. When
the arc is established, the wire feed speed is controlled
by the wire feed speed control knob on the MobileFeed
front panel.
3.1.3 WIRE FEED SPEED (CONSTANT SPEED)
The MobileFeed 200 AVS can be switched to a “Non” Volt-
age Control Mode where the wire feed speed remains rela-
tively constant and will not change speed with changes
in arc voltage. Locate switch SW1 on the PC board and
position S1 and S2. See Figure 3-2 and Table 3.1.
Position S1 - open
Position S2 - closed
SW1
Figure 3.2
5 AMP
CIRCUIT BREAKER
3.1.4 5 amp CIRCUIT BREAKER (CB1)
This resettable 5 amp circuit breaker, in series with mo-
tor armature, protects the control board from damage if
the motor is stalled.
(Factory settings are as follows: S1 - closed, S2 - open)
28
SECTION 3 OPERATION
Table 3.1 MobileFeed Dip Switch Table
Switch Position
OPEN (OFF)
CLOSED (ON)
Description
Factory Setting - Constant Current Operation ( “Voltage Control Mode” )
In this operation mode the MobileFeed feeder is ready for connection to a “ Constant
Current “ power source which typically provides a high open circuit voltage and low
short circuit current which makes arc starting dicult. Therefore, “slow run-in” of the
wire is automatically enabled if OCV exceeds 33 volts to provide good and reliable
arc starting. The arc length during welding is determined by a combination of the
wire feed speed knob position (MobileFeed feeder front panel) and the weld “Cur-
rent” setting on the CC power source. When a good welding condition is achieved,
the arc length will be maintained by changes in wire feed speed provided by arc volt-
age control. Variables causing changes in arc voltage, for example, wire “stick-out”,
wire density or shielding variations, will cause the wire feed speed to compensate to
maintain the arc length preset.
Alternate Setting - Constant Voltage Operation ( “Constant Wire Feed Speed” )
In this operation mode the feeder is ready for connection to “ Constant Voltage “
power source which is typically used for most GMAW (MIG/MAG) welding. CV power
sources provide high short circuit currents for good arc starting and wire burn-o.
“Slow run-in” of the wire is automatically disabled. The arc length while welding is de-
termined by a combination of the wire feed speed knob position (MobileFeed feeder
front panel) and the weld “Voltage” setting on the CV power source. When a good
welding condition is achieved, the arc length will be maintained by the power source
and the wire feed speed will remain constant. Any variations in wire “stick-out”, wire
density or shielding variations, could cause the arc length (arc voltage) variations.
NOTE:
If both switches are placed in the OPEN (O) position the wire feed motor is disabled and the motor will NOT run.
1
2
Rocker
Down
OPEN
1
2
Rocker
Down
OPEN
The DIP switches are located on the control PCB.
29
SECTION 3 OPERATION
3.2 OPERATING PROCEDURES
3.2.1 OPERATING SAFETY PRECAUTIONS
Comply with all ventilation, re 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 ash
goggles with lter lenses under his helmet. The hel-
met lter plate should be shade number 11 (nonfer-
rous) or 12 (ferrous). All those viewing the arc should
use helmets with lter plates, as well as ash goggles.
Nearby personnel should wear ash goggles.
B. The radiant energy of the arc can decompose chlo-
rinated solvent vapors, such as trichloroethane and
perchlorethylene, to form phosgene, even when
these vapors are present in low concentrations. DO
NOT weld where chlorinated solvents are present in
atmospheres in or around the arc.
C. DO NOT touch the electrode, contact tip or metal parts
when power is ON: all are electrically energized (HOT)
and can cause a possibly fatal shock. DO NOT allow
electrode to touch grounded metal. It will create an
arc ash that can injure eyes. It may also start a re or
cause other damage.
D. When working in a conned space, be sure it is safe
to enter. The conned space should be tested for
adequate oxygen (at least 19%) with an approved
oxygen measuring instrument. The conned space
should not contain toxic concentrations of fumes
or gases. If this cannot be determined, the operator
should wear an approved air supplied breathing ap-
paratus. Avoid gas leaks in a conned space, as the
leaked gas can dangerously reduce oxygen concen-
tration in the breathing air. DO NOT bring gas cylin-
ders into conned spaces. When leaving a conned
space, shut OFF gas supply at the source to prevent
gas from leaking into the space. Check the breathing
atmosphere in the conned 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.
F. Never operate equipment in a damp or wet area with-
out suitable insulation for protection against shock.
Keep hands, feet and clothing dry at all times.
G. Whenever the equipment is left unattended, turn
OFF all control power, power supply switches and gas
supplies. Open the main line switch.
H. Wear dark substantial clothing to protect exposed
skin from arc burn, sparks and ying hot metal.
I. Turn o welding power before adjusting or replacing
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 ash. Keep clear of feed
rolls and drive gears.
Prior to welding, it is imperative that proper protective
clothing (welding coat and gloves) and eye protection
(glasses and/or welding helmet) be put on. Failure to
comply may result in serious injury
WARNING
WARNING
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 conned space may
result in a build-up of fumes, displacing oxygen.
CAUTION
WARNING
30
WELD DATA TABLE
WIRE
FEED
SPEED
(IPM)
FLUX CORE
E70T-1 & 2
.045
WIRE /DIAMETER
.045
.052
1/16
.052
1/16
.035
.045
1/16
3/64
1/16
3/64
1/16
METAL CORE
STEEL
SOLID WIRE
Al/Si
ALUMINUM
Al/Mg
ALUMINUM
ARC VOLTS / AMPS (WELD CURRENT)
100
150
200
250
300
350
400
450
500
550
600
650
29
25
30
33
36
29
150
30
250
33
290
34
330
155
300
460
500
37
500
210
33
365
30
300
27
190
33
410
33
450
29
260
28
250
30
270
29
300
29
275
30
325
32
400
30
350
30
300
34
450
25
180
25
200
26
215
27
230
28
245
25
260
26
280
27
300
26
290
27
340
30
400
28
320
30
340
25
110
25
140
26
150
26
190
26
200
23
260
30
300
32
350
27
205
27
220
22
100
23
150
23
175
24
190
25
205
25
220
23
200
25
250
27
280
27
290
28
340
32
300
32
350
39
500
ARC VOLTS / AMPS (WELD CURRENT)
WIRE FEED SPEED (IPM)
WIRE / DIAMETER
FLUX CORE
E70T-1 & 2
METAL
CORE
STEEL
SOLID WIRE
AL / Si
ALUMINUM
AL / Mg
ALUMINUM
SECTION 3 OPERATION
3.3 SETTING A WELDING PROCEDURE
QUICK SET-UP PROCEDURE
For Constant Voltage (CV) Power Source - Set the arc voltage 1.
desired on the P/S.
For Constant Current (CC) power source - Set the weld CUR-2.
RENT desired.
On the MobileFeed Unit - Set the wire feed speed knob at #5.3.
31
NOTE
On many CV power sources the actual welding arc voltage is usually less the “Open Circuit Voltage” (OCV) set on the power
source front panel. Therefore, an extra 3 to 6 volts should be added to the power source front panel setting to achieve the
“actual” arc voltage needed or shown in the tables.
* MobileFeed Wire Feed Speed Knob Position
WIRE FEED SPEED TABLE
WFS
Set
19 V 20 V 21 V 22 V 23 V 24 V 25 V 26 V 27 V 28 V 29 V 30 V 31 V 32 V 33 V 34 V
Min 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 4 5 5 6 6 7 7 7 9 11 12 15 14 13 13 11
2 44 51 56 65 70 74 77 85 90 93 95 103 102 102 101 100
3 99 109 116 129 136 140 144 155 165 173 179 196 198 200 201 205
4 152 163 170 184 196 204 211 230 241 250 256 275 282 287 291 302
5 210 225 235 255 270 281 290 315 329 339 347 370 379 385 390 405
6 267 282 292 312 331 345 356 388 412 430 443 483 490 495 499 510
7 334 354 368 395 415 430 441 475 503 524 540 587 594 599 603 615
8 380 411 431 472 494 511 523 560 589 610 626 675 685 693 698 715
9 385 427 454 510 536 556 571 615 649 674 693 750 770 785 796 830
Max 395 435 462 515 544 565 581 630 667 695 716 779 803 820 833 873
Min
Max
* Wire
Speed Set
SECTION 3 OPERATION
3.4 SHUTDOWN
A. Release torch trigger to break the arc.
B. When leaving the equipment unattended, always shut OFF and disconnect all power to the equipment and shut o the
shielding gas supply at source.
MOBILEFEED 200 WITH
CONSTANT CURRENT POWER SOURCES
Using the table, select the weld CURRENT / VOLT-1.
AGE needed for the wire type and diameter to be
welded.
Set the power supply CURRENT using the cur-2.
rent control knob on the front panel of the power
source.
Read the WIRE FEED SPEED (WFS) at the top of the 3.
column for the wire type, diameter and weld VOLT-
AGE / CURRENT chosen.
Use the VOLTAGE and WFS in the WFS Table to de-4.
termine the MobileFeed wire feed knob position.
Strike an arc then trim the arc length as needed us-5.
ing the VOLTS / WFS knob.
MOBILEFEED 200 WITH
CONSTANT VOLTAGE POWER SOURCES
Using the table, select the weld VOLTAGE / CUR-1.
RENT needed for the wire type and diameter to be
welded.
Set the power supply VOLTAGE using the volt-2.
age control knob on the front panel of the power
source.
Read the WIRE FEED SPEED (WFS) at the top of the 3.
column for the wire type, diameter and weld VOLT-
AGE / CURRENT chosen.
Use the VOLTAGE and WFS in the WFS Table to de-4.
termine the MobileFeed wire feed knob position.
Strike an arc then trim the arc length as needed us-5.
ing the VOLTS / WFS knob.
NOTE
Using the “Constant Feed” dip switch settings when using a CC power source is NOT RECOMMENDED. Extreme wire feed
speed sensitivity exists making it dicult to set stable welding condition. The arc stability is very dependant on maintain-
ing constant TTW distance which is almost impossible to control when welding manually. “Constant Speed” settings is only
recommended for use with CV power sources.
Typical welding voltages for 5000 Aluminum are between 21 and 25 volts which limits the wire feed speed of the Mobile-
Feed especially if trying to weld with 035” diameter 5356 alloy. Welding with wire diameters ≤3/64” and/or below 22 arc
volts could cause problems with limited wire feed speed and the inability to achieve a good welding condition.
