mobilemaster iv cvcc - esab equipment/wire... · mobilemaster iv cvcc manufacturer or his...

MobileMaster IV cvccPORTABLE “OFF THE ARC” WIRE FEEDERS

This manual provides instructions for units starting with Serial No. WxJ501xxx

ESAB ABSE--695 81 LAXÅSWEDENPhone +46 584 81 000Fax +46 584 123 08

www.esab.com

030210

ESAB subsidiaries and representative offices

EuropeAUSTRIAESAB Ges.m.b.HVienna--LiesingTel: +43 1 888 25 11Fax: +43 1 888 25 11 85

BELGIUMS.A. ESAB N.V.BrusselsTel: +32 2 745 11 00Fax: +32 2 726 80 05

THE CZECH REPUBLICESAB VAMBERK s.r.o.PragueTel: +420 2 819 40 885Fax: +420 2 819 40 120

DENMARKAktieselskabet ESABCopenhagen--ValbyTel: +45 36 30 01 11Fax: +45 36 30 40 03

FINLANDESAB OyHelsinkiTel: +358 9 547 761Fax: +358 9 547 77 71

FRANCEESAB France S.A.Cergy PontoiseTel: +33 1 30 75 55 00Fax: +33 1 30 75 55 24

GERMANYESAB GmbHSolingenTel: +49 212 298 0Fax: +49 212 298 204

GREAT BRITAINESAB Group (UK) LtdWaltham CrossTel: +44 1992 76 85 15Fax: +44 1992 71 58 03

ESAB Automation LtdAndoverTel: +44 1264 33 22 33Fax: +44 1264 33 20 74

HUNGARYESAB KftBudapestTel: +36 1 20 44 182Fax: +36 1 20 44 186

ITALYESAB Saldatura S.p.A.Mesero (Mi)Tel: +39 02 97 96 81Fax: +39 02 97 28 91 81

THE NETHERLANDSESAB Nederland B.V.UtrechtTel: +31 30 248 59 22Fax: +31 30 248 52 60

NORWAYAS ESABLarvikTel: +47 33 12 10 00Fax: +47 33 11 52 03

POLANDESAB Sp.z.o.oWarszawTel: +48 22 813 99 63Fax: +48 22 813 98 81

PORTUGALESAB LdaLisbonTel: +351 1 837 1527Fax: +351 1 859 1277

SLOVAKIAESAB Slovakia s.r.o.BratislavaTel: +421 7 44 88 24 26Fax: +421 7 44 88 87 41

SPAINESAB Ibérica S.A.Alcobendas (Madrid)Tel: +34 91 623 11 00Fax: +34 91 661 51 83

SWEDENESAB Sverige ABGothenburgTel: +46 31 50 95 00Fax: +46 31 50 92 22

ESAB International ABGothenburgTel: +46 31 50 90 00Fax: +46 31 50 93 60

SWITZERLANDESAB AGDietikonTel: +41 1 741 25 25Fax: +41 1 740 30 55

North and South AmericaARGENTINACONARCOBuenos AiresTel: +54 11 4 753 4039Fax: +54 11 4 753 6313

BRAZILESAB S.A.Contagem--MGTel: +55 31 333 43 33Fax: +55 31 361 31 51

CANADAESAB Group Canada Inc.Missisauga, OntarioTel: +1 905 670 02 20Fax: +1 905 670 48 79

MEXICOESAB Mexico S.A.MonterreyTel: +52 8 350 5959Fax: +52 8 350 7554

USAESAB Welding & Cutting ProductsFlorence, SCTel: +1 843 669 44 11Fax: +1 843 664 44 58

Asia/PacificCHINAShanghai ESAB A/PShanghaiTel: +86 21 6539 7124Fax: +86 21 6543 6622

