ESAB Mig 2E WIRE FEEDER Instruction manual

INSTRUCTION MANUAL
WIRE FEEDER
EFFECTIVE WITH SERIAL NUMBER WK-I930001
F15-143-C
October, 2008
Mig 2E
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding 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 (Section I) before installing or operating this equipment.
Be sure this information reaches the operator. You can get extra copies through your supplier.
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 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.
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
1 SAFETY ................................................................................................................................3
2 DESCRIPTION AND SPECIFICATION ...................................................................................7
2.1 Mig 2E Wire Feeder ................................................................................................7
2.2 Mig 2E Wire Feeder Option .....................................................................................7
3 EQUIPMENT ...........................................................................................................................9
3.1 General ...................................................................................................................9
3.2 Companion Equipment and Accessories.................................................................9
3.3 Accessories.............................................................................................................9
4 INSTALLATION .....................................................................................................................10
4.1 Installation .............................................................................................................10
5 OPERATION .........................................................................................................................11
5.1 Adjustments and Operation...................................................................................11
5.2 Operating Sequence .............................................................................................11
6 SERVICE ..............................................................................................................................12
6.1 Maintenance .........................................................................................................12
7 REPLACEMENT PARTS.......................................................................................................15
7.1 General .................................................................................................................15
i
2
SAFETY PRECAUTIONS
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.
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 long-sleeve
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.
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 non­flammable 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 Pro-
--
cesses", available from the National Fire Protection 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 confined, or if there is danger of falling.
1. Be sure the power source frame (chassis) is connected 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 off the power before removing your gloves.
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.
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:
1. Welders having pacemakers should consult their physi­cian before welding. EMF may interfere with some pace­makers.
2. Exposure to EMF may have other health effects 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.
3
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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. 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, stainless 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 opera­tions. 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 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.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
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 violently 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 fittings in good condition. Follow manufacturer's operating instructions for mounting regu­lator to a compressed gas cylinder.
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.
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.
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.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:
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.
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 equipment, 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"
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.
SP98-10
4
PRÉCAUTIONS DE SÉCURITÉ
AVERTISSEMENT: Ces règles de sécurité ont pour objet d’ assurer votre protection. Veillez à lire et à observer les précautions énoncées ci-dessous avant de monter l’ équipement ou de commercer à l’utiliser. Tout défaut d’observation de ces précautions risque d’entraîner des blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la peau et des yeux dues au rayonnement de l’arc électrique ou du métal incandescent, lors du soudage au plasma ou à l’électrode ou lors du gougeage à l’arc, peuvent s’avérer plus graves que celles résultant d’une exposition prolongée au soleil. Aussi convient-il d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de vous protéger les yeux, le visage, le cou et les oreilles des étincelles et du rayonnement de l’arc électrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce qu’elles ne s’exposent pas à son rayonnement, ni à celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans rebord, des chaussures à embout d’acier et un casque de soudage ou une calotte de protection, afin d’éviter d’exposer la peau au rayonnement de l’arc électrique ou du métal incandescent. ll est également souhaitable d’utiliser un tablier ininflammable de façon à se protéger des étincelles et du rayonnement thermique.
c. Les étincelles ou les projections de métal incandes-
cent risquent de se loger dans des manches retroussées, des bords relevés de pantalons ou dans des poches. Aussi convient-il de garder boutonnés le col et les manches et de porter des vêtements sans poches à l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité à l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on effectue des opérations de soudage ou de coupage à l’arc. Utilisez des lunettes de sécurité à écrans ou verres latéraux pour piquer ou meûler le laitier. Les piquetures incandescentes de laitier peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de 100 à 114 dB) et exigent par conséquent l’emploi de dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de laitier incandescent ou d’étincelles peuvent provoquer de graves incendies au contact de matériaux combustibles solides, liquides ou gazeux. Aussi faut-il observer les précautions suivantes:
a. Éloigner suffisamment tous les matériaux combus-
tibles du secteur où l’on exécute des soudures ou des coupes à l’arc, à moins de les recouvrir complètement d’une bâche non-inflammable. Ce type de matériaux comprend notamment le bois, les vêtements, la sciure, l’essence, le kérosène, les peintures, les solvants, le gaz naturel, l’acétylène, le propane et autres sub­stances combustibles semblables.