32
SECTION 3 OPERATION
33
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 before attempting any
inspection or work on the inside 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 equip-
ment should be undertaken by a competent individual
having at least general experience in the maintenance
and repair of semi-conductor electronic equipment.
Maintenance or repair should not be undertaken by
anyone not having such qualications.
As an aid in checking and servicing, refer to the following
pages; Schematic Diagram and/or Wiring Diagram.
4.2 INSPECTION AND SERVICE
Keep equipment in clean and safe operating condition,
free of oil, grease, and (in electrical parts) liquid and metal-
lic 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 electrical
connections. Loose power connections overheat during
welding.
Immediately replace all worn or damaged power cables
and connectors. Check for frayed and cracked insulation,
particularly in areas where conductors enter Equipment.
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 electrical
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 re.
Body contact with a bared cable, connector, or uncov-
ered conductor can shock, possibly fatally.
WARNING
WARNING
WARNING
Keep power cables dry, free of oil and grease, and protect-
ed 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 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 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.
4.2.2 SOLENOID VALVE REPLACEMENT
If there is no gas ow through the wire feeder, the gas
solenoid valve may be clogged or electrically malfunc-
tioning and it should be replaced. When replacing the
gas solenoid valve, the inlet (with the word IN) must face
the rear of the unit.
4.2.3 GENERAL REPLACEMENT
The views in the Parts Section indicate wire drive and
feeder parts.
SECTION 4 MAINTENANCE
34
4.3 TROUBLESHOOTING
If welding equipment does not work properly, 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 overheating
or sparking.
To avoid shock, do not touch electrode wire or parts in
contact with it, or uninsulated cable or connections.
B. Check all gas hoses and connections, owmeters, and
regulators for possible sources of leakage, breakdown,
or intermittent failure.
C. Isolate trouble to one part of the welding installation:
primary power supply, power source, wire feeder, or
wire guide train (casing, drive rolls, liners, and con-
tact tip). If this inspection indicates trouble in the
wire feeder, refer to the following pages; Schematic
Diagram and/or Wiring Diagram.
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 qualied, as described in the maintenance
section.
CAUTION
WARNING
WARNING
SECTION 4 MAINTENANCE
35
SECTION 4 MAINTENANCE
NOTE:
Schematics and Wiring Diagrams on 279.4mm x 431.8mm
(11” x 17”) paper are included inside the back cover of this manual.
36
SECTION 4 MAINTENANCE
37
SECTION 5 REPLACEMENT PARTS
5.1 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.
5.2 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
5.0 Replacement Parts
38
SECTION 5 REPLACEMENT PARTS
ITEM
N0.
PART OR
CODE N0.
SYMBOL
(ELEC-AY
DESCRIPTION
0558005796
0558004709
22
11
11
1
1
11
11
1
1
11
11
22
11
44
11
11
1
1
ARAR
ARAR
1
ARAR
ARAR
11
ARAR
ARAR
ARAR
ARAR
11
ARAR
ARAR
11
11
11
11
11
11
1
1
11
11
11
95
2
28
1
103
2
112
1
112
1
40
1
105
1
80
AR
1 34916
BUSBAR TAB
2 8634709 FUSE HOLDER
3
4 80558003975 "D" SHAFT CRSTL .625D X 4.25LG
5 8950249 SOL1 VALVE SOL 1/4NPT 24VAC
80558006156 SOL1 VALVE SOL 1/8NPT 24VAC
6 82062161 CB1 CIRCUIT BREAKER 5A
7 993837 GROMMET .44ID .56GD
8 950263 NPL HEX 1/4 NPTM 3/16*ID HOSE
8993108 NPL HEX 1/8 NPTM 3/16*ID HOSE
9 0558001176 R1 POT 10K 3W
10 80558038286 PCB1 PCB MAIN CONTROL
11 8950302 WASHER SHLDR
12 8952626 HANDLE FOLDING TWO POSITION
13 8952687 STUD RUBBER PLAT MT
14 80558008042 CABLE WORK 10'
15 634517 S1 SW TGGL DPST 2POS 15A 125V Q/D
16 0558006693 FIT BRS ELBOW 1/4 NPT 45
0558006692 FIT BRS ELBOW 1/8 NPT 45
17 61341090 SCREW MACH HEXHD .250-20X1.00
18 61325904 SCR 10-24 X .75
19 858V58 ADAPT B/A-F GAS 1/4 NPTM BKHD
20 61325880 SCREW PHTF #8-32 X .50
21 63310916 LOCK NUT #10
22 61341144 SCREW HEX CAP 3/8-16 X .75
23 73585980 CMPD ELEC JNT ALCOA 2 EJC
24 63300100 NUT 30001 STLZPC 0.250-20
25
26 63300136 NUT HEX 3/8-16
27 22993476 FOAM STRIP.188X.750
28 61344089 SCR 1/4-20X.75 SKT FLT HX
29 64302037 WASHER LOCK .375
30
31
32 64302996 WASHER LOCK 1/4
33 950906 FAST-ON TERM 1/4 X 18 AWG
34 61388144 SCR .375 NYLOC HX CAP
35 0146970001 BRAKE PAD
36 0147315001 LOCK KEY
37 0558001082 J5 COMPACT/EURO TORCH ADAPTOR PKG
38
0558002033 KNOB .787 DIA.
39
0558004715 CABLE PLUG-LC-40
13733936 CABLE PLUG 400A
40
0558004912 MACHINE CASE 200AVS FEEDER
41
0558004913 CHASSIS FEEDER 200AVS
42
0558004914Y SPOOLER SUPPORT BRKT 200AVS
39
SECTION 5 REPLACEMENT PARTS
104
1
102
2
108
2
54
1
57
1
5
1
79
1
45
1
78
1
56
1
109
1
105
2
53
1
51
2
77
2
51
2
80
AR
1
1
93
1
32
2
11
2
17
2
66
2
110
1
98
1
97
1
12
1
76
1
80
AR
70
1
18
2
69
2
101
2
86
2
24
2
60
1
2
1
19
1
113
1
87
1
23
AR
23
AR
84
REF
87
1
23
AR
23
AR
1
1
84
REF
16
1
88
1
115
1
8
1
74
1
105
2
20
2
63
1
102
2
114
2
114
2
83
1
92
1
80
AR
124
2
123
2
20
2
111
2
106
2
K1
NON-CE UNITS
CE UNITS
ALL UNITS
CE VERSION
PCB2
NON CE VERSION
(PICTURED)
(FW)
CE VERSION
(PICTURED)
F1
PCB2
P1
SOL1
104
1
102
2
108
2
54
1
57
1
5
1
79
1
45
1
78
1
56
1
109
1
105
2
53
1
51
2
77
2
51
2
80
AR
1
1
93
1
32
2
11
2
17
2
66
2
110
1
98
1
97
1
12
1
76
1
80
AR
70
1
18
2
69
2
101
2
86
2
24
2
60
1
2
1
19
1
113
1
87
1
23
AR
23
AR
84
REF
87
1
23
AR
23
AR
1
1
84
REF
16
1
88
1
115
1
8
1
74
1
105
2
20
2
63
1
102
2
114
2
114
2
83
1
92
1
80
AR
124
2
123
2
20
2
111
2
106
2
K1
NON-CE UNITS
CE UNITS
ALL UNITS
CE VERSION
PCB2
NON CE VERSION
(PICTURED)
(FW)
CE VERSION
(PICTURED)
F1
PCB2
P1
SOL1
40
SECTION 5 REPLACEMENT PARTS
37
1
39
1
27
AR
23
AR
75
1
21
2
71
1
42
1
119
2
29
1
26
1
7
1
34
1
113
1
100
3
49
1
107
1
61
1
38
1
120
AR
18
2
46
1
118
1
9
1
15
1
89
4
36
1
84
REF
41
1
112
2
66
1
64
1
29
1
4
1
57
1
116
1
22
1
50
1
10
1
72
1
55
1
68
1
59
1
99
4
35
1
20
2
105
2
58
2
58
2
62
4
82
4
44
1
99
2
81
AR
105
2
105
2
13
4
48
1
47
1
125
2
14
1
120
AR
114
2
81
AR
6
1
73
1
43
1
94
1
118
1
LC-40 PICTURED
S1
R1
PCB1
K1
J5
PCB1
P1
P2
P3
P4
(FW)
M1
CB1
D
R2
E
41
SECTION 5 REPLACEMENT PARTS
104
1
102
2
108
2
54
1
57
1
5
1
79
1
45
1
78
1
56
1
109
1
105
2
53
1
51
2
77
2
51
2
80
AR
1
1
93
1
32
2
11
2
17
2
66
2
110
1
98
1
97
1
12
1
76
1
80
AR
70
1
18
2
69
2
101
2
86
2
24
2
60
1
2
1
19
1
113
1
87
1
23
AR
23
AR
84
REF
87
1
23
AR
23
AR
1
1
84
REF
16
1
88
1
115
1
8
1
74
1
105
2
20
2
63
1
102
2
114
2
114
2
83
1
92
1
80
AR
124
2
123
2
20
2
111
2
106
2
K1
NON-CE UNITS
CE UNITS
ALL UNITS
CE VERSION
PCB2
NON CE VERSION
(PICTURED)
(FW)
CE VERSION
(PICTURED)
F1
PCB2
P1
SOL1
42
SECTION 5 REPLACEMENT PARTS
37
1
39
1
27
AR
23
AR
75
1
21
2
71
1
42
1
119
2
29
1
26
1
7
1
34
1
113
1
100
3
49
1
107
1
61
1
38
1
120
AR
18
2
46
1
118
1
9
1
15
1
89
4
36
1
84
REF
41
1
112
2
66
1
64
1
29
1
4
1
57
1
116
1
22
1
50
1
10
1
72
1
55
1
68
1
59
1
99
4
35
1
20
2
105
2
58
2
58
2
62
4
82
4
44
1
99
2
81
AR
105
2
105
2
13
4
48
1
47
1
125
2
14
1
120
AR
114
2
81
AR
6
1
73
1
43
1
94
1
118
1
LC-40 PICTURED
S1
R1
PCB1
K1
J5
PCB1
P1
P2
P3
P4
(FW)
M1
CB1
D
R2
E
43
SECTION 5 REPLACEMENT PARTS
104
1
102
2
108
2
54
1
57
1
5
1
79
1
45
1
78
1
56
1
109
1
105
2
53
1
51
2
77
2
51
2
80
AR
1
1
93
1
32
2
11
2
17
2
66
2
110
1
98
1
97
1
12
1
76
1
80
AR
70
1
18
2
69
2
101
2
86
2
24
2
60
1
2
1
19
1
113
1
87
1
23
AR
23
AR
84
REF
87
1
23
AR
23
AR
1
1
84
REF
16
1
88
1
115
1
8
1
74
1
105
2
20
2
63
1
102
2
114
2
114
2
83
1
92
1
80
AR
124
2
123
2
20
2
111
2
106
2
K1
NON-CE UNITS
CE UNITS
ALL UNITS
CE VERSION
PCB2
NON CE VERSION
(PICTURED)
(FW)
CE VERSION
(PICTURED)
F1
PCB2
P1
SOL1
44
SECTION 5 REPLACEMENT PARTS
81F26
45
SECTION 5 REPLACEMENT PARTS
ITEM
N0.