INDIAESAB India LtdCalcuttaTel: +91 33 478 45 17Fax: +91 33 468 18 80

INDONESIAP.T. Esabindo PratamaJakartaTel: +62 21 460 01 88Fax: +62 21 461 29 29

MALAYSIAESAB (Malaysia) Snd BhdSelangorTel: +60 3 703 36 15Fax: +60 3 703 35 52

SINGAPOREESAB Singapore Pte LtdSingaporeTel: +65 861 43 22Fax: +65 861 31 95

ESAB Asia/Pacific Pte LtdSingaporeTel: +65 861 74 42Fax: +65 863 08 39

SOUTH KOREAESAB SeAH CorporationKyung--NamTel: +82 551 289 81 11Fax: +82 551 289 88 63

UNITED ARAB EMIRATESESAB Middle EastDubaiTel: +971 4 338 88 29Fax: +971 4 338 87 29

Representative officesBULGARIAESAB Representative OfficeSofiaTel/Fax: +359 2 974 42 88

EGYPTESAB EgyptDokki--CairoTel: +20 2 390 96 69Fax: +20 2 393 32 13

ROMANIAESAB Representative OfficeBucharestTel/Fax: +40 1 322 36 74

RUSSIA--CISESAB Representative OfficeMoscowTel: +7 095 937 98 20Fax: +7 095 937 95 80

ESAB Representative OfficeSt PetersburgTel: +7 812 325 43 62Fax: +7 812 325 66 85

DistributorsFor addresses and phonenumbers to our distributors inother countries, please visit ourhome page

www.esab.com

0558005327 03/2008

Instruction Manual

2

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!

3

DECLARATION OF CONFORMITYaccording to the Low Voltage Directive 73/23/EEC, to the EMC Directive 89/336/EEC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSEenligt Lågspänningsdirektivet 73/23/EEG, EMC-Direktivet 89/336/EEG

Type of equipment Materialslag Wire feeder

Brand name or trade mark Fabrikatnamn eller varumärkeESAB

Type designation etc. Typbeteckning etc.MobileMaster IV cvcc

Manufacturer or his authorised representative established within the EEA Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB AB Herkulesgatan 72, Box 8004, SE-402 77 Göteborg, Sweden Phone: +46 31 509 000, Fax: +46 31 509 261

The following harmonised standards in force within the EEA have been used in the design:Följande harmoniserande standarder har använts i konstruktionen:EN 60974-1, Arc welding equipment – Part 1: Welding power sources EN 50 199, Electromagnetic compatibility (EMC) Product standard for arc welding equipment

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised representative established within the EEA, that the equipment in question complies with the safety requirements stated above.Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inomEES, att angiven materiel uppfyller säkerhetskraven angivna ovan.

Date DatumLaxå 2004-12-23

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1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.2 Receiving & Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.1 Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.2 Welding Wire Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.3 Torch Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.4 Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.5 Threading the Welding Wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 3.6 Brake Drag Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 4.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 4.2 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.3 Changing Meter Display - IPM TO MPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4.4 Setting a Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 4.5 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.2 Inspection and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5.3 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

section / title page

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7

sectIon 1 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 instal-lation 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 oper-ating 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 pro-tective 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 work piece has been completely cleaned so that there are no substances on the work piece 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 stan-dard 51B, "fire prevention in use of cutting and Welding processes", available from the national fire protection association, Battery march 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.

8


1. Be sure the power source frame (chassis) is con-nected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. 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 recommenda-tions. Do not mistake the work lead for a ground cable.

electrIc anD MagnetIc fIelDs — May be dangerous. electric cur-rent flowing 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 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 work piece 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 confined 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 specific ventilation recommendations.

9


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 fittings 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 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 con-nected. 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 instal-lation, 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 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


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

sectIon 1 segurIDaD1.2 safety - spanish

aDVertencIa: estas precauciones de seguridad son para su protección. ellas hacen resumen de información prove-

niente 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 pre-cauciones 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 entre-namiento 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 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-flamable 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 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 cau-sando 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 rela-cionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. no trabaje den-tro o fuera de contenedores o tanques cerrados. estos pueden explotar si contienen vapores inflamables.