b. Les étincelles ou les projections de métal incandes-
cent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y déclencher une ignition lente cachée. Veiller à protéger ces ouvertures des étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface de barils, bidons, réservoirs ou autres contenants usagés, avant de les avoir nettoyés de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à servir immédiatement, tel qu’un tuyau d’arrosage, un seau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur
de façon à vous assurer qu’aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc au plasma exige l’emploi de tensions à vide relativement importantes; or, celles-ci risquent de causer des dommages corporels graves et même mortels en cas d’utilisation inadéquate. La gravité du choc électrique reçu dépend du chemin suivi par le courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous ten-
sion venir au contact direct de la peau ou de vêtements humides. Veillez à porter des gants bien secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assu­rer votre isolation corporelle en portant des gants secs et des chaussures à semelles de caoutchouc et en vous tenant sur une planche ou une plate-forme sèche.
c. Mettez toujours à la terre le poste de soudage/coupage
en le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en effet provoquer une surchauffe de l’équipement et un danger d’incendie. Ne pas enrouler ou passer le câble autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce en
un point aussi proche que possible de la zone de travail. Le branchement des câbles de masse à l’ossature du bâtiment ou en un point éloigné de la zone de travail augmente en effet le risque de pas­sage d’un courant de sortie par des chaînes delevage
5
9/97
des câbles de grue ou divers chemins électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de travail, des câbles, du porte-électrode et du poste de soudage/coupage. Réparez immédiatement toute fuite d’eau.
4. VENTILATION-- La respiration prolongée des fumées résultant des opérations de soudage/coupage, à l’intérieur, d’un local clos, peut provoquer des mal­aises et des dommages corporels. Aussi convient-il d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventila­tion naturelle ou à l’aide de moyens mécaniques. N’effectuez jamais de travaux de soudage ou de coupage sur des matériaux de zinc, de plomb, de beryllium ou de cadmium en l’absence de moyens mécaniques de ventilation capables d’empêcher l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure chloré résultant d’opérations voisines de dégraissage ou de pulvérisation. La chaleur dégagée ou le rayonnement de l’arc peut déclencher la formation de phosgène -- gaz particulièrement toxique -- et d’autres gaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de l’équipement dénote un défaut de ventilation. Arrêtez­vous de travailler afin de prendre les mesures néces­saires à l’amélioration de la ventilation. Ne poursuivez pas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande est munie d’un ventilateur destiné à empêcher la forma­tion de poches d’hydrogène, lesquelles présentent un danger d’explosion; ce ventilateur ne fonctionne que si l’interrupteur correspondant du panneau avant se trouve placé en position ON (Marche). Veillez à manœuvrer cette commande en vérifiant si le couvercle est bien en place, de façon à assurer l’efficacité de la ventilation ainsi réalisée. Ne jamais débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il nécessaire de disposer en permanence d’un dispositif adéquat de ventilation de type aspirant, afin d’élimi­ner du voisinage de l’opérateur tout dégagement de fumée visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise qualité mais, chose plus grave encore, d’entraîner
des dommages corporels graves, voire mortels en déclenchant des incendies ou des chocs électriques. Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qua-
lifié l’installation, le dépannage et l’entretien du poste de soudage et de coupage. N’effectuez aucune réparation électrique sur l’équipement à moins d’être qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/ coupage, avant d’avoir débranché l’alimentation électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon d’alimentation et le poste de soudage/coupage. N’utilisez jamais le poste ou l’équipement s’il présente une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et
des équipements accessoires. Gardez-les à l’écart des sources de charleur, notamment des fours, de l’humidité, des flaques d’eau maintenez-les à l’abri des traces d’huile ou de graisse, des atmosphères corro­sives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tous
les panneaux de l’armoire de commande en veillant à les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément à
son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES À LA SÉCURITÉ--
Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et l’utilisation d’équipements de soudage et de coupage électriques et sur les méthodes de travail recommandées, demandez un exemplaire du livret N° 52529 “Precautions and Safe Practices for Arc Weld­ing, Cutting and Gouging” publié par ESAB. Nous conseillons également de consulter les publications sui-vantes, tenues à votre disposition par l’American Welding Society, 550 N.W. LeJuene Road, Miami, FL 32126:
a. “Safety in Welding and Cutting” AWS Z49.1 b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cut-
ting” AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Weld-
ing” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
9/97
6
SECTION 2
DESCRIPTION AND SPECIFICATION
2.1 Mig 2E Wire Feeder
The Mig 2E Wire Feeder (Figure 2-1 and Table 2-1) described in this manual is designed for short arc, spray arc mig or cored wire welding with a constant potential (CP) welding power source.