PART OR
CODE N0.
SYMBOL
(ELEC-AY
DESCRIPTION
43 0558004915B CONTROL GUARD 200AVS
44 0558004916 DRIVE STAND INSULATOR
45 0558004917 COVER PCB 200AVS
46 0558004918Y CONTACTOR SUPPORT SHORT
47 0558004919 PLATE DISPLAY 200AVS
48 80558003353 STRAIN RELIEF INPUT NPT 3/4
49 0558004920 HUB SPOOL 200AVS
50 8951529 M1 MOTOR GEAR KSV 5035/556 (TAC)
51 182W12 FOOT RUBBER
52 61325878 SCR .164-32X.38 PAN QX
53 60909636 CLOS PE CAPLUG #6
54 8951126 CLAMP 1-EAR 10.0 GER
55 2062348 P2 PLUG HOUSING *9 POS NYLON
56 80558001339 COMPACT 4 ROLL WDS -66964
57 813735590 K1 CONTACT 1 POLE *12VDC 500ADC
58 63311886 NUT .164 NYLOC
59 837580 P4 ASSY SHORTING PLUG 6 PIN
60 13735464 F1 FUSE SLO-BLO 10 AMP
61 8951474 SWITCH SEAL BLACK
62 64304110 WSR FLAT .312
63 0558001079 GUIDE TUBE
0558001078 COM/EURO .035/.045 GUIDE TUBE
64 63310100 NUT 1/4-20 LOCK
65 64302920 WSR 52002 STLZPC 0.190
66 64304075 WSR PLAIN STLZPC .250
67 64302887 #8 LOCK WSR
68 950097 P1,P3 HOUSING CONTACT 5 PIN
69 64304050 WSR 53001 STLZPC 0.190
70 951009 P1 RCPT 6 POS 10A 300V
71 950995 CABLE TIE 14.6"LG
72 951007 P1 RCPT P/C* *5POS 10A 300V
73 951283 STRAIN RELIEF 1/2"
74 8950823 SNAP BUSHING 11/16
75 61341133 SCREW HEX CAP 3/8-16 X 1.0
76 0558954033 RATING LABBEL MOBILEFEED
77 837334 NUT HANDLE
78 954698 LABEL WARN GEAR PINCH HAZARD
79 0558954057 LABEL WARN ROLL PINCH HAZARD
0558005796
0558004709
11
11
11
11
11
11
11
11
44
ARAR
1
11
11
11
11
ARAR
11
11
11
ARAR
1
1
ARAR
ARAR
ARAR
ARAR
22
ARAR
11
ARAR
11
11
1 1
ARAR
11
22
11
11
0558005796
0558004709
ARAR
ARAR
ARAR
11
11
11
AR AR
ARAR
1
ARAR
ARAR
11
11
11
22
1 1
1
ARAR
33
ARAR
ARAR
22
11
ARAR
ARAR
ARAR
2
2
1
1
ARAR
44
ARAR
ARAR
1
11
22
ARAR
ARAR
AR
AR
22
ITEM
N0.
PART OR
CODE N0.
SYMBOL
(ELEC-AY
DESCRIPTION
80 73585435 ADH LOCTITE #242
81 76200103 SOLDER KESTER 24-6040-0027
82 63311121 LOCK NUT .312
83 13730763 NAME PLATE CODE SERIAL STOCK
84 0558004722 KIT CABLE MOBILE FEED
85 0558004719 WIRE KIT 200AVS
86 63300916 NUT 30024 STLZPC 0.190-24
87 64302150 WSR LOCK 0.438
88 0558005822B BRKT SOLENOID
89 61387910 SCR #10-32X.38W/LOCK
90
91 180W68 TYWRAP SMALL
92 0558005303 COVER WIRE REEL 200AVS
93 80558038284 PCB2 PCB RECTIFIER
94 17240001 R2 RESISTOR 1Ohm 25W
95 61344165 SCR 5/16-18X.625BLK SKT FLT HEX
96
97 954470 LABEL ESAB 3.63 X 6.00
98 2091514 LABEL WARNING GENL 7.0W X 5.06
99 61325851 SCR #6-32 X .38 PH TTF
100 2064055 WASHER SPRING 3/8
101 64302920 WASHER LOCK #10
102 61325900 SCR #10-24 X .38 PH TTF
103 61340361 SCR 5/16-18X.75 BLK SL HEX
104 13730222 SNAP BUSING 9/16
105 64304887 WSR 53001 STLZPC 0.164
106 64304175 WASHER FLAT 1/2"
107 61325087 SCR 1/4-20 X .50 QUADRX
108 821161 FEED ROLL (045-1/16) SERRATED
821156 FEED ROLL (.035/.045) V-SMOOTH
109 954565 LABEL CE LOGO
110 955269 LABEL CAUTION READ MANUAL
111 64302175 WAHER LOCK 1/2"
112 61308899 SCR #8-32 X 1.5
113 64104125 WSR FLT .375 BRASS
114 99510492 RIVET 1/8 GRIP .251-.312
115 0558005821 HOSE ASSEMBLY 18" MOBILEFEED CE
116 0156617001 BRAKE WASHER
117
118 639533 SNAP BUSHING
119 71200732 ADV .SI-RBR CLR
120 90863003 TUBING SHRINK .38
121
122
123 61325878 SCR .164-32 X .38
124 64302887 WSHR LOCK .164
125 0558006743 INSULATOR PIN
46
SECTION 5 REPLACEMENT PARTS
ITEM
N0.
PART OR
CODE N0.
SYMBOL
(ELEC-AY
DESCRIPTION
43 0558004915B CONTROL GUARD 200AVS
44 0558004916 DRIVE STAND INSULATOR
45 0558004917 COVER PCB 200AVS
46 0558004918Y CONTACTOR SUPPORT SHORT
47 0558004919 PLATE DISPLAY 200AVS
48 80558003353 STRAIN RELIEF INPUT NPT 3/4
49 0558004920 HUB SPOOL 200AVS
50 8951529 M1 MOTOR GEAR KSV 5035/556 (TAC)
51 182W12 FOOT RUBBER
52 61325878 SCR .164-32X.38 PAN QX
53 60909636 CLOS PE CAPLUG #6
54 8951126 CLAMP 1-EAR 10.0 GER
55 2062348 P2 PLUG HOUSING *9 POS NYLON
56 80558001339 COMPACT 4 ROLL WDS -66964
57 813735590 K1 CONTACT 1 POLE *12VDC 500ADC
58 63311886 NUT .164 NYLOC
59 837580 P4 ASSY SHORTING PLUG 6 PIN
60 13735464 F1 FUSE SLO-BLO 10 AMP
61 8951474 SWITCH SEAL BLACK
62 64304110 WSR FLAT .312
63 0558001079 GUIDE TUBE
0558001078 COM/EURO .035/.045 GUIDE TUBE
64 63310100 NUT 1/4-20 LOCK
65 64302920 WSR 52002 STLZPC 0.190
66 64304075 WSR PLAIN STLZPC .250
67 64302887 #8 LOCK WSR
68 950097 P1,P3 HOUSING CONTACT 5 PIN
69 64304050 WSR 53001 STLZPC 0.190
70 951009 P1 RCPT 6 POS 10A 300V
71 950995 CABLE TIE 14.6"LG
72 951007 P1 RCPT P/C* *5POS 10A 300V
73 951283 STRAIN RELIEF 1/2"
74 8950823 SNAP BUSHING 11/16
75 61341133 SCREW HEX CAP 3/8-16 X 1.0
76 0558954033 RATING LABBEL MOBILEFEED
77 837334 NUT HANDLE
78 954698 LABEL WARN GEAR PINCH HAZARD
79 0558954057 LABEL WARN ROLL PINCH HAZARD
0558005796
0558004709
11
11
11
11
11
11
11
11
44
ARAR
1
11
11
11
11
ARAR
11
11
11
ARAR
1
1
ARAR
ARAR
ARAR
ARAR
22
ARAR
11
ARAR
11
11
1 1
ARAR
11
22
11
11
0558005796
0558004709
ARAR
ARAR
ARAR
11
11
11
AR AR
ARAR
1
ARAR
ARAR
11
11
11
22
1 1
1
ARAR
33
ARAR
ARAR
22
11
ARAR
ARAR
ARAR
2
2
1
1
ARAR
44
ARAR
ARAR
1
11
22
ARAR
ARAR
AR
AR
22
ITEM
N0.
PART OR
CODE N0.
SYMBOL
(ELEC-AY
DESCRIPTION
80 73585435 ADH LOCTITE #242
81 76200103 SOLDER KESTER 24-6040-0027
82 63311121 LOCK NUT .312
83 13730763 NAME PLATE CODE SERIAL STOCK
84 0558004722 KIT CABLE MOBILE FEED
85 0558004719 WIRE KIT 200AVS
86 63300916 NUT 30024 STLZPC 0.190-24
87 64302150 WSR LOCK 0.438
88 0558005822B BRKT SOLENOID
89 61387910 SCR #10-32X.38W/LOCK
90
91 180W68 TYWRAP SMALL
92 0558005303 COVER WIRE REEL 200AVS
93 80558038284 PCB2 PCB RECTIFIER
94 17240001 R2 RESISTOR 1Ohm 25W
95 61344165 SCR 5/16-18X.625BLK SKT FLT HEX
96
97 954470 LABEL ESAB 3.63 X 6.00
98 2091514 LABEL WARNING GENL 7.0W X 5.06
99 61325851 SCR #6-32 X .38 PH TTF
100 2064055 WASHER SPRING 3/8
101 64302920 WASHER LOCK #10
102 61325900 SCR #10-24 X .38 PH TTF
103 61340361 SCR 5/16-18X.75 BLK SL HEX
104 13730222 SNAP BUSING 9/16
105 64304887 WSR 53001 STLZPC 0.164
106 64304175 WASHER FLAT 1/2"
107 61325087 SCR 1/4-20 X .50 QUADRX
108 821161 FEED ROLL (045-1/16) SERRATED
821156 FEED ROLL (.035/.045) V-SMOOTH
109 954565 LABEL CE LOGO
110 955269 LABEL CAUTION READ MANUAL
111 64302175 WAHER LOCK 1/2"
112 61308899 SCR #8-32 X 1.5
113 64104125 WSR FLT .375 BRASS
114 99510492 RIVET 1/8 GRIP .251-.312
115 0558005821 HOSE ASSEMBLY 18" MOBILEFEED CE
116 0156617001 BRAKE WASHER
117
118 639533 SNAP BUSHING
119 71200732 ADV .SI-RBR CLR
120 90863003 TUBING SHRINK .38
121
122
123 61325878 SCR .164-32 X .38
124 64302887 WSHR LOCK .164
125 0558006743 INSULATOR PIN
47
Figure 29 - Auto-Lift Mini Four Roll Geared Wire Drive System - 0558001339
1
1A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
ITEM
ITEM
PART NO
.