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 corriente alterna (ac) en áreas húmedas, de movimiento confinado en lugares estrechos o si hay

posibilidad de caer al suelo.

12

sectIon 1 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 específicas 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 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.

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 específicas en la ventilación.

13

sectIon 1 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 cualificado para efec-tuar 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.

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

sectIon 1 segurIDaD

sIgnIfIcaDo De los sIMBolos -- según usted avanza en la lectura de este folleto: los símbolos sig-nifican ¡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.

15

sectIon 1 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 :

1. Éloignez suffisamment tous les matériaux combus-tibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininflammable. 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 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 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 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 sur-chargé 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.

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.

aVertIsseMent : ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de pré-caution provenant des références dans

la section des Informations de sécurité supplémen-taires. avant de procéder à l'installation ou d'utiliser l'unité, assurez-vous de lire et de suivre les précau-tions de sécurité ci-dessous, 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.

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 proces-sus 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 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 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 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 per-sonnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

16


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 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. 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 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.

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 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 effectuer 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 spécifiques 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 effets néfastes inconnus pour la santé.

17


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 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 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.

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 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 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 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 dis-position par le Compressed Gas Association, 1235 Jefferson 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


sIgnIfIcatIon Des sYMBolesce symbole, utilisé partout dans ce manuel, signifie "attention" ! soyez vigilant ! Votre sécurité est en jeu.

signifie un danger immédiat. la situation peut entraîner des blessures graves ou mortelles.

signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

signifie un danger qui peut entraîner des blessures corporelles mineures.

Danger

aVertIsseMent

attentIon

19

Arc voltage feeder capable of use with CC or CV units.•Available with “NAS” or “CC” torch connection.•4 roll drive unit•All units include secondary contactor.•Built for harsh environments such as construction sites, •pipe lines, shipyards, offshore, general fabrication, mo-bile welding rigs and more.Totally enclosed, impact-resistant case protects welding •wire from dirt, metal grit, moisture and other contami-nants - a unique “rain gutter” door design keeps water from dripping into the wire compartment.Metal reinforced, flame retardant, molded composite •plastic case will stand extreme abuse like hot slag, grind-ing sparks, corrosive chemicals, knocks, bumps, drops and more.Operates with reverse polarity (wire DC +) or straight po-•larity (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 operation.Electronic Dynamic Braking•Safety features include insulated case, low voltage torch •trigger circuit and overload protection.Designed to meet the most rigid standards. CSA certified •for USA and Canadian requirements. Meets lEC-974-1 specifications.Three-year-warranty•

Ordering Information

Each MobileMaster IV cvcc wire feeder includes gas solenoid and .045-1/16 in. (1.2-1.6 mm) dual groove serrated feed rolls.

MobileMaster IV cvcc, cc ............................... 0558001333MobileMaster IV cvcc, cc w/Meters .......... 0558001802

SpecificationsMobileMaster IV cvccWire Speed Range* ......................................50 - 700 ipm (1.3 - 17.8 m/min) * actual speed range will depend on the arc voltageWire Diameter Capacity ................................. .030 - 5/64 in. (0.8 - 2.0 mm)Primary Input** (open circuit voltage or arc voltage)

Minimum....................................................................................................16 vdc Maximum ........................................................................ 100 vdc (113v peak)** not for use with AC power

Weight ................................................................................................ 30 lbs (13 kg)

MobileMaster IV cvcc

Common to MobileMaster IV cvcc

Standard - 2 in. (5.1 cm) I.D. spindle hub 8 in. (20.3 cm)O.D. spools - require adaptor P/N 17511 10 in. (25.4 cm)O.D. spools - require adaptor P/N 34330 12 in. (30.5 cm)O.D. spools - no adaptor required 14 lb. (6.5 kg) coils - require adaptor P/N 37337

Physical Dimensions

W x H x L ....................... 9.5 in. (24.1 cm) x 14.0 in. (35.6 cm) x 26.9 in. (68.3 cm)

MobileMaster IV cvcc feeders will fit through 16 in. (41 cm) diameter hole.