Secondary input from the Power Source can be DC "+" or DC "-" depending on the requirements of the wire type being used.
Mig spot welding can be done with the Mig 2E if it is equipped with optional spot-welding features. Addi­tion of spot-welding circuitry in no way modifies capability of the unit for normal mig, or cored wire welding.
The Mig 2E uses a PM wire drive motor designed to feed wires from .023 to 5/64-inches in diameter. Rate of wire feed (50-650 inches per minute) is precisely controlled by a solid-state, Pulse Width Modulated (PWM) governor printed circuit board housed in the control assembly. For operator safety, the torch switch is energized by 12 volts ac supplied by the control. All interconnecting cables and hoses are quickly de­tachable to provide maximum portability of the wire feeder.
The Mig 2E wire feeder is designed to set on flat surfaces or mount on a swivel post, if desired, allowing movement as necessary during torch operations. The standard features of the Mig 2E wire feeder follows:
2-roll geared drive stand
One drive roll and one pressure roll
Internal gas solenoid
Ten-foot (3m) control cable w/19-pin amphenol style plug (factory installed)
Ten-foot (3m) gas hose w/fittings (factory installed)
"Euro" style torch connection
"ON" indicator light
Wire feed speed potentiometer
2.2 Mig 2E Wire Feeder Option. The following
option is available from ESAB or your supplier.
Spot/Burnback/Pre-postflow/Trigger Lock Mod- ule (P/N 34182). Easy to install kit permits the operator to set times for spot welding (0-5 sec), wire burnback (0-0.6 sec), gas preflow (0-5 sec) and gas postflow (0-7.5 sec). This module also includes trigger lock which allows the welder to make long welds without continuously depressing the torch trig­ger. Includes module and current detector.
Table 2-1. Mig 2E Specifications
Input Power Required ....................................................... 42 V ac, 5A, 50/60 Hz, 1-phase
Wire Feed Speed Range ................................................ 50-650 in./min. (1.3-16.5 m/min.)
Wire Sizes Accommodated:
Hard/Soft............................................................ .023 thru 1/16 in. (0.6 thru 1.6 mm)
Flux Cored ......................................................... .035 thru 5/64-in. (0.9 thru 2.0 mm)
Length ........................................................................................................... 21 in. (54 cm)
Width9 in. (23 cm)
Height* ....................................................................................................... 9.25 in. (24 cm)
Weight (approx**)....................................................................................... 28 lbs (12.7 kg)
*Add 2-3/4-in. (7 cm) for spindle and spindle arm. **8-ft (2.4m) control cable and hose included in specified weight.
7
SECTION 2
POWER "ON" INDICATOR
DESCRIPTION AND SPECIFICATION
REEL STAND
WIRE SPOOL HUB
WIRE FEED SPEED CONTROL
REEL STAND
WELDING POWER INPUT STAND
MIG TORCH CONNECTOR RECEPTACLE
FRONT VIEW
DOOR LATCH
PRE GAS FLOW*
POST GAS FLOW*
SPOT WELD TIME* BURN BACK WELD TIME*
CONTINUOUS, SPOT,* TRIGGER LATCH
5 A CIRCUIT BREAKER
GAS CONNECTION
*Included with option module P/N 34182
CONTROL CABLE
REAR VIEW
Figure 2-1. Mig 2E Wire Feeder
8
SECTION 3 EQUIPMENT
3.1 General.
C. Counterbalance Mini-Boom (P/N 34322). Keeps
This section describes the Mig 2E Wire Feeder and the recommended companion equipment and acces­sories required to properly operate the Mig 2E. The optional accessories available through ESAB (or your ESAB supplier) will also be addressed.