16
17
18
19
20
21
22
23
24
25
26
27
28
0558001743
0558001744
952927
0558001745
0558001746
23612368
23612477
0558001747
23612474
23612472
34609
0558001748
0558001749
0558003538
0558003539
0558001752
PART NO
.
DESCRIPTION
0558001753
0558001754
0558001755
0459441880
0558003540
34608
952925
23612460
23612470
23612462
0558001757
0558001895
0558001758
0558003542
Feed Plate
Safety Guard
Screw, Thumb (M6X12)
Pressure Arm
Bogie
Pressure Roll
Axle Pressure Roll
Locating Pin
Nut, Pressure Roll Axle
Circlip
Retaining Screw Pressure Arm
Spring Bogie Auto Lift
Spring to Pressure Arm Auto Lift
Spacer Tube, Small
Spacer Tube, Big
Spacer Tube Pressure Arm Auto Lift
DESCRIPTION
Spacer Tube Bogie
Axle Pressure Arm
Allen Screw
Gear Adaptor Feed Roll
Axle Gear Adaptor Feed Roll
Washer, Retaining Screw
Knurled Screw
Pressure Device w/Scale
Locating Pin, 2.5 x 12 Pressure Device
Screw (Center) Guide
Center Guide (Hard Wire)
Center Guide for (Aluminum)
Inlet Guide (Aluminum & Steel)
Main Gear Drive
1
1
1
1
1
2
2
1
2
1
1
1
1
2
2
1
Q TY.
1
1
1
2
2
3
3
1
Pkt. 5
1
1
1
1
1
Q TY.
DRIVE ROLLS
(See Drive Roll & Guide Tube Selection
Guide in SECTION 1)
SECTION 5 REPLACEMENT PARTS
48
SECTION 5 REPLACEMENT PARTS
0558006838 MobileFeed 200 HUB KIT
Item # Quantity Part Number Description
1 1 0156617001 Brake Washer
2 1 0146970001 Brake Pad
3 1 0558004920 Hub Spool 200AVS
4 3 2064055 Washer, Spring, 0.375”
5 1 64104125 Washer, Flat, Brass, 0.375”
6 1 6138 814 4 Screw, Socket, Hex, Stainless Steel, .375-16 x .75 Nylok
7 1 0147315001 Lock Key
0558006839 MobileFeed 300 HUB KIT
Item # Quantity Part Number Description
1 1 0156617001 Brake Washer
2 1 0146970001 Brake Pad
3 1 0146968880 Hub Spool 300AVS
4 2 0146969001 Pressure Spring
5 1 64104125 Washer, Flat, Brass, 0.375”
6 1 6138 814 4 Screw, Socket, Hex, Stainless Steel, .375-16 x .75 Nylok
7 1 0147315001 Lock Key
49
Original release 05 / 2005.
10 / 2005 - Removed magnetic ground pick-up from illustrations and Replacement Parts (Item 83) per ECN
#053136.
01 / 2006 - Updated Schematic and removed Wiring Diagram. Added “CE” version. Changed product name
from MobileMaster 8AVS to MobileFeed 200 AVS. Updated Replacement Parts.
Reference ECN #053192.
06 / 2006 - Updated per Joe DeVito inputs.
07 / 2006 - Updated per Joe DeVito inputs.
10 / 2006 - Updated Replacement Parts and wire feeder illustrations.
04 / 2007 - Updated Drive Roll and Guide Tube table in Section 1 per Mike Palumbo inputs.
03 / 2008 - Updated pictures and updated Replacement Parts section per CN#083002.
04 / 2008 - Updated picture and Replacement Parts section (pages 40, 44 and 46) per John Magee inputs.
07 / 2008 - Updated Replacement Parts section, added hub kit parts along with other minor text changes
per John Magee red-lines.
REVISION HISTORY
0558004754 07 / 2008
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES

Transcripción de documentos

MobileFeed 200 AVS Portable “Off The Arc” Wire Feeder Instruction Manual 0558004754 07 / 2008 Be sure this information reaches the operator. You can get extra copies through your supplier. caution These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding 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 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 or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the 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 service facility designated by the manufacturer. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! 4 TABLE OF CONTENTS SECTION TITLE PAGE SAFETY PRECAUTIONS........................................................................................................................... 7 SECTION 1 1.1 1.2 1.3 DESCRIPTION............................................................................................................... 19 General..........................................................................................................................................................21 Receiving-Handling..................................................................................................................................21 Description..................................................................................................................................................21 SECTION 2 2.1 2.2 2.3 2.4 2.5 2.6 INSTALLATION............................................................................................................. 23 Drive Rolls....................................................................................................................................................23 Welding Wire Speed.................................................................................................................................23 Torch Connections....................................................................................................................................24 Supply Connections.................................................................................................................................24 Threading the Welding Wire..................................................................................................................25 Brake Drag Adjustment...........................................................................................................................25 SECTION 3 OPERATION.................................................................................................................. 27 3.1 Controls........................................................................................................................................................27 3.1.1 Power Switch..............................................................................................................................................27 3.1.2 Wire Feed Speed (Arc Voltage Control).............................................................................................27 3.1.3 Wire Feed Speed (Constant Speed)....................................................................................................27 3.1.4 5 amp Circuit Breaker (CB1)...................................................................................................................27 3.2 Operating Procedures.............................................................................................................................29 3.2.1 Operating Safety Precautions...............................................................................................................29 3.3 Setting A Welding Procedure................................................................................................................30 3.4 Shutdown....................................................................................................................................................31 SECTION 4 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 MAINTENANCE............................................................................................................ 33 Maintenance...............................................................................................................................................33 Inspection and Service............................................................................................................................33 Wire Feeder.................................................................................................................................................33 Solenoid Valve Replacement................................................................................................................33 General Replacement..............................................................................................................................33 Troubleshooting........................................................................................................................................34 SECTION 5 REPLACEMENT PARTS................................................................................................. 37 5 TABLE OF CONTENTS 6 safety precautions 1.0 Safety Precautions 1.1 Safety - English WARNING: These Safety Precautions are for your protection. They summarize precautionary 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. FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore: 1. Remove all combustible materials well away from the work area or cover the materials with a protective 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 produce 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. 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 necessary. 7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 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 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 longsleeve shirt, cuffless 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 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. 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 confined, or if there is danger of falling. 7 safety precautions 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 3. Welders should use the following procedures to minimize exposure to EMF: 2. Connect the workpiece to a good electrical ground. A. Route the electrode and work cables together. Secure them with tape when possible. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. 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. 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. 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. 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. Therefore: 9. Turn off the power before removing your gloves. FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. 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. 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. 2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases. ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 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 improve ventilation in the work area. Do not continue to operate if physical discomfort persists. 1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. 4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations. 2. Exposure to EMF may have other health effects which are unknown. 8 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.) 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power. 3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition. CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 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. 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 regulator to a compressed gas cylinder. 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. 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. ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529. 3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders. 4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder. The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 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. 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" EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 9 safety precautions 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances." Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved. Means immediate hazards which, if not avoided, will result in immediate, 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. 10 sEGURIDAD 1.2 Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora. ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte. FUEGO Y EXPLOSIONES -- El calor de las flamas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones. Por lo tanto: 1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc. 2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos. 3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inflamables. 4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso. 5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego. 6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario. 7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco, como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto: 1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección. 2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido. 3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas. 4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados. 5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable como división. 6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo. CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo. 11 sEGURIDAD 1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de tierra física. 3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal. 4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos. 5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder. 6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra. 7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma. 8. Use guantes secos y sin agujeros antes de energizar el equipo. 9. Apage el equipo antes de quitarse sus guantes. 10. Use como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra. 3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF: A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible. B. Nunca envuelva los cables de soldar alrededor de su cuerpo. C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo. D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la soldadura. E. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo. HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto: 1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales. 2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es. 3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste. 4. Haga referencia a la publicación ANSI/ASC Standard Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación. CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente eléctrica fluye através de cualquier conductor causando a nivel local Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto: 1. Soldadores u Operadores que use marca-pasos para el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos. 2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos. 12 sEGURIDAD 5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.) 1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo. 2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria. 3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones. 4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo. 5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones. 6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna manera. MANEJO DE CILINDROS-- Los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto: 1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido. INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form 52-529. 2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico. Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted: 3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto: 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 13 sEGURIDAD SIGNIFICADO DE LOS sImbolOs -- Según usted avanza en la lectura de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se trata de su seguridad. Significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte. Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte. Significa el posible riesgo que puede resultar en menores daños a la persona. 14 sÉCURITÉ 1.3 Safety - French INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. Par conséquent : AVERTISSEMENT : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les fiches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles. 1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc. 2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent. 3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inflammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser. 4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement. 5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie. 6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin. 7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent: 1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches. 2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent. 3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes afin de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par rayonnement. 4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant. 5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininflammable. 6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité. CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose. 15 sÉCURITÉ 1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée. 2. Branchez la pièce à traiter à une bonne mise de terre électrique. 3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d'éviter le risque de choc électrique mortel. 4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés. 5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation. 6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre. 7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc. 8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous. 9. Mettez l'équipement hors tension avant d'enlever vos gants. 10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre. 3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques : A. Acheminez l'électrode et les câbles de masse ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible. B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps. C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même côté de votre corps. D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder. E. Veillez à garder la source d'alimentation pour le soudage et les câbles à une distance appropriée de votre corps. LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent : 1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique. N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation efficaces. Ne respirez pas les vapeurs de ces matériaux. 2. N'effectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lorsque la chaleur ou le rayonnement de l'arc entre en contact avec les vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques. 3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste. 4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation. CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conducteur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent : 1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques. 2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé. 16 sÉCURITÉ 5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.) ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent : 1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualifié. N'effectuez aucune réparation électrique à moins d'être qualifié à cet effet. 2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique. 3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque. 4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des flaques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries. 5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état. 6. Utilisez l'équipement conformément à son usage prévu et n'effectuez aucune modification. MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent : 1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé. 2. Fixez les cylindres dans une position verticale, à l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique. 3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin. 4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes. Ne jamais amorcer l'arc sur un cylindre. 5. Pour de l'information supplémentaire, consultez CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202. INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529. Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 : 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" 17 sÉCURITÉ SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu. DANGER Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles. AVERTISSEMENT Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles. ATTENTION Signifie un danger qui peut entraîner des blessures corporelles mineures. 18 SECTION 1 • • • • • • • • • • • • DESCRIPTION Arc voltage feeder capable of use with Constant Current (CC) or Constant Voltage (CV) units Available with “CC” torch connection 4 roll drive stand Secondary contactor Built for harsh environments such as construction sites, pipe lines, shipyards, offshore, general fabrication, mobile welding rigs and more Totally enclosed, impact-resistant case protects welding wire from dirt, metal grit, moisture and other contaminants. Molded plastic case will stand extreme abuse like hot slag, grinding sparks, corrosive chemicals, knocks, bumps, drops and more Operates with reverse polarity (wire DC +) or straight polarity (wire DC-) Permanent magnet drive motor with PWM drive, solid state control - provides powerful, dependable wire feeding and controlled wire acceleration for smooth arc starts and chatterfree solenoid operation Electronic Dynamic Braking Safety features include insulated case, low voltage torch trigger circuit and overload protection Meets lEC-974-1 specifications. Ordering Information MobileFeed 200 AVS Feeder Each MobileFeed wire feeder includes gas solenoid and dual groove feed rolls. (AVS = Arc Voltage Sensing) MobileFeed 200 AVS LC40 .............................. 0558004709 Includes .045 - 1/16 in. (1.2 - 1.6 mm) serrated groove drive rolls. Common to MobileFeed 200 AVS MobileFeed 200 AVS OKC CE ......................... 0558005796 Standard - 2-in (5.1 cm) ID spindle hub 8 in. OD (20.3 cm) spools - no adaptor required Includes .035 - .045 in. (0.9 - 1.2 mm) V groove drive rolls. Note: 0558004709 has LC40 type cable connector and 0558005796 has OKC type cable connector. Physical Dimensions Case W x H x L..................................................................... 6.75” x 14.00” x 18.50” ................................................................................. (171mm x 356mm x 470mm) Specifications MobileFeed feeders will fit through 14.25 in. (362mm) diameter hole. MobileFeed 200 AVS Wire Speed Range*....................................... 