INSTRUCTION MANUAL
MobileMaster 2CVCC
PORTABLE OFF THE ARC WIRE FEEDERS
F-15-435
June, 1998
This manual provides complete instructions for the following units starting with Serial No. WORI807001:
36655 - MobileMaster 2cvcc, Basic
36656 - MobileMaster 2cvcc with Contactor
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 on pages 3 and 4 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, plainly worn distorted or contaminated, should be replaced immediately. Should such repair or replacement
become necessary, ESAB recommends that a telephonic or written request for service advice be made to the ESAB
Authorized Distributor from whom purchased or to the nearest ESAB Sales Office.
This equipment or any of its parts should not be altered without the prior written approval of ESAB. 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 ESAB or a a service facility designated by ESAB.
TABLE OF CONTENTS
SECTION TITLE PAGE
SAFETY PRECAUTIONS ................................................................................. 3-4
SECTION 1 DESCRIPTION .................................................................................................... 7
1.1 General ................................................................................................................ 7
1.2 Receiving-Handling .............................................................................................. 7
1.3 Description ........................................................................................................... 7
1.4 Optional Accessories ........................................................................................... 7
1.5 Safety................................................................................................................... 7
SECTION 2 INSTALLATION ................................................................................................... 8
2.1 Drive Rolls ........................................................................................................... 8
2.2 Welding Wire Speed ............................................................................................ 8
2.3 Torch Connections ............................................................................................... 8
2.4 Supply Connections ............................................................................................. 9
2.5 Threading the Welding Wire .............................................................................. 10
2.6 Brake Drag Adjustment ...................................................................................... 10
SECTION 3 OPERATION ....................................................................................................... 11
3.1 Controls .............................................................................................................. 11
3.1.1 Power Switch ......................................................................................................11
3.1.2 Wire Feed Speed ................................................................................................11
3.1.3 Optional Meter .................................................................................................... 11
3.2 Operating Procedures ......................................................................................... 11
3.2.1 Operating Safety Precautions .............................................................................11
3.3 Welding Procedure ............................................................................................ 12
3.4 Shutdown ........................................................................................................... 12
SECTION 4 MAINTENANCE ................................................................................................ 13
4.1 Maintenance ...................................................................................................... 13
4.2 Inspection and Service ....................................................................................... 13
4.2.1 Wire Feeder ....................................................................................................... 13
4.2.2 Drive Roll Pressure Adjustment ......................................................................... 13
4.2.3 Solenoid Valve Replacement ............................................................................. 13
4.2.4 General Replacement ........................................................................................ 13
4.3 Troubleshooting ................................................................................................. 13
SECTION 5 REPLACEMENT PARTS ................................................................................... 17
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 Processes", 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
11/95
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.
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:
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."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate hazards which, if not avoided, will result in
immediate, serious personal injury or
loss of life.
Used to call attention to potential hazards which could result in personal injury
or loss of life.
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
Used to call attention to hazards which
could result in minor personal injury.
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 incandescent
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
tension 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
assu-rer 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
5
9/97
levage, 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’élimi-ner 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 Cutting”
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.
6
SECTION 1 DESCRIPTION
1.1 GENERAL
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.
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.
1.3 DESCRIPTION
The MobileMaster 2cvcc is a push type portable wire
feeder designed for maximum versatility. The unit operates entirely on the arc voltage from a constant current or constant voltage welding power source.
The unit is designed for use with hard, soft, and cored
electrodes (gas shielded or self-shielded) from 0.023
through 5/64 diameter with wire feed speed from 50
to 700 IPM. The feeder components are totally enclosed
in a rugged case for optimum mobility.
There are two models of the MobileMaster 2cvcc available. P/N 36655 is the basic model which is used when
secondary contactor is not required. P/N 36656 is the
same as P/N 36655 except it has factory installed
contactor.
1.4 OPTIONAL ACCESSORIES
1.4.1 Argon Flowmeter Kit, P/N 36658; CO2 Flowmeter Kit, P/N 37365 - These kits include an adjust-
able flowmeter with a protective guard and mounting
hardware for mounting to rear of MobileMaster unit.
1.4.2 Digital Meter Kit, P/N 23540446 - This LCD
meter is simple to mount and displays welding voltage
while welding.
1.4.3 Gas Pre/Postflow with Burnback Kit, P/N
36661 - This kit provides adjustment for shielding gas
preflow and postflow times. Adjustable burnback stops
the wire feed before the arc is stopped to keep the wire
from sticking to the weld.
1.4.4 Burnback Control Kit, P/N 36657 - This kit has
adjustable burnback control for stopping the wire feed
before the arc stops.