3.2 Companion Equipment and Acces­sories.
A. Constant potential power source. Use the Mig
2E with power sources such as: 352cv, 353cv, 452cv, 453cv, 652cvcc, 653cvcc, SVI-300i, or SVI-450i
B. Extension Cables. Multi-conductor cable with
19-pin amphenol plug and receptacle. Used to extend 8-ft (2.4m) cable supplied with wire feeder.
• 30-foot (9.1 m) P/N 34378
• 60-foot (18.3 m) P/N 34377
C. 115 V ac to 42 V ac Interface (P/N 34351).
Adapts Mig 2E to power sources with only 115 V ac auxiliary and contactor. Includes interface box and adapter cables for power sources not equipped with 42 vac control circuitry.
D. ESAB mig welding torch. Torch with contact tip,
wire conduit and outlet guide for wire size/type to be employed.
E. Shielding gas regulator/flowmeter and fitted hose
to bring gas from flowmeter to wire feeder. Such as:
Regulator/Flowmeters: R-5007 Argon/Helium/Nitrogen, P/N 998124. R-5008 CO2, P/N 998125.
F. Drive Roll and Guide Tube. (Refer to Table 3-
1). The Mig 2E wire feeder comes equipped with a drive roll and a guide tube for wire sizes .035 to .045 (0.9 to 1.2 mm). Select other size drive rolls from Table 3-1 for the wire size and type to be used.
3.3 Accessories
A. Swivel Post (P/N 34350). Installs into tube on
power sources such as 650cvcc or SVI 450i cvcc and allows the wire feeder to freely swivel on post.
B. Swivel Post w/Mounting Bracket (P/N 34075).
Attaches to Inverter Cart (P/N 31700) or other flat mounting surfaces and allows the wire feeder to freely swivel on the post.
9
torch-cables off the floor and reduces wire feed­ing problems caused by sharp bends in torch conduits or cables. Includes boom, swivel post and mounting hardware.
D. Boom Hanging Bracket Kit (P/N 34321). In-
cludes hanging bracket and mounting hard­ware.
E. Carrying Handle Kit (P/N 34320). Includes
handle with rubber grip and mounting hardware.
F. Wire Reel Adapter (P/N 34323). Use with 60 or
65-lbs. (27 or 30 kg) coils.
G. Spool Spacer (P/N 34330). For adapting 10-in
(25.4 cm) spools.
H. Spool Cover Kit (P/N 34326). Includes clear
cover and mounting hardware.
I. Wire Feeder Wheel Cart (P/N 34324). Cart
makes it easy to roll wire feeder around job sight. Cart is 5-7/8-in (15 cm) high and includes base, front swivel caster wheels, rear caster wheels and mounting hardware.
T able 3-1. Drive Roll & Guide Tube Selection
Upper
Wire T ype / Lower Pressure Guide
Diameter Drive Roll Roll Tube
Hard Wires (“V” groove)
.023 in. (0.6mm) 21155 2361 2368 21163 .030 in. (0.8mm) 21155 2361 2368 21164 .035 in. (0.9mm)* 21156 2361 2368 21165 .040 in. (1.0mm)* 21156 2361 2368 21165 .045 in. (1.2mm)* 21156 2361 2368 21165 .052 in. (1.4mm) 21157 2361 2368 21166 1/16 in. (1.6mm) 21157 2361 2368 21166
Soft (aluminum) Wires (“U” groove)
.030 in. (0.8mm) 21160 2361 2368 21164 .035 in. (0.9mm) 21160 2361 2368 21165 3/64 in. (1.2mm) 21161 2361 2368 21165 1/16 in. (1.6mm) 21161 2361 2368 21166
Cored Wires (Serrated “V” groove)
.030 in. (0.8mm) 21160 2361 2369 21164 .035 in. (0.9mm) 21160 2361 2369 21165 .040 in. (1.0mm) 21161 2361 2369 21165 .045 in. (1.2mm) 21161 2361 2369 21165 .045 in. (1.2mm)† 37319 37319 21165 .052 in. (1.4mm) 21161 2361 2369 21166 .052 in. (1.4mm)† 37319 37319 21166 1/16 in. (1.6mm) 21161 2361 2369 21166 1/16 in. (1.6mm)† 37320 37320 21166 5/64 in. (2.0mm) 21162 2361 2369 21166 5/64 in. (2.0mm)† 37320 37320 21166
* Supplied with Mig 2E wire feeder. † Recommended for use with soft cored wires that are easy to flatten.