50 - 800 ipm (1.3 - 20.3 m/min) * actual speed range will depend on the arc voltage Wire Diameter Capacity................................... .030 - 5/64 in. (0.8 - 2.0 mm) Primary Input** (open circuit voltage or arc voltage) Minimum..................................................................................................16.5vdc Maximum.......................................................................... 100vdc (113v peak) ** not for use with AC power Weight ..............................................................................................26 lbs (11.8 kg) Required Accessories Drive Rolls & Guide Tubes ............................. see table on next page 19 SECTION 1 DESCRIPTION Controls are located on a recessed front panel to protect dial and switch Clamp Shock mounts and a flexible base provide “give” to the case enabling the wire feeder to survive a drop, even fully loaded Voltage pickup cable is included with MobileFeed 200 AVS Wire drive system uses dual groove feed rolls. Built-in, insulated quick connector - no extra gas hoses or switch cables hanging from the feeder Drive Rolls and Guide Tubes for: MobileFeed 200 AVS Outlet Guide Tube Wire Diameter Desc. .030 in. (0.8 mm) V-Groove .040 in. (1.0 mm) .040 in. (1.0 mm) EURO Qty Center Guide Roll Qty 0369 557 002 2 0558001077 1 0558001757 1 0558001758 1 V-Groove 0369 557 002 2 0558001078 1 0558001757 1 0558001758 1 V-Groove 0369 557 003* 2 0558001078 1 0558001757 1 0558001758 1 .045 in. (1.2 mm) V-Groove 0369 557 003* 2 0558001078 1 0558001757 1 0558001758 1 .045 in. (1.2 mm) V-Groove X2 0369 557 010 2 0558001078 1 0558001757 1 0558001758 1 .052 in. (1.4 mm) V-Groove 0369 557 013 2 0558001079 1 0558001757 1 0558001758 1 .062 in. (1.6 mm) V-Groove 0369 557 013 2 0558001079 1 0558001757 1 0558001758 1 .030 in. (0.8 mm) K-Cored 21160 2 0558001077 1 0558001757 1 0558001758 1 .035 in. (0.9 mm) K-Cored 21160 2 0558001078 1 0558001757 1 0558001758 1 .045 in. (1.2 mm) K-Cored 21161 2 0558001079 1 0558001757 1 0558001758 1 .052 in. (1.4 mm) K-Cored 21161 2 0558001079 1 0558001757 1 0558001758 1 1/16 in. (1.6 mm) K-Cored 21161 2 0558001079 1 0558001757 1 0558001758 1 5/64 in. (2.0 mm) K-Cored 21162 2 0558001079 1 0558001757 1 0558001758 1 3/64 in. (1.2 mm) U-Soft 21159 2 0558001898 1 0558001895 1 0558001758 1 1/16 in. (1.6 mm) U-Soft 21159 2 0558001898 1 0558001895 1 0558001758 1 + *As delivered on 0558005796, 0558005728 and 0558005832 Two lower drive rolls are required for four roll drive systems. + Use flat, plain pressure roll(s) (P/N 0455 907 001) supplied with wire feeder. 20 Qty Inlet Guide Qty SECTION 1 DESCRIPTION 1.1 GENERAL 1.3 DESCRIPTION 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 performance of this equipment. The MobileFeed 200 AVS is a portable wire feeder designed for maximum versatility. The unit is powered entirely on the arc voltage from a constant current or constant voltage welding power source. All models include a secondary contactor for added operator safety. The unit is designed for use with hard, soft, and cored electrodes (gas shielded or self-shielded) from 0.030” (0.8mm) through 5/64” (1.98mm) diameter with wire feed speed from 50 to 800 IPM (1.8-20.3 m/mm). The feeder components are totally enclosed in a rugged case for optimum mobility. 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 carrier. A copy of the bill of lading and freight bill will be furnished by the carrier on request if occasion to file claim arises. NOTE The MobileFeed 200 AVS is not recommended for short circuiting transfer using constant current power sources due to the limited short circuit current available on constant current power sources. TABLE 1-1 SPECIFICATIONS Wire Feed Speed Maximum open circuit voltage Wire diameters 50 - 800 in./min. (1.3 - 20.3 m/min.) 100 vdc (113 vdc peak) Hard: .030” (0.8mm), .035” (0.9mm), .045” (1.2mm), .052” (1.4mm), 1/16” (1.6mm) Soft: .035” (0.9mm), 3/64” (1.2mm), 1/16” (1.6mm) Cored: .030” (0.8mm), .035” (0.9mm), .045” (1.2mm), .052” (1.4mm), 1/16” (1.6mm), 5/64” (2.0mm) Wire package Motor type Brake type (wire) Control Feed System On-Off Switch Run in start 8” (203mm) diameter spool DC permanent magnet pre-lubricated, totally enclosed Drag Solid State Push Standard Automatic if required. Height Width Length Weight (with contactor, without spool) 14.00” (356mm) 6.75” (171mm) 18.50” (470mm) 26 lbs. (11.8Kg) The MobileFeed 200 AVS will fit through a 14.25” (362mm) dia. hole. 21 SECTION 1 22 DESCRIPTION SECTION 2 INSTALLATION 2.1 DRIVE ROLLS AND GUIDE TUBES 2.2 WELDING WIRE INSTALLATION The drive rolls have two grooves. The unit is supplied ready to feed 0.045”, .052” or 1/16” (1.2 to 1.6mm) diameter cored wires or .035 - .045 (0.9 - 1.2mm) hard wires depending on the part number ordered. (Other drive rolls are available to feed other sizes of hard wire, soft wire, and cored wire. See Drive Roll and Guide Tube Selection Chart and Table 1-1) Install a spool of welding wire on the hub as follows: A. Turn the red spool retainer in the hub as shown in picture below. B. Place the wire spool on the hub to rotate counterclockwise as the wire is unwound; hub pin must engage the hole in the wire spool. C. Turn the red spool retainer in the hub to lock the retaining tabs. A. Release the pressure roll assembly lever and lift the Pressure Roll Assembly upward. B. Remove the knurled screw holding the drive roll to the gear adaptor. C. Check and install proper guide tubes. D. Reverse or replace drive rolls with the required size designation which is imprinted on the side of the roll facing out. E. Replace the screw removed in Step B and tighten. F. Thread the wire and secure the pressure roll assembly. PRESSURE ROLL ASSEMBLY LEVER PRESSURE ROLL PRESSURE ROLL ASSEMBLY KNURLED SCREW Drive Roll Detail SPOOL RETAINER WIRE SPOOL HUB Spindle Detail 23 DRIVE ROLL SECTION 2 INSTALLATION WARNING 2.3 TORCH CONNECTIONS 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. The torch adaptor on the MobileFeed connects directly to the wire feeder wire drive assembly, power and shielding gas supply. Line up the torch connector with the wire feeder adaptor, push on firmly and hand tighten the locking collar on the Euro Connector. B. Connect a second welding cable (work lead) between the opposite polarity output connection on the power source and the work piece. C. Connect the wire feeder work lead (voltage pick-up) alligator clip to the work piece. D. If using with gas shielded wire, connect the inlet gas hose to the gas inlet connections on the rear of the feeder. caution 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. 1. 2.4 SUPPLY CONNECTIONS 2. WARNING 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. 3. 4. Make sure all hose and cable connections are tight. Turn power source “ON” and close the contactor if power source is equipped with an output contactor control switch. Open circuit voltage must be present to operate the wire feeder. Turn wire feeder power switch “ON”. Inspect all gas connections for leaks. The MobileFeed 200 AVS can be used with either DCEP or DCEN polarity without modifications. WARNING A. Connect the welding cable from the power source; positive terminal for gas shielded flux cored or solid wires, or negative for most gasless self-shielded cored wires, to the weld cable lug connection extending from the rear of the MobileFeed 200 AVS feeder. Unless starting to weld, do not allow the welding wire to touch a grounded metal surface. The welding wire becomes electrically hot when the secondary contactor is closed. Keep fingers clear of the drive rolls; they will start turning when the torch trigger is pressed. 5. 6. If using gas shielded wires, adjust the gas flowmeter to the desired flow rate by closing the gun trigger switch. Turn power source and wire feeder OFF when not in use. POWER SOURCE MOBILEFEED - (or +) TORCH + (or -) WORK LEAD WELDING CABLES WORK Figure 2.2 - Typical Set-up of MobileFeed 200 AVS 24 SECTION 2 INSTALLATION 2.5 THREADING THE WELDING WIRE 2.6 BRAKE DRAG ADJUSTMENT WARNING Brake disc friction should provide enough drag to keep the wire spool from spinning freely after the wire feed stops. When the wire feeder is connected to the power source, the work lead from the power source is connected to the work piece and the power source is energized, closing the torch trigger will cause the welding wire to become electrically hot and will cause the drive rolls to turn. Keep fingers clear! The brake hub is adjusted when delivered, if readjustment is required, follow the instructions below. Adjust the brake hub so that wire is slightly slack when wire feed stops. Adjusting the braking torque: A. Turn OFF the power source and the wire feeder. B. Release the pressure roll assembly lever and check for the proper drive roll, groove position and wire guides. caution Before threading welding wire, 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 liner. • Turn red handle to the unlocked position and pull straight out to remove. • Using a 0.31” (7.9mm) Allen wrench, turn the Nyloc screw clockwise to increase the braking torque. • Using a 0.31” (7.9mm) Allen wrench, turn the Nyloc screw counterclockwise to reduce the braking torque. C. Feed the wire from the spool through the inlet guide along the drive roll groove and into the outlet guide tube. 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. NYLOC SCREW RED HANDLE 25 SECTION 2 26 INSTALLATION SECTION 3 OPERATION 3.1 CONTROLS 3.1.1 POWER SWITCH The ON-OFF switch on the front of the wire feeder case energizes the wire feeder when the feeder is connected to the power source and the work piece, and the power source is turned ON with the contactor closed. 3.1.3 WIRE FEED SPEED (CONSTANT SPEED) The MobileFeed 200 AVS can be switched to a “Non” Voltage Control Mode where the wire feed speed remains relatively constant and will not change speed with changes in arc voltage. Locate switch SW1 on the PC board and position S1 and S2. See Figure 3-2 and Table 3.1. 3.1.2 WIRE FEED SPEED (ARC VOLTAGE CONTROL) The wire feed speed is controlled by the wire feed speed dial on the front of the wire feeder case. When connected to a constant voltage (cv) type power source, the wire feed speed dial controls the welding current. Turning the dial clockwise increases welding current; turning it counterclockwise decreases welding current. SW1 Position S1 - open Position S2 - closed When connected to a constant current (cc) type power source, the wire feed speed dial controls the arc voltage. Turning the wire feed speed dial clockwise decreases arc voltage; turning it counterclockwise increases arc voltage. The actual wire feed speed for any given setting varies with the arc voltage. Increasing arc voltage causes an increase in wire feed speed. Figure 3.2 (Factory settings are as follows: S1 - closed, S2 - open) The MobileFeed 200 AVS wire feeder is equipped with automatic “Slow wire run-in”. If the wire feeder senses that the power source output voltage is in excess of 33 volts, the “run-in” wire speed automatically decreases for a fixed period of time (250ms) to improve arc starts. When the arc is established, the wire feed speed is controlled by the wire feed speed control knob on the MobileFeed front panel. 