ESAB Crater Control Kit Installation manual

CRATER CONTROL KIT

for MobileMaster 2 cv Wire Feeder

To install kit, proceed as follows:

To prevent accidental electric shock, be sure control cable is disconnected from power
source or interface box before working inside the wire feeder.

F-15-472

August, 1998

Installation Instructions

P/N. 36660

1. Remove all input power from the wire feeder , and
open the feeder door.

2. Remove and retain the three screws securing the
Bottom side cover of the P.C. Board compartment.

3. Remove and retain the three screws securing the
upper front panel to the wire feeder and pull the
front panel away from the feeder.

4. Locate the wire harness from the front panel po­tentiometers and remove the jumper plug connect­ing it to the main wire harness. This plug, is a
seven-pin double male connector and should be
directly behind the front panel. Retain this plug as
it will be required if for any reason the Crater Con­trol Kit is removed from the feeder.

5. If the feeder has a Pre-flow / Post-flow kit installed,
connect the Green and Violet leads from the
Pre-flow / Post-flow kit to the Green and Violet
leads of the Crater Control Kit. This will allow the
automatic Crater function to be used.

6. A current detector module has been supplied with
the option module. The current detector is required
for automatic operation of the Crater function. The
current detector consists of a U shaped steel
piece and a reed switch assembly. Between the
torch connection and the wire drive stand there is
a brass connection tube. To install the current de­tector , first install the Crater Control into the open­ing where the bottom side cover plate was re­moved and secure with the three screws previ­ously removed. Route the leads of the reed switch
assembly through the hole in the bottom of the
P.C. Board compartment. Remove one nut from
the reed switch assembly and adjust the other nut
to the end of the threads toward the leads. Slip
the U shaped piece over the connection tube
with the open end down. Slip the reed switch

through the holes in the U shaped piece with
the leads facing away from you and install the other
nut. Do not overtighten.

7. Locate the two 7 pin female plugs in the wire har­ness where the 7 pin double male jumper plug
was removed. Connect these two plugs to recep­tacles P1 and P2 of the Crater Control Board. The
wire harness is designed to prevent connecting
these plugs to the wrong receptacles on the Cra­ter Control Board.

8. Re-Install the upper front panel and secure with
the three previously removed screws.

Set-up And Operation

1. Set the front panel wire speed and voltage poten­tiometers for the desired Main welding condition.

2. Set the Crater Control potentiometers for the de­sired Crater condition.

3. Place the Crater Control switch in the desired po­sition :

Panel:Feeder operates normally from the front
panel (Main) controls only.

Crater: Feeder operates normally from the Cra­ter Controls only.

Auto: The arc is initiated at the Main welding con­dition and remains at that condition until the torch
trigger is released. When the torch trigger is re­leased , the feeder changes to the Crater condi­tion and continues to weld until the torch trigger is
depressed a second time to terminate the weld.

Be sure this information reaches the operator.
You can get extra copies through your supplier.

D-36660

8

1

7, 13

6

3

PCB1

See Detail A

4

4

F-15-472 8/98