Order both lower drive roll and upper pressure roll.

If a Geared Pressure Roll is desired, order P/N 23612397.





SECTION 4 INSTALLATION
4.1 Installation
1. Release the pressure drive roll lever and lift the assembly upward.
This wire feeder should NOT be earth or chassis grounded. The feeder has rubber feet to keep it insulated. In a boom mounted arrangement, there must be an insulator between the boom and feeder chassis. If not properly insulated and if wire touches the chassis, such as "bird nesting", current may heat the wire and wire may contact circuit compo­nents, causing the PC board to fail.
After checking to be sure you have all required compo­nents and accessories (refer to Section 3), refer to Figure 2-1 for connections.
A. Remove input power from power source or inter-
face box.
B. Hose and Electrical Connections. Connect shield-
ing gas supply hose. Connect control cable to power source. If power source has been used with another type feeder, check to make certain that no wiring changes have been made which permit actuation of contactor by some means other than power received through the welding control cable receptacle. Any such modifications must be removed before attaching control cable to power source.
C. Wire Spool.
As with any work area, make sure safety glasses with side shields are worn when handling or chang­ing wire or clipping wire off at the spool or at the end of the torch. Hold onto the wire coming off the spool with one hand before clipping. Serious eye injury can result due to the resilience of the wire which can quickly unravel, or a cut wire end which may shoot across the room.
Install a spool of welding wire on the hub as follows:
1. Unscrew spool nut from hub.
2. Place wire spool on hub to rotate clockwise as wire is unwound; hub pin must engage hole in spool.
3. Install spool nut.
D. Drive Rolls. The drive roll has two grooves; the
small groove feeds 0.035 in. diameter wire, the large groove feeds 0.045 in. wire. The groove nearest the gear motor feeds the wire. If the required groove is not correctly positioned, per­form the following:
2. Remove the retaining screw holding the drive roll to the gear.
3. Reverse the drive roll on the drive roll shaft.
4. Replace the screw and tighten.
5. Secure the pressure drive roll assembly.
E. Threading Wire.
1. Ensure control cable is disconnected from power source or interface box.
When the control cable is connected to power source or interface box and the power is on and gun trigger is depressed, the welding wire becomes electrically hot, and the wire feed rolls are acti­vated.
2. Release pressure drive roll assembly and lift upward. Check that proper wire diameter groove is in the inner position.
Before threading welding wire through liner, make sure chisel point and burrs have been removed from wire end to prevent wire from jamming in torch or liner.
3. Feed the wire from the spool through the inlet guide, across the drive roll groove and into gun outlet guide.
Make sure that the proper "outlet guide tube" is inserted into the front-panel torch fitting for the size and type of wire being used.
To ensure proper wire feeding, it is important that the wire be kept clean and that the drive rolls be periodically cleaned of any chips or scale that might be carried into the torch liner and cause sticking.
4. Lower pressure roll assembly and secure. Check that the gears mesh. Feed wire through to torch tip using the torch trigger.
F. Brake Drag Adjustment. Brake disc friction should
provide enough drag to keep the wire spool or core from spinning freely after wire feed stops. If adjustment is required, turn adjusting screw (lo­cated inside hub) clockwise to increase drag, counterclockwise to decrease it. Drag should be just low enough to limit wire overrun.
10
SECTION 5
OPERATION
5.1 Adjustments and Operation
A. Control Setting.
1. Apply power to wire feeder.
2. Set the wire feed rate by adjusting the WIRE FEED SPEED and VOLTS control knobs on the front panel.
NOTE: Steps 3 and 4 apply only if spot/burnback/
pre-postflow/trigger lock module option is installed (P/N 34182).