3.1.4 5 amp CIRCUIT BREAKER (CB1) This resettable 5 amp circuit breaker, in series with motor armature, protects the control board from damage if the motor is stalled. WELDING CABLE CONNECTION WIRE SPEED CONTROL POWER ON-OFF SWITCH 5 amp Circuit Breaker WORK LEAD TORCH CONNECTION SHIELD GAS CONNECTION Figure 3.1 - Controls and Connections, MobileFeed 200 AVS 27 SECTION 3 Table 3.1 OPERATION MobileFeed Dip Switch Table Switch Position OPEN (OFF) CLOSED (ON) Description OPEN 1 2 Rocker Down OPEN 1 2 Rocker Down Factory Setting - Constant Current Operation ( “Voltage Control Mode” ) In this operation mode the MobileFeed feeder is ready for connection to a “ Constant Current “ power source which typically provides a high open circuit voltage and low short circuit current which makes arc starting difficult. Therefore, “slow run-in” of the wire is automatically enabled if OCV exceeds 33 volts to provide good and reliable arc starting. The arc length during welding is determined by a combination of the wire feed speed knob position (MobileFeed feeder front panel) and the weld “Current” setting on the CC power source. When a good welding condition is achieved, the arc length will be maintained by changes in wire feed speed provided by arc voltage control. Variables causing changes in arc voltage, for example, wire “stick-out”, wire density or shielding variations, will cause the wire feed speed to compensate to maintain the arc length preset. Alternate Setting - Constant Voltage Operation ( “Constant Wire Feed Speed” ) In this operation mode the feeder is ready for connection to “ Constant Voltage “ power source which is typically used for most GMAW (MIG/MAG) welding. CV power sources provide high short circuit currents for good arc starting and wire burn-off. “Slow run-in” of the wire is automatically disabled. The arc length while welding is determined by a combination of the wire feed speed knob position (MobileFeed feeder front panel) and the weld “Voltage” setting on the CV power source. When a good welding condition is achieved, the arc length will be maintained by the power source and the wire feed speed will remain constant. Any variations in wire “stick-out”, wire density or shielding variations, could cause the arc length (arc voltage) variations. The DIP switches are located on the control PCB. NOTE: If both switches are placed in the OPEN (Off ) position the wire feed motor is disabled and the motor will NOT run. 28 SECTION 3 OPERATION 3.2 OPERATING PROCEDURES 3.2.1 OPERATING SAFETY PRECAUTIONS Comply with all ventilation, fire and other safety requirements for arc welding as established in the SAFETY Section at the front of this manual. G. Whenever the equipment is left unattended, turn OFF all control power, power supply switches and gas supplies. Open the main line switch. H. Wear dark substantial clothing to protect exposed skin from arc burn, sparks and flying hot metal. I. Turn off welding power before adjusting or replacing electrodes. 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 helmet. The helmet filter plate should be shade number 11 (nonferrous) or 12 (ferrous). All those viewing the arc should use helmets with filter plates, as well as flash goggles. Nearby personnel should wear flash goggles. B. The radiant energy of the arc can decompose chlorinated solvent vapors, such as trichloroethane and perchlorethylene, to form phosgene, even when these vapors are present in low concentrations. DO NOT weld where chlorinated solvents are present in atmospheres in or around the arc. C. DO NOT touch the electrode, contact tip or metal parts when power is ON: all are electrically energized (HOT) and can cause a possibly fatal shock. DO NOT allow electrode to touch grounded metal. It will create an arc flash that can injure eyes. It may also start a fire or cause other damage. 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 approved oxygen measuring instrument. The confined 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. 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. WARNING 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. WARNING Prior to welding, it is imperative that proper protective clothing (welding coat and gloves) and eye protection (glasses and/or welding helmet) be put on. Failure to comply may result in serious injury caution Do not terminate the arc by removing the torch from the weld area. Release the torch trigger to stop welding before removing the torch. WARNING Failure to shut OFF shield gas in a confined space may result in a build-up of fumes, displacing oxygen. 29 SECTION 3 OPERATION 3.3 SETTING A WELDING PROCEDURE QUICK SET-UP PROCEDURE 1. 2. 3. For Constant Voltage (CV) Power Source - Set the arc voltage desired on the P/S. For Constant Current (CC) power source - Set the weld CURRENT desired. On the MobileFeed Unit - Set the wire feed speed knob at #5. WELD DATA TABLE WIRE/DIAMETER / DIAMETER WIRE 100 150 .045 FLUX CORE FLUX CORE E70T-1 & 2 E70T-1 & 2 .052 1/16 25 155 27 190 FEED SPEED(IPM) (IPM) SPEED FEED WIRE WIRE 200 250 300 350 400 450 29 150 30 300 30 300 .045 METAL METAL CORE CORE .052 30 300 1/16 29 275 30 350 29 210 33 365 28 250 29 300 32 400 32 300 26 280 25 180 27 300 25 200 28 320 SOLID WIRE 1/16 AL / Si Al/Si ALUMINUM ALUMINUM AL / Mg Al/Mg ALUMINUM ALUMINUM 3/64 26 190 27 205 27 220 1/16 3/64 1/16 22 100 25 220 28 340 39 500 32 350 30 325 34 450 26 290 25 110 27 340 25 140 25 260 30 400 26 150 26 200 23 150 23 260 30 300 23 175 24 190 32 350 25 205 23 200 25 250 27 280 27 290 .045 26 215 27 230 30 340 VOLTS/ /AMPS AMPS (WELD CURRENT) ARC ARC VOLTS (WELD CURRENT) 30 600 34 330 37 500 36 500 33 450 30 270 .035 STEEL STEEL SOLID WIRE 550 33 290 30 250 33 460 33 410 29 260 500 28 245 650 SECTION 3 MobileFeed 200 WITH CONSTANT CURRENT Power Sources 1. 2. 3. 4. 5. OPERATION MobileFeed 200 WITH CONSTANT VOLTAGE Power Sources Using the table, select the weld CURRENT / VOLTAGE needed for the wire type and diameter to be welded. Set the power supply CURRENT using the current control knob on the front panel of the power source. Read the WIRE FEED SPEED (WFS) at the top of the column for the wire type, diameter and weld VOLTAGE / CURRENT chosen. Use the VOLTAGE and WFS in the WFS Table to determine the MobileFeed wire feed knob position. Strike an arc then trim the arc length as needed using the VOLTS / WFS knob. 1. 2. 3. 4. 5. Using the table, select the weld VOLTAGE / CURRENT needed for the wire type and diameter to be welded. Set the power supply VOLTAGE using the voltage control knob on the front panel of the power source. Read the WIRE FEED SPEED (WFS) at the top of the column for the wire type, diameter and weld VOLTAGE / CURRENT chosen. Use the VOLTAGE and WFS in the WFS Table to determine the MobileFeed wire feed knob position. Strike an arc then trim the arc length as needed using the VOLTS / WFS knob. NOTE Using the “Constant Feed” dip switch settings when using a CC power source is NOT RECOMMENDED. Extreme wire feed speed sensitivity exists making it difficult to set stable welding condition. The arc stability is very dependant on maintaining constant TTW distance which is almost impossible to control when welding manually. “Constant Speed” settings is only recommended for use with CV power sources. Typical welding voltages for 5000 Aluminum are between 21 and 25 volts which limits the wire feed speed of the MobileFeed especially if trying to weld with 035” diameter 5356 alloy. Welding with wire diameters ≤3/64” and/or below 22 arc volts could cause problems with limited wire feed speed and the inability to achieve a good welding condition. WIRE FEED SPEED TABLE *WFS Wire Speed SetSet 19 V 20 V 21 V 22 V 23 V 24 V 25 V 26 V 27 V 28 V 29 V 30 V 31 V 32 V 33 V 34 V Min Min 1 2 3 4 5 6 7 8 9 Max 0 4 44 99 152 210 267 334 380 385 395 0 5 51 109 163 225 282 354 411 427 435 0 5 56 116 170 235 292 368 431 454 462 0 6 65 129 184 255 312 395 472 510 515 0 6 70 136 196 270 331 415 494 536 544 0 7 74 140 204 281 345 430 511 556 565 0 7 77 144 211 290 356 441 523 571 581 0 7 85 155 230 315 388 475 560 615 630 0 9 90 165 241 329 412 503 589 649 667 0 11 93 173 250 339 430 524 610 674 695 0 12 95 179 256 347 443 540 626 693 716 0 15 103 196 275 370 483 587 675 750 779 0 14 102 198 282 379 490 594 685 770 803 0 13 102 200 287 385 495 599 693 785 820 0 13 101 201 291 390 499 603 698 796 833 0 11 100 205 302 405 510 615 715 830 873 * MobileFeed Wire Feed Speed Knob Position NOTE On many CV power sources the actual welding arc voltage is usually less the “Open Circuit Voltage” (OCV) set on the power source front panel. Therefore, an extra 3 to 6 volts should be added to the power source front panel setting to achieve the “actual” arc voltage needed or shown in the tables. 3.4 SHUTDOWN A. Release torch trigger to break the arc. B. When leaving the equipment unattended, always shut OFF and disconnect all power to the equipment and shut off the shielding gas supply at source. 31 SECTION 3 32 OPERATION SECTION 4 MAINTENANCE 4.1 MAINTENANCE WARNING Be sure the branch circuit or main disconnect switch is OFF or electrical input circuit fuses are removed from the power source main supply before attempting any inspection or work on the inside 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. Keep power cables dry, free of oil and grease, and protected 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 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 improper feeding. WARNING 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 electronic equipment. Maintenance or repair should not be undertaken by anyone not having such qualifications. 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 accumulation being removed may do. As an aid in checking and servicing, refer to the following pages; Schematic Diagram and/or Wiring Diagram. 4.2.2 SOLENOID VALVE REPLACEMENT If there is no gas flow through the wire feeder, the gas solenoid valve may be clogged or electrically 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 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. 4.2.3 GENERAL REPLACEMENT The views in the Parts Section indicate wire drive and feeder parts. Regularly check cylinder valves, regulators, hoses, and gas connections for leaks with soap solution. Check for and tighten loose hardware including electrical connections. Loose power connections overheat during welding. Immediately replace all worn or damaged power cables and connectors. Check for frayed and cracked insulation, particularly in areas where conductors enter Equipment. 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 electrical hazards. WARNING 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. 33 SECTION 4 MAINTENANCE 4.3 TROUBLESHOOTING If welding equipment does not work properly, inspect as follows: WARNING A. With all power controls ON and other operating controls at required settings, visually check all power cables and connections for evidence of overheating or sparking. 