Required AccessoriesDrive Rolls & Guide Tubes ............................ see table on next page

sectIon 2 DescrIptIon

Features

20

Optional Accessories

gas flowmeter Kit - Includes an adjustable flowmeter with mounting hardware and pro-tective guard that attaches to rear of MobileMaster IV cvcc feeders. Flow tube is calibrated in cubic feet per hour and liters per min.For CO2 shielding gas, order .................................................................37365For Argon shielding gas mixtures, order .........................................36658

Digital Meter Kit - This kit provides a digital display of voltage and wire feed speed (ipm

or m/min) ..............................................................................................2354 0446gas pre/postflow w/Burnback Kit - This kit provides adjustment for shielding gas preflow time (sec) and

postflow time (sec). Adjustable burnback stops the wire feed before the arc is stopped and keeps the wire from sticking to the weld puddle. .......................................................................................................... 36661

Burnback control Kit - Adjustable burnback stops the wire feed before the arc is stopped ...

.......................................................................................................................... 36657contactor replacement ...................................................................1373 5590coil adaptor - adapting to 14 lb. (6.5 kg) coils .................................... 37337spool adaptor - Use for adapting to 8 in. (20.3 cm) diameter spools...................... 17511spool adaptor - Use for adapting to 10 in. (25.4 cm) diameter spools ................... 34330

Drive Roll and Guide Tube Selection

Optional control kitsare available for theMobileMaster IV cvcc

Shock mounts and a flexible base provide

“give” to the case enabling the wire feeder to survive a drop,

even fully loadedWire drive system uses dual groove feed rolls and gear-driven pressure roll for maximum feeding force

Door latch, hinge and recessed fold-down top

handle

Controls are located on a recessed front panel to protect dials and switches

“Rain Gutter” arounddoor keeps water from

getting inside feederOptional Digital Meter (see Accessories for details)

Unique rear handle makes it easy to maneuver feeders into tight spots

Built-in, insulated quick connector - no extra gas hoses or switch cables hanging from the feeder

Voltage pickup cable is included with MobileMaster IV cvcc

guide tubeeuro

* Two drive rolls are required for four roll drive systems. ** Use flat, plain pressure roll(s) (P/N 2361 2397) supplied with

wire feeder. *** Flat, knurled pressure roll(s) (P/N 2361 2369).

hard Wires (“V” groove) .035 in. (0.9 mm) 21156** 0558001078 .045 in. (1.2 mm) 21156** 0558001078 .052 in. (1.4 mm) 21157** 0558001079 1/16 in. (1.6 mm) 21157** 0558991079

cored Wires (Knurled “V” groove) .035 in. (0.9 mm) 21160*** 0558001077 .040 in. (1.0 mm) 21161*** 0558001078 .045 in. (1.2 mm) 21161*** 0558001079 .052 in. (1.4 mm) 21161*** 0558001079 1/16 in. (1.6 mm) 21161*** 0558991079 5/64 in. (2.0 mm) 21162*** 0558001079

Wire type& Diameter roll Drive*

soft (aluminum) Wire (“u” groove) .035 in. (0.9 mm) 21158** 0558001897 3/64 in. (1.2 mm) 21159** 0558001898 1/16 in. (1.6 mm) 21159** 0558001898

Current Wire SpoolHub Configuration


Built-in, insulated gun holder

5 ampCircuit Breaker

21

2.1 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.

2.2 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 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.

taBle 2-1. specIfIcatIons

Wire Feed SpeedMaximum open circuit voltageWire diameters

50 - 800 in./min. (1.3 - 20.3 m/min.)100 vdcHard: .030” (0.8 mm), .035” (0.9 mm), .045” (1.2 mm), .052” (1.4 mm), 1/16” (1.6 mm)Soft: .035” (0.9 mm), 3/64” (1.2 mm), 1/16” (1.6 mm)Cored: .030” (0.8 mm), .035” (0.9 mm), .045” (1.2 mm), .052” (1.4 mm), 1/16” (1.6 mm), 5/64” (2.0 mm)

Wire supplyMotor typeBrake type (wire)ControlFeed SystemOn-Off SwitchRun in start

8” (203 mm), 10” (254 mm) and 12” (305 mm) diameter spools or 14 -lb. (6.4 kg) coils*DC permanent magnet pre-lubricated, totally enclosedDragSolid StatePushStandardAutomatic if required.