3. Set the BURNBACK control on the rear panel to the desired setting (orange: 0-0.6 seconds), depending on the amount of burnback desired. The higher the setting, the greater the amount of time that the contactor is held in to allow the wire to burn back out of the puddle, after releasing the torch switch.
4. If spot welding is to be performed, set rear­panel switch to "SPOT" position, set spot­welding potentiometer for time period (range: 0 to 5 seconds).
the arc. The switch lever must be depressed for the duration of the weld. Welding action will be stopped and all services discontinued when the lever is released and returns to its original posi­tion. If the torch is withdrawn from the workpiece during welding, the arc will be interrupted, but shielding gas flow and welding wire feed will continue until the switch lever is released.
Do not allow metal-to-metal contact between the wire feeder chassis and a metal surface connected in any way to a welding ground. With such contact, a poor welding ground connection may create a difference in potential that sends part of the weld­ing current through the safety ground wiring in the control cable and wire feeder, resulting in burnout of that wiring and/or damage to wire feeder cir­cuitry. If the safety ground burns out, the operator may be exposed to 115 V shock hazard.
NOTE: If trigger lock-in circuit is selected, the
torch switch can be released as soon as arc has been struck. When weld is com­plete, services are discontinued by clos­ing torch switch again.
B. Feeding Wire. If wire has been threaded through
torch and contact tip as directed in Section 4, simply cut off wire, as required, so that the wire extends about 1/2-inch beyond the end of the torch nozzle.
C. Shielding Gas Flow Rate. Depress gas PURGE
switch (located under the feeder cover) and set desired gas flow rate at the shielding gas regu­lator-flowmeter. Hold switch in at least 15 seconds to insure adequate purging of gas hose and torch.
NOTE: Pre and Postflow adjustment applies
only if Spot/Burnback/Pre-Postflow/Trig­ger Lock Module option is installed (P/N
34182).
Set pre and postflow potentiometers for the desired preflow interval (range: 0-5 seconds) and postflow interval (range: 0 to 7.5 seconds).
D. Making the Weld. Start to weld by pressing the
torch switch lever to actuate the torch switch. This closes the welding contactor, and starts wire feed and gas flow. Then touch the end of the welding wire to the workpiece to establish
5.2 Operating Sequence.
A. Normal.
1. Close torch switch.
-- Gas solenoid opens, weld contactor closes, wire feed motor runs.
2. Release torch switch.
-- Wire feed motor deenergized, brake cir­cuit effective.
-- Burnback circuit deenergized.
3. Burnback circuit times out (delay determined by setting of Burnback potentiometer).
-- Weld contactor opens.
-- Gas solenoid valve closes.
B. Spot Weld.
1. Close torch switch.
-- Gas solenoid, weld contactor, wire feed motor energized.
-- Spotweld timing circuit energized.
2. Spotweld circuit times out (interval estab­lished by setting of spotweld potentiometer).
-- Wire feed motor deenergized, brake cir­cuit effective.
-- Burnback circuit energized.
11
SECTION 5 OPERATION
3. Burnback circuit times out (interval estab­lished by setting of burnback potentiometer).
-- Weld contactor opens.
4. Release torch switch.
-- Gas solenoid valve closes.
C. Pre-flow/Post-Flow. Same as "NORMAL" except
that when torch switch is closed, only gas solenoid valve is immediately energized. Contactor and wire feed motor are energized only after interval established by setting of preflow potentiometer. When torch switch is opened, gas solenoid valve
SECTION 6
6.1 Maintenance.
If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained per­sons to inspect, clean, or repair this equipment. Use only recommended replacement parts.
Little maintenance is required to keep the wire feeder in top operating condition. It is important, however, that moving parts such as feed and pressure rolls, wire feed motor, etc., be kept clean and free of dust or dirt. Cleaning is best accomplished by regularly blowing off these parts with dry compressed air. This should be done once for every eight hours of operating time, more often if necessary.
remains energized until interval established by setting of postflow potentiometer has elapsed.