1.4.5 Welding Contactor Kit, P/N 36662 - Available
as an accessory for the basic MobileMaster 2cvcc
(36655). It is factory installed on units with contactor
(36656). This kit keeps the welding torch from being
electrically hot except when the torch trigger is engaged.
1.4.6 Contactor Point Replacement Kit,
P/N 13736628
1.4.7 Spool Adaptor, 8-in. Spool, P/N 17511
Spool Adaptor, 10-in. Spool, P/N 34330
Coil Adaptor, 14-lb. Coil, P/N 37337
Required if using wire from a 8 or 10-in. spool or 14-lb.
(6.4 kg) coil.
1.5 SAFETY
Before the equipment is put into operation, the safety
section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications.
TABLE 1-1. SPECIFICATIONS
Wire Feed Speed 50 - 700 in./min. (1.3 - 17.8 m/min.)
Maximum open circuit voltage 100 vdc
Wire diameters Hard: .023 (0.6mm), .030 (0.8mm), .035 (0.9mm), .045 (1.2mm), .052 (1.4mm), 1/16 (1.6mm)
Wire supply 8 (203mm), 10 (254mm) and 12 (305mm) diameter spools or 14-lb. (6.4kg) coils*
Motor type DC permanent magnet pre-lubricated, totally enclosed
Brake type (wire) Drag
Control Solid State
Feed System Push
On-Off Switch Standard
Run in start Automatic if required.
Height 14.0 (356mm)
Width 9.5 (241mm)
Length 26.9 (683mm)
Weight (without spool and no contactor) 26 lbs. (11.8kg)
Weight (with contactor, without spool) 30 lbs. (13.6mg)
*8-in. spool requires spool adaptor P/N 17511; 10-in spool requires spool adaptor P/N 34330; and 14-lb coil requires coil adaptor P/N 37337.
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)
The MobileMaster 2cvcc will fit through a 16 (406mm) dia. Hole.
7
SECTION 2 INSTALLATION
2.1 DRIVE ROLLS
The unit is supplied ready to feed 0.045, .052 or 1/16
(1.2 to 1.6mm) diameter cored wires. (Other drive rolls
are available to feed other sizes of hard wire, soft wire,
and cored wire. See Table 2.1.) The drive roll has two
grooves; the small groove feeds 0.045 diameter wire,
the large groove feeds .052 and 1/16 diameter wire. The
groove nearest the gear motor feeds the wire. If the required groove is not in that position or a different drive
roll is required:
A. Release the pressure roll assembly lever and lift
the assembly upward.
B. Remove the screw holding the drive roll to the gear
motor shaft.
C. Remove the drive roll and reverse or replace with
the required size for the wire chosen.
D. Secure the screw removed in B and tighten.
E. Secure the pressure roll assembly.
2.2 WELDING WIRE SPOOL
Install a spool of welding wire on the hub as follows:
A. Unscrew the spool nut from the hub.
B. Place the wire spool on the hub to rotate clock-
wise as the wire is unwound; hub pin must engage
the hole in the wire spool.
C. Screw the spool nut into the hub.
NOTE: If using wire from an 8 or 10-in. spool or from a
14-lb. coil, install proper adaptor (see 1.4.4).
Table 2-1. Drive Roll & Guide Tube Selection
Upper
Wire Type / Lower Pressure Guide
Diameter Drive Roll Roll Tube
Hard Wires (V groove)
.023 in. (0.6mm) 21155 2361 2397 21163
.030 in. (0.8mm) 21155 2361 2397 21164
.035 in. (0.9mm) 21156 2361 2397 21165
.040 in. (1.0mm) 21156 2361 2397 21165
.045 in. (1.2mm) 21156 2361 2397 21165
.052 in. (1.4mm) 21157 2361 2397 21166
1/16 in. (1.6mm) 21157 2361 2397 21166
Soft (aluminum) Wires (U groove)
.035 in. (0.9mm) 21158 2361 2397 21167**
3/64 in. (1.2mm) 21159 2361 2397 21168**
1/16 in. (1.6mm) 21159 2361 2397 Not Reqd
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 MobileMaster wire feeder.
Recommended for use with soft cored wires that are easy to flatten.
Order both lower drive roll and upper pressure roll.
** Requires Support Tube 21169.
PRESSURE
ROLL
TORCH
CONNECTION
DRIVE
ROLL
WIRE
SPOOL HUB
WELDING CABLE
CONNECTION
GUIDE TUBE
Figure 2.1 - Typical Set-up of MobileMaster 2cvcc
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