HeightWidthLengthWeight (without spool and no contactor)Weight (with contactor, without spool)

14.0” (356 mm) The MobileMaster IV cvcc will fit through a 16” (406 mm) dia. hole. 9.5” (241 mm)26.9 (683 mm)26 lbs. (11.8 kg)30 lbs. (13.6 mg)

*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.

2.3 DescrIptIon

The MobileMaster IV cvcc is a push type portable wire feeder designed for maximum versatility. The unit oper-ates 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 elec-trodes (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.

note

the MobileMaster IV cvcc is not recommended for short circuiting transfer using constant current power sources due to the limited short current available.


22


23

figure 3.1 - typical set-up of MobileMaster IV cvcc

3.1 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 avail-able to feed other sizes of hard wire, soft wire, and cored wire. See Drive Roll and Guide Tube Selection in Section 2) 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 thumb 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.

3.2 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 clockwise 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 Optional Ac-cessories).

PRESSUREROLL

TORCHCONNECTION

DRIVEROLL

WELDING CABLECONNECTION

CURRENT WIRE SPOOLHUB CONFIGURATION

sectIon 3 InstallatIon

24

3.3 torch connectIons

The torch adaptor on the MobileMaster IV cvcc 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.

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.

3.4 supplY connectIons

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.

The MobileMaster IV cvcc can be used with either polarity without modifications.

A. Connect the proper polarity output welding cable from the power source; positive terminal for gas shielded wires, or negative for most gasless self-shielded cored wires, to the weld cable lug connection extending from the rear of the MobileMaster IV cvcc feeder.

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.

B. Connect a second welding cable to the opposite po-larity output connection on the power source and to the work piece.

C. Connect the wire feeder work lead 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 con-tactor. Open circuit voltage must be present to operate the wire feeder.

3. Turn the wire feeder ON and close the torch trig-ger.

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.

4. Inspect all gas connections for leaks. 5. If using gas shielded wires, adjust the gas flow-

meter to the desired flow rate. 6. Turn power source and wire feeder OFF.

figure 2.2 - typical set-up of MobileMaster IV cvcc

- (or +) + (or -)


25

3.5 threaDIng the WelDIng WIre

When the wire feeder is connected to the power source, the work lead from the power source connected to the work piece, the wire feeder work lead connected to the work, and the power source is turned on with the contactor closed, the wire feeder is energized when the wire feeder is turned on. closing the torch trigger will cause the welding wire to become electrically hot, and will cause the drive rolls to turn. Keep fingers clear!

A. Turn OFF the power source and the wire feeder.B. Release the pressure roll assembly levers and check

for the proper drive roll and groove position.

Before threading welding wire through the casing, make sure the chisel point and burrs have been re-moved from the end of the wire to prevent the wire from jamming in the torch casing or liner.

C. Feed the wire from the spool through the inlet guide along the drive roll groove and into the torch inlet guide.

D. Lower the pressure roll assemblies 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.


3.6 BraKe Drag aDJustMent

Brake disc friction should provide enough drag to keep the wire spool from spinning freely after the wire feed stops. If adjustment is required, turn the adjusting screw clockwise to increase drag, counterclockwise to decrease drag. Drag should be just enough to limit wire overrun.

26


27figure 4.1 - controls and connections, MobileMaster IV cvcc

10A FUSE

OPT. METER KIT

POWER ON-OFF SWITCH

WIRE SPEEDCONTROL

WORK LEADTORCH

CONNECTION

WELDING CABLECONNECTION

SHIELD GASCONNECTION

sectIon 4 operatIon4.1 controls

4.1.1 poWer sWItchThe 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.