D. Trigger Latch. Same as "NORMAL" except that
closing of torch switch energizes the lock-in circuit, so torch switch lever can be released after the arc is initiated. At end of weld, momen­tary closing of the torch switch initiates the sequence that normally follows opening of that switch. Trigger latch can only be set during time arc is established.
SERVICE
A. 42 Volt Wire Feeder and Control Circuits.
If it should become necessary to replace the 10 amp wire feeder circuit breaker or any other circuit breaker/fuse in the welding machine, ensure that the proper size is used as a replacement.
The 42-volt circuit is protected by a 10 amp circuit breaker located at the rear of the wire feeder. Failure of this circuit breaker will shut off the contactor, shielding gas, and wire feeder.
B. Wire Feeder. As soft wire is fed, the drive rolls
may pick up metal from the wire surface. Accu­mulation on the rolls may score the wire with resulting unwanted friction and improper feeding.
Inspect the rolls regularly and clean them with a 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.
12
Figure 6-1. Schematic Diagram - Mig 2E Wire Feeder
D-34190-A
13
Figure 6-1. Wiring Diagram - Mig 2E Wire Feeder
D-34153-B
14
SECTION 7 REPLACEMENT PARTS
7.1 General.
Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part number and part name, as illustrated on the figure. DO NOT ORDER BY PART NUMBER ALONE.
Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.
Replacement parts may be ordered from your distribu­tor. Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide on the last page of this manual for a list of customer service phone num­bers.
15
SECTION 7
10
POWER
V
2
3
1
5
4
0
WIRE FEED
SPEED
REPLACEMENT PARTS
1
2
6
7
8
9
10
4
Ite m No.
1
2
4 5 6 7 8 9
1 1 1 1 1 1 1 1 1 1 1 1
Qty
Req.
Figure 7-1. Mig 2E Wire Feeder (Front View)
Part
No. D escription
32112GY 952924 952929 23612350 23610528 23610696
13730623
32113GY 676876
2062018 13730611 13792157
8,7,6
PANE L, CONTROL TORCH ADAPTOR ASSY. includes: C O NN E C TIO N TU B E POWER LUG HOUS ING AD A PTOR, STRAIGHT ADAPTOR, BLOCK ASSEMBLY LATC H, DOOR FRONT PANEL INSULATOR, 10 M IL, NOME X 2X 2.5 P OTENTIOM E TE R, 10 K KNOB LIGHT, PILOT
5
Ckt.
Symbol
J2
R1
PL1
16
SECTION 7 REPLACEMENT PARTS
4
1
Item
No.
1 2 3 4 5 6 7 8
8
4
3
2
6
6
7
(DRIVE STAND REMOVED FOR CLARITY)
Figure 7-2. Mig 2E Wire Feeder (Right Side, Cover Removed)
Qty Req.
1 4 1 1 1 2 1 1
37712GY 951531 674156 21156
952939 13730583 950823
21165
Part
No. Description
REEL STAND FOOT MOUNTING
ADAPTER, POWER CABLE, MOLDED FEED ROLL, .035-.045 DRIVE STA ND, 2-ROLL (See Fig. 7-6) BUSHING, TE RMINA L SNAP BUSHING GUIDE TUBE .035 - .045
Ckt.
Symbol
TB1
TP1, TP2
17
SECTION 7
REPLACEMENT PARTS
3
6
8
10
SEE DETAIL A
1
13
16
14
SEE FIGURE 7-4
2
DETAIL A
Figure 7-3. Mig 2E Wire Feeder (Top View, Cover Removed)
17
4
12
Item
No.
1 2 3 4 6 8
10 12 13 14 16 17
Qty
Req.
1 1 1 2 1 1 1 1 1
10'
1 1
Part
No. Description
34136GY 951530 951174 952860
993717 13792051 13730469 31463 951528 997887 136Z08 35N22
BASE MOTOR, WIRE F EED CLAMP, 1 EAR #10 US CLAMP, 1 EAR #12.8 GER TRANSFORMER, CONTROL VALVE , SOLENO ID RECTIFIER BR IDGE PC BOARD CONTROL CA BLE ASS Y, 10 C OND. 19-PIN CONN. HOS E, WATER NUT, HOS E NIPP LE, H OSE
18
Ckt.
