ESAB Voltage Error with Digital Meter Kit Installation on MobileMaster IV “Off the arc"" Wire Feeder Troubleshooting instruction

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DATE: June 4, 2003 BULLETIN NO:M_03_011

TITLE/ PRODUCT NAME: Voltage Error with Digital Meter Kit

Installation on MobileMaster IV “Off the arc” Wire Feeder

RATING:

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(Action is Required) (Potential Problem)

_
(Action is Optional) (Enhanced Product)

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(Unrestricted) (Restricted Distribution)

PRODUCT SERIES/ MODEL: Digital Meter Kit (PN – 23540446) and MobileMaster Feeder

MobileMaster IV CC (Euro) 0558001333

MobileMaster IV NAS 0558001334

MobileMaster IV CC (Euro) w/Meters 0558001802

MobileMaster IV NAS w/Meters 0558001801

SERIAL NO: All

SUMMARY: Recent changes made to the MobileMaster to improve reliability and weld performance on

power sources with low OCV, has affected the accuracy of the arc voltage reading when the digital
meter kit is installed into the MobileMaster. The arc voltage will read from 4 to 8 volts lower than the
actual arc voltage at the gun. The following wiring changes to the MobileMaster will correct the volt
meter error and improve accuracy to within +/- 1 volt.

OPERATIONAL IMPACT: Welding performance is not affected by this change but the feeder will be
able to operate at lower open circuit voltages (OCV) thereby extending the wire feed speed operating
range.

_ DIRECTIVE _X_ ALERT

X_ INFORMATION _X_ PRODUCT IMPROVEMENT

X_ General Distribution _ _ Business Confidential

ACTION:

• Locate the two bridge rectifiers (BR1 & BR2) mounted to the inside panel of the

MobileMaster IV cvcc PCB compartment.

Bridge

Rectifiers

• Cut the tie-wraps on the wiring harness and remove the yellow jumper wire connected

between the bridge rectifiers from the double spaded connectors on each bridge.

Jumper Ends

• Move the 2

nd

yellow wire from the front bridge (BR-2) to the rear bridge (BR-1) where the

jumper was just removed and reconnect capacitor and MOV.

• Insert a new wire from the empty terminal of the contactor assembly to the empty terminal of

• Reassemble unit and weld test. Volt meter should now read within 1 volt accuracy of the

CONTACT:

ESAB Welding & Cutting Products
Product & Service Information Group
843-664-4416 Phone
843-664-5539 FAX

the Front bridge (BR-2). Route the new wire behind the spool post and gas solenoid,
through the hole on the bottom side of the PCB compartment to the bridge.

actual arc voltage.