4.1.2 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 MobileMaster IV wire feeder is equipped with auto-matic “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 MobileMaster IV front panel.

4.1.3 WIre feeD speeD (constant speeD)The MobileMaster IV 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 4-2. Factory settings are as follows: S1 - closed, S2 - open.

Position S1 - open

Position S2 - closed

SW1

figure 4.2

DIp switch functions

The DIP switches are located on the control PCB mounted inside the upper compartment of the wire feeder. See fol-lowing table for switch positions and description.

5A CIRCUIT BREAKER

4.1.4 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.

28

sectIon 4 operatIon

MobileMaster IV Dip switch table

switch positionopen (off)

closeD (on)Description

factory setting - constant current operation ( “Voltage control Mode” ) In this operation mode the MobileMaster IV 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 (MobileMaster IV 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 (MobileMaster IV 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 (Off) position the wire feed motor is disabled and the motor will NOT run.

1

2

RockerDown

OP

EN

1

2

RockerDown

OP

EN

29

sectIon 4 operatIon

4.2 operatIng proceDures

4.2.1 operatIng safetY precautIonsComply with all ventilation, fire 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 flash goggles with filter lenses under his helmet. The hel-met filter plate should be shade number 11 (nonfer-rous) 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 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 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 ap-paratus. Avoid gas leaks in a confined space, as the leaked gas can dangerously reduce oxygen concen-tration in the breathing air. DO NOT bring gas cylin-ders 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 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 flying hot metal.

I. Turn off 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 flash. 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

cautIon

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 confined space may result in a build-up of fumes, displacing oxygen.

30

sectIon 4 operatIon

4.3 changIng Meter DIsplaY - IpM to MpM

WarnIng

1

2

1

2

SW1 SW1

Wire Speed IPM Wire Speed MPM

RockerDown

RockerDown

OP

EN

OP

EN

to preVent accIDental electrIc shocK, Be sure control caBle Is DIsconnecteD froM poWer source Before WorKIng InsIDe the WIre feeDer.

1. Make sure control cable is removed from the power source.

2. Remove meter panel from front panel of the wire feeder. Retain mounting screws.

3. Check the setting of the “dip switches” on the digital meter board. These switches can be set up for meter to read in inches per minute (IPM) or in meters per minute (MPM) as shown below. The meter is factory set in IPM positions.

Set the switch on the digital meter to the desired mode of operation. If the IPM mode is selected, the meter will read the PRE-SET wire speed when not feeding wire and the ACTUAL wire speed when feeding wire. If the VOLTS mode is selected, the meter will only read the ACTUAL voltage.

DIGITAL METERPC BOARD

DIGITAL METER

DIP SWITCHES

31

QuIcK set-up proceDure

For Constant Voltage (CV) Power Source - Set the arc voltage desired on the 1. P/S.For Constant Current (CC) power source - Set the weld CURRENT desired.2. On the MobileMaster IV Unit - Set the wire feed speed knob at #5.3.

4.4 settIng a WelDIng proceDure

WELD DATA TABLEWIRE FEED SPEED (IPM)

FLUX COREE70T-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

STEELSOLID WIRE

Al/SiALUMINUM

Al/MgALUMINUM

ARC VOLTS / AMPS (WELD CURRENT)

100 150 200 250 300 350 400 450 500 550 600 65029

25 30 33 36

29150

30250

33290

34330

155 300 460 50037

500

210

33365

30300

27190

33410

33450

29260

28250

30270

29300

29275

30325

32400

30350

30300

34450

25180

25200

26215

27230

28245

25260

26280

27300

26290

27340

30400

28320

30340

25110

25140

26150

26190

26200

23260

30300

32350

27205

27220

22100

23150

23175

24190

25205

25220

23200

25250

27280

27290

28340

32300

32350

39500

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 4 operatIon

32

noteUsing 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 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-Master IV 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.