Symbol
M1
T1
SOL1
BR1
PCB1
SECTION 7 REPLACEMENT PARTS
7
8
3
9
1
2
Item No.
1
2 3 4 5 6 7 8 9
10
10
Qty Req.
2 1 2 1 1 1 1 1 1 1
6
4
5
3
Figure 7-4. Mig 2E Wire Feeder Wire Spool Hub Assembly
Part
No. Description
92040101
23600010
92056007
23600952 23606237 23600255 36756 23600982 63300136 64302037
SCREW R.H.M. 3/8-16X.75 NUT, PLASTIC
WASHER, FLAT 3/8"
WASHER D-TYPE HUB REEL BRAKE DISC "D" S H AF T SPRING NUT HEX 3/8-16
WASHER LOC K 3/8
Ckt.
Symbol
19
SECTION 7
REPLACEMENT PARTS
1
7
TOP VIEW
2
8
END VIEW
SIDE VIEW
3
4
5
6
Figure 7-5. Mig 2E Wire Feeder External Views
Item
No.
1 2 3 4 5 6 7 8
Qty
Req.
1 1 1 1 1 1
1
1
Part
2091514 34142YL 34140GY 2062161 98W85
950823 13730222 954698
No. Description
LABEL, WARNING COVER, TOP COVER, OPTION, BAFFLE CIRCUIT BREAKER, 5A STRAIN RELIEF .875 M.H. SNAP BUSHI NG SNAP BUSHI NG LABEL WARNING PINCH HAZARD (Inside Cover)
20
Ckt.
Symbol
CB1
SECTION 7 REPLACEMENT PARTS
18
14
10,6
2,4
7,8
9
20
21
1,3
5
11
15
16
12,13
Item
No.
1 2 3 4 5 6 7 8 9
10
11 12 13 14 15 16 17 18 19
20
21
19
Qty
Req.
2
2 3
Figure 7-6. Mig 2-Roll Drive Stand
Part
No. Description
1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1
1 1
952939 952704 23612477 23612475 23612474 23612625 23612472 23612368 23612476 23612460 23612473 23612461 21156
944
952 952925 23612478 34608 952945 952926 23612462 23612662 23612663
2 ROLL WIRE DRIVE S YSTEM, CONSISTS OF: PRESSURE ARM ASSY., (incls. 2, 3, 4, 7, 8) AXLE, PRESSURE ROLL PRESSURE ARM AXLE NUT PIVOT PIN CIRCLIP PRESSURE ROLL, SMOOTH SPACER PRESSURE DEVICE ASSY. LOCATING PIN INLET GUIDE DRIVE ROLL, .035" - .045" (See Table 3-1) ADAPTOR DRIVE ROLL FEED ROLL THUMB SCREW FEED PLATE WASHER RETAINING SCREW FEED ROLL SPACER THUMB SCREW M6X16 SC REW, MOTOR MOUNTING SPACER TUBE (Pressure Arm) SPRING PRESSURE ARM
21
SECTION 7
REPLACEMENT PARTS
22
SECTION 7 REPLACEMENT PARTS
INSTRUCTION MANUAL CHANGES
The "A" edition (3/98) corrected some text errors, reformatted Section I, Table 1, and changed the Reel Stand, Feed Roll, Base, Guide Tube, Top Cover and Option Cover.
The "B" edition (8/99) changed the Water Hose, Drive Stand, Reel Stand, D-Shaft and the Torch Adaptor is now offered completely assembled. The "C" edition (10/08) updated wiring diagram with revised information per ECN# 083192.
23
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information
Telephone: (800)362-7080 / Fax: (800) 634-7548
Telephone: (800)783-5360 / Fax: (800) 783-5362
Telephone: (800) 235-4012/ Fax: (888) 586-4670
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST Performance Features Technical Specifications Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548
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 / Fax: (843) 664-4454 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
Eastern Distribution Center
Central Distribution Center
Western Distribution Center
Hours: 7:30 AM to 4:00 PM EST
Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
F15-143-C 10 / 08 PRINTED IN U.S.A.
IF YOU DO NOT KNOW WHOM TO CALL
Hours: 7:30 AM to 5:00 PM EST
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