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. WARNING caution To avoid shock, do not touch electrode wire or parts in contact with it, or uninsulated cable or connections. B. Check all gas hoses and connections, flowmeters, and regulators for possible sources of leakage, breakdown, or intermittent failure. C. Isolate trouble to one part of the welding installation: primary power supply, power source, wire feeder, or wire guide train (casing, drive rolls, liners, and contact tip). If this inspection indicates trouble in the wire feeder, refer to the following pages; Schematic Diagram and/or Wiring Diagram. Do not make any repairs to equipment unless you are fully qualified, as described in the maintenance section. 34 SECTION 4 MAINTENANCE NOTE: Schematics and Wiring Diagrams on 279.4mm x 431.8mm (11” x 17”) paper are included inside the back cover of this manual. 35 SECTION 4 36 MAINTENANCE SECTION 5 REPLACEMENT PARTS 5.0 Replacement Parts 5.1 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. 5.2 Ordering 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. Note Bill of material items that have blank part numbers are provided for customer information only. Hardware items should be available through local sources. 37 SECTION 5 103 2 112 1 80 AR REPLACEMENT PARTS 105 1 112 1 95 2 28 1 38 40 1 110 1 CE UNITS SECTION 5 REPLACEMENT PARTS SOL1 5 1 123 2 80 AR 16 1 8 1 80 AR 56 1 54 1 124 2 N (P (FW) 115 1 88 1 105 2 20 2 19 1 CE VERSION (PICTURED) 87 1 87 1 84 REF 84 REF 23 AR 23 AR K1 1 1 113 1 23 AR 57 1 1 1 12 1 23 AR ALL UNITS 97 1 92 1 NON-CE UNITS 98 1 110 1 CE UNITS 39 SOL1 102 2 SECTION 5 REPLACEMENT PARTS R2 81 AR 114 2 120 AR 94 1 E 7 1 66 1 (FW) 64 1 105 2 112 2 47 1 R1 9 1 D 81 120 AR 38 AR 1 CB1 6 1 S1 15 1 41 1 99 2 43 1 35 1 49 1 113 1 100 3 34 1 61 1 27 AR 14 1 36 1 89 4 44 1 46 1 107 1 13 4 62 4 82 4 105 2 20 2 105 2 73 1 42 1 58 2 58 2 84 REF 39 1 48 1 LC-40 PICTURED 40 118 1 SECTION 5 REPLACEMENT PARTS 78 1 79 1 76 1 114 2 83 1 114 2 45 1 92 1 CE VERSION 102 2 109 1 NON-CE UNITS 98 1 16 1 8 1 80 AR 56 1 54 1 108 2 63 1 F1 2 1 104 1 NON CE VERSION (PICTURED) 19 1 87 1 84 REF K1 102 2 23 AR 41 20 2 105 2 53 1 60 1 64 1 105 2 SECTION 5 112 W) 2 47 1 R1 9 1 D REPLACEMENT PARTS 81 120 AR 38 AR 1 CB1 6 1 S1 15 1 61 1 99 2 43 1 27 AR PCB1 P1 72 10 1 1 14 1 44 1 105 2 73 1 P2 55 1 P3 68 1 P4 59 1 99 4 42 1 58 2 M1 50 1 58 2 71 1 119 2 PCB1 84 REF 39 1 48 1 LC-40 PICTURED 118 1 118 1 K1 57 1 22 1 116 1 42 29 1 4 1 J5 37 1 18 2 21 2 125 2 23 AR 75 1 29 1 26 1 SECTION 5 CE VERSION REPLACEMENT PARTS 109 1 80 AR 106 2 111 2 77 2 56 1 108 2 51 2 63 1 F1 2 1 60 1 104 1 NON CE VERSION (PICTURED) 19 1 20 2 105 2 53 1 2 PCB 74 1 51 2 PCB2 P1 93 1 70 1 18 2 69 2 43 101 2 86 2 11 2 17 2 66 2 32 2 24 2 0558004709 0558005796 SECTION 5 2 2 1 1 1 2 8634709 1 1 ITEM N0. PART OR CODE N0. SYMBOL (ELEC-AY REPLACEMENT PARTS DESCRIPTION BUSBAR TAB 34916 FUSE HOLDER 3 4 80558003975 5 8950249 1 80558006156 1 "D" SHAFT CRSTL .625D X 4.25LG SOL1 VALVE SOL 1/4NPT 24VAC SOL1 VALVE SOL 1/8NPT 24VAC CB1 CIRCUIT BREAKER 5A 1 1 6 82062161 1 1 7 993837 GROMMET .44ID .56GD 8 950263 NPL HEX 1/4 NPTM 3/16*ID HOSE 1 8993108 1 9 0558001176 NPL HEX 1/8 NPTM 3/16*ID HOSE R1 POT 10K 3W PCB1 PCB MAIN CONTROL 1 1 1 1 10 80558038286 2 2 11 8950302 WASHER SHLDR 1 1 12 8952626 HANDLE FOLDING TWO POSITION 4 4 13 8952687 STUD RUBBER PLAT MT 1 1 14 80558008042 1 1 15 634517 16 0558006693 FIT BRS ELBOW 1/4 NPT 45 0558006692 FIT BRS ELBOW 1/8 NPT 45 1 1 CABLE WORK 10' S1 SW TGGL DPST 2POS 15A 125V Q/D AR AR 17 61341090 SCREW MACH HEXHD .250-20X1.00 AR AR 18 61325904 SCR 10-24 X .75 1 19 858V58 ADAPT B/A-F GAS 1/4 NPTM BKHD AR AR 20 61325880 SCREW PHTF #8-32 X .50 AR AR 21 63310916 LOCK NUT #10 1 1 22 61341144 SCREW HEX CAP 3/8-16 X .75 AR AR 23 73585980 CMPD ELEC JNT ALCOA 2 EJC AR AR 24 63300100 NUT 30001 STLZPC 0.250-20 25 AR AR 26 63300136 NUT HEX 3/8-16 AR AR 27 22993476 FOAM STRIP.188X.750 1 1 28 61344089 SCR 1/4-20X.75 SKT FLT HX AR AR 29 64302037 WASHER LOCK .375 30 31 AR AR 32 64302996 WASHER LOCK 1/4 1 1 33 950906 FAST-ON TERM 1/4 X 18 AWG 1 1 34 61388144 SCR .375 NYLOC HX CAP 1 1 35 0146970001 BRAKE PAD 1 1 36 0147315001 LOCK KEY 1 1 1 1 1 37 38 39 0558001082 1 1 1 1 1 1 1 40 41 42 0558002033 81F26 0558004715 13733936 0558004912 0558004913 0558004914Y J5 COMPACT/EURO TORCH ADAPTOR PKG KNOB .787 DIA. CABLE PLUG-LC-40 CABLE PLUG 400A MACHINE CASE 200AVS FEEDER CHASSIS FEEDER 200AVS SPOOLER SUPPORT BRKT 200AVS 44 0558005796 REPLACEMENT PARTS 0558004709 SECTION 5 ITEM N0. 1 1 43 0558004915B CONTROL GUARD 200AVS 1 1 44 0558004916 DRIVE STAND INSULATOR 1 1 45 0558004917 COVER PCB 200AVS 1 1 46 0558004918Y CONTACTOR SUPPORT SHORT 1 1 47 0558004919 PLATE DISPLAY 200AVS 1 1 48 80558003353 1 1 49 1 1 50 8951529 4 4 51 182W12 FOOT RUBBER AR AR 52 61325878 SCR .164-32X.38 PAN QX 53 60909636 CLOS PE CAPLUG #6 1 PART OR CODE N0. SYMBOL (ELEC-AY DESCRIPTION STRAIN RELIEF INPUT NPT 3/4 0558004920 HUB SPOOL 200AVS M1 MOTOR GEAR KSV 5035/556 (TAC) 1 1 54 8951126 1 1 55 1 1 56 80558001339 1 1 57 813735590 AR AR 1 1 59 837580 P4 1 1 60 F1 1 1 61 8951474 SWITCH SEAL BLACK AR AR 62 64304110 WSR FLAT .312 63 0558001079 GUIDE TUBE 0558001078 COM/EURO .035/.045 GUIDE TUBE 1 58 1 2062348 CLAMP 1-EAR 10.0 GER P2 COMPACT 4 ROLL WDS -66964 K1 63311886 13735464 PLUG HOUSING *9 POS NYLON CONTACT 1 POLE *12VDC 500ADC NUT .164 NYLOC ASSY SHORTING PLUG 6 PIN FUSE SLO-BLO 10 AMP AR AR 64 63310100 NUT 1/4-20 LOCK AR AR 65 64302920 WSR 52002 STLZPC 0.190 AR AR 66 64304075 WSR PLAIN STLZPC .250 AR AR 67 64302887 2 2 68 950097 AR AR 69 64304050 1 1 70 951009 AR AR 71 950995 1 1 72 951007 1 1 73 951283 #8 LOCK WSR P1,P3 HOUSING CONTACT 5 PIN WSR 53001 STLZPC 0.190 P1 RCPT 6 POS 10A 300V CABLE TIE 14.6"LG P1 RCPT P/C* *5POS 10A 300V STRAIN RELIEF 1/2" 1 74 8950823 SNAP BUSHING 11/16 AR AR 75 61341133 SCREW HEX CAP 3/8-16 X 1.0 1 1 76 0558954033 RATING LABBEL MOBILEFEED 2 2 77 837334 NUT HANDLE 1 1 78 954698 LABEL WARN GEAR PINCH HAZARD 1 1 79 0558954057 LABEL WARN ROLL PINCH HAZARD 1 45 0558005796 REPLACEMENT PARTS 0558004709 SECTION 5 AR AR 80 73585435 ADH LOCTITE #242 AR AR 81 76200103 SOLDER KESTER 24-6040-0027 AR AR 82 63311121 LOCK NUT .312 1 1 83 13730763 NAME PLATE CODE SERIAL STOCK 1 1 84 0558004722 KIT CABLE MOBILE FEED 1 1 85 0558004719 WIRE KIT 200AVS AR 86 63300916 NUT 30024 STLZPC 0.190-24 AR AR 87 64302150 WSR LOCK 0.438 1 88 0558005822B BRKT SOLENOID AR AR 89 61387910 SCR #10-32X.38W/LOCK TYWRAP SMALL AR ITEM N0. PART OR CODE N0. SYMBOL (ELEC-AY DESCRIPTION 90 AR AR 91 180W68 1 1 92 0558005303 1 1 93 80558038284 PCB2 PCB RECTIFIER 1 1 94 17240001 R2 RESISTOR 1Ohm 25W 2 2 95 61344165 SCR 5/16-18X.625BLK SKT FLT HEX 97 954470 LABEL ESAB 3.63 X 6.00 98 2091514 LABEL WARNING GENL 7.0W X 5.06 99 61325851 SCR #6-32 X .38 PH TTF COVER WIRE REEL 200AVS 96 1 1 1 AR 3 AR 3 100 2064055 WASHER SPRING 3/8 AR AR 101 64302920 WASHER LOCK #10 AR AR 102 61325900 SCR #10-24 X .38 PH TTF 2 1 2 103 61340361 SCR 5/16-18X.75 BLK SL HEX 1 104 13730222 SNAP BUSING 9/16 AR AR 105 64304887 WSR 53001 STLZPC 0.164 AR AR 106 64304175 WASHER FLAT 1/2" AR AR 107 61325087 SCR 1/4-20 X .50 QUADRX 2 108 821161 2 AR 4 821156 FEED ROLL (045-1/16) SERRATED FEED ROLL (.035/.045) V-SMOOTH 1 109 954565 LABEL CE LOGO 1 110 955269 LABEL CAUTION READ MANUAL AR 111 64302175 4 112 61308899 WAHER LOCK 1/2" SCR #8-32 X 1.5 AR AR 113 64104125 WSR FLT .375 BRASS AR AR 114 99510492 RIVET 1/8 GRIP .251-.312 1 1 115 0558005821 HOSE ASSEMBLY 18" MOBILEFEED CE 1 116 0156617001 BRAKE WASHER 117 2 2 118 639533 SNAP BUSHING AR AR 119 71200732 ADV .SI-RBR CLR AR AR 120 90863003 TUBING SHRINK .38 121 122 2 AR 123 61325878 SCR .164-32 X .38 AR 124 64302887 WSHR LOCK .164 2 125 0558006743 INSULATOR PIN 46 SECTION 5 REPLACEMENT PARTS DRIVE ROLLS (See Drive Roll & Guide Tube Selection Guide in SECTION 1) Figure 29 - Auto-Lift Mini Four Roll Geared Wire Drive System - 0558001339 ITEM PART NO. DESCRIPTION 1 1A 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Feed Plate Safety Guard Screw, Thumb (M6X12) Pressure Arm Bogie Pressure Roll Axle Pressure Roll Locating Pin Nut, Pressure Roll Axle Circlip Retaining Screw Pressure Arm Spring Bogie Auto Lift Spring to Pressure Arm Auto Lift Spacer Tube, Small Spacer Tube, Big Spacer Tube Pressure Arm Auto Lift 0558001743 0558001744 952927 0558001745 0558001746 23612368 23612477 0558001747 23612474 23612472 34609 0558001748 0558001749 0558003538 0558003539 0558001752 QTY. ITEM 1 1 1 1 1 2 2 1 2 1 1 1 1 2 2 1 16 17 18 19 20 21 22 23 24 25 26 27 28 47 PART NO. 0558001753 0558001754 0558001755 0459441880 0558003540 34608 952925 23612460 23612470 23612462 0558001757 0558001895 0558001758 0558003542 DESCRIPTION QTY. Spacer Tube Bogie Axle Pressure Arm Allen Screw Gear Adaptor Feed Roll Axle Gear Adaptor Feed Roll Washer, Retaining Screw Knurled Screw Pressure Device w/Scale Locating Pin, 2.5 x 12 Pressure Device Screw (Center) Guide Center Guide (Hard Wire) Center Guide for (Aluminum) Inlet Guide (Aluminum & Steel) Main Gear Drive 1 1 1 2 2 3 3 1 Pkt. 5 1 1 1 1 1 SECTION 5 REPLACEMENT PARTS Item # 1 2 3 4 5 6 7 Quantity 1 1 1 3 1 1 1 0558006838 MobileFeed 200 HUB KIT Part Number Description 0156617001 Brake Washer 0146970001 Brake Pad 0558004920 Hub Spool 200AVS 2064055 Washer, Spring, 0.375” 64104125 Washer, Flat, Brass, 0.375” 61388144 Screw, Socket, Hex, Stainless Steel, .375-16 x .75 Nylok 0147315001 Lock Key Item # 1 2 3 4 5 6 7 Quantity 1 1 1 2 1 1 1 0558006839 MobileFeed 300 HUB KIT Part Number Description 0156617001 Brake Washer 0146970001 Brake Pad 0146968880 Hub Spool 300AVS 0146969001 Pressure Spring 64104125 Washer, Flat, Brass, 0.375” 61388144 Screw, Socket, Hex, Stainless Steel, .375-16 x .75 Nylok 0147315001 Lock Key 48 REVISION HISTORY Original release 05 / 2005. 10 / 2005 - Removed magnetic ground pick-up from illustrations and Replacement Parts (Item 83) per ECN #053136. 01 / 2006 - Updated Schematic and removed Wiring Diagram. Added “CE” version. Changed product name from MobileMaster 8AVS to MobileFeed 200 AVS. Updated Replacement Parts. Reference ECN #053192. 06 / 2006 - Updated per Joe DeVito inputs. 07 / 2006 - Updated per Joe DeVito inputs. 10 / 2006 - Updated Replacement Parts and wire feeder illustrations. 04 / 2007 - Updated Drive Roll and Guide Tube table in Section 1 per Mike Palumbo inputs. 03 / 2008 - Updated pictures and updated Replacement Parts section per CN#083002. 04 / 2008 - Updated picture and Replacement Parts section (pages 40, 44 and 46) per John Magee inputs. 07 / 2008 - Updated Replacement Parts section, added hub kit parts along with other minor text changes per John Magee red-lines. 49 ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Part Numbers Technical Applications Specifications Hours: 8:00 AM to 5:00 PM EST Equipment Recommendations D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST F. WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone: (800) ESAB-123 Fax: (843) 664-4462 Hours: 7:30 AM to 5:00 PM EST or visit us on the web at http://www.esabna.com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback & Support 0558004754 07 / 2008
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52

ESAB MobileFeed 200 AVS Manual de usuario

ESAB
Marca
ESAB
Modelo
MobileFeed 200 AVS
Categoría
Sistema de soldadura
Tipo
Manual de usuario
Descargar PDF
informe

En otros idiomas

Documentos relacionados