4a. Flip the MobileMaster IV digital display switch to the WFS position.

5a. Release the pressure roll assembly and pull the gun trigger then set the WFS on the digital display using the VOLTS / WFS knob.

6a. Reset the pressure roll assembly and strike an arc then trim the arc length as needed using the VOLTS / WFS knob.

MobileMaster IV withconstant 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.

MobileMaster IV withconstant 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 3. top of the column for the wire type, diam-eter and weld VOLTAGE / CURRENT chosen.

noteIf dIgital meter is installed skip to step

4A.

Use the VOLTAGE and WFS in the WFS Table to de-4. termine the MobileMaster IV wire feed knob posi-tion.Strike an arc then trim the arc length as needed us-5. ing the VOLTS / WFS knob.

noteIf dIgital meter is installed skip to step

4A.

4a. Flip the MobileMaster IV digital display switch to the WFS position.

5a. Release the pressure roll assembly and pull the gun trigger then set the WFS on the digital display using the VOLTS / WFS knob.

6a. Reset the pressure roll assembly and strike an arc then trim the arc length as needed using the VOLTS / WFS knob.

Use the VOLTAGE and WFS in the WFS Table to deter-4. mine the MobileMaster IV wire feed knob position.Strike an arc then trim the arc length as needed us-5. ing the VOLTS / WFS knob.

sectIon 4 operatIon

33

noteOn 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.

* MobileMaster IV Wire Feed Speed Knob Position

WIRE FEED SPEED TABLEWFSSet 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 01 4 5 5 6 6 7 7 7 9 11 12 15 14 13 13 112 44 51 56 65 70 74 77 85 90 93 95 103 102 102 101 1003 99 109 116 129 136 140 144 155 165 173 179 196 198 200 201 2054 152 163 170 184 196 204 211 230 241 250 256 275 282 287 291 3025 210 225 235 255 270 281 290 315 329 339 347 370 379 385 390 4056 267 282 292 312 331 345 356 388 412 430 443 483 490 495 499 5107 334 354 368 395 415 430 441 475 503 524 540 587 594 599 603 6158 380 411 431 472 494 511 523 560 589 610 626 675 685 693 698 7159 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

4.5 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.

sectIon 4 operatIon

34

sectIon 4 operatIon

35

5.1 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 qualifications.

As an aid in checking and servicing, refer to the following pages; Schematic Diagram and/or Wiring Diagram.

5.2 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.

WarnIng

WarnIng

WarnIngIf 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 uncov-ered conductor can shock, possibly fatally.

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.

5.2.1 WIre feeDerWhen 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.

5.2.2 solenoID ValVe replaceMentIf there is no gas flow 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.

5.2.3 general replaceMentThe views in the Parts Section indicate wire drive and feeder parts.

sectIon 5 MaIntenance

36

5.3 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, 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 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 qualified, as described in the maintenance section.

cautIon

WarnIng

WarnIng


37

note:Schematics and Wiring Diagrams on 279.4mm x 431.8mm

(11” x 17”) paper are included inside the back cover of this manual.


38


39

sectIon 6 replaceMent parts

6.1 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.

6.2 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

6.0 replacement parts

40

FUSE

HO

LDER

15A

250

V - 6

3470

9(F

1) F

USE

, SLO

BLO

10A

250

V - 1

3735

464

(S1)

SW

ITCH

, TO

GG

LE S

PDT

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42

(C1) CAPACITOR, 1.0UF 630WVDC - 951028

(BR1,BR2) (2) RECT. 35A 400V - 13730469(MOV1) VARISTOR, METAL OXIDE 950428

(R2) RESISTOR, 5W - 17615250

(P4) SHORTING PLUG ASSY. - 37580

(PCB1) CONTROL BOARD ASSY. - 0558038286

figure 6.3 - MobileMaster IV cvcc, right Inside View With upper and lower Blanking plates removed


43

figure 6.4 - auto-lift Mini four roll geared Wire Drive system - 0558001339for units with serial numbers starting xxxJ228001 (Mid July 2002 forward)

for units with serial numbers xxxJ228001 (Mid July 2002 forward)


DRIVE ROLLS (See Drive Roll & Guide Tube Selection Guide in SECTION 1)

IteM part no. QtY. DescrIptIon IteM part no. QtY. DescrIptIon

1 0558001743 1 Feed Plate 15 0558001752 1 Spacer Tube Pressure Arm Auto Lift

1A 0558001744 1 Safety Guard 16 0558001753 1 Spacer Tube Bogie

2 952927 1 Screw, Thumb (M6X12) 17 0558001754 1 Axle Pressure Arm

3 0558001745 1 Pressure Arm 18 0558001755 1 Allen Screw

4 0558001746 1 Bogie 19 0459441880 2 Gear Adaptor Feed Roll

5 23612368 2 Pressure Roll 20 0558003540 2 Axle Gear Adaptor Feed Roll

6 23612477 2 Axle Pressure Roll 21 34608 3 Washer, Retaining Screw

7 0558001747 1 Locating Pin 22 952925 3 Knurled Screw

8 23612474 2 Nut, Pressure Roll Axle 23 23612460 1 Pressure Device W/Scale

9 23612472 1 Circlip 24 23612470 Pkt. 5 Locating Pin, 2.5 x 12 Pressure Device

10 34609 1 Retaining Screw Pressure Arm 25 23612462 1 Screw (Center) Guide

11 0558001748 1 Spring Bogie Auto Lift 26 0558001757 1 Center Guide (Hard Wire)

12 0558001749 1 Spring to Pressure Arm Auto Lift 0558001895 1 Center Guide for (Aluminum)

13 0558003538 2 Spacer Tube, Small 27 0558001758 1 Inlet Guide (Aluminum & Steel)

14 0558003539 2 Spacer Tube, Big 28 0558003542 1 Main Gear Drive

44

figure 6.5 - auto-lift Mini four roll geared Wire Drive system - 0558001339for units with serial numbers between xxxJ102026 - xxxJ228001 (prior to Mid July 2002)

DRIVE ROLLS (See Drive Roll & Guide Tube Selection Guide in SECTION 1)

NOTE: Measure hole placementto distinguish between early & cur-rent version drive stands


IteM part no. QtY. DescrIptIon IteM part no. QtY. DescrIptIon

1 0558001743 1 Feed Plate 15 See Fig. 6.4 Same as new style

1A See Fig. 6.4 Same as new style 16 See Fig. 6.4 Same as new style

2 See Fig. 6.4 Same as new style 17 See Fig. 6.4 Same as new style



5 See Fig. 6.4 Same as new style 20 0558001756 2 Axle Gear Adaptor Feed Roll





10 See Fig. 6.4 Same as new style 25 23612462 1 Screw Intermediate Guide


12 See Fig. 6.4 Same as new style

13 0558001750 2 Spacer Tube, Small 27 0558001758 1 Inlet Guide (Aluminum & Steel)

14 0558001751 2 Spacer Tube, Big 28 0558002149 1 Main Gear Drive

for units with serial numbers between xxxJ102026-xxxJ228001 (prior to Mid July 2002)

45

figure 6.6 - Wire spool hub assembly


Item no. Qty. req’d. part no. Description

2 1 64302037 Lockwasher, 3/8”3 1 61341144 Screw, 3/8-16 x .754 2 948255 Pad, Braking5 1 0558003320 Washer, D-Type6 1 634347 Clip, Hitch7 1 92044046 Screw, 12043 STLZPC, 3/8-16 x 1.008 1 92056007 Washer, Plain 3/8”9 1 23600982 Spring

10 1 948258 Spindle, Molded11 1 36756 “D” Shaft

4

56

7

81

9

10

11

2, 3

46

notes

47

Original release - April, 2005 1.

Revision 10/2006 - updated wiring diagram and changed control board part number from 38142 to 2. 0558038286 per CN #063163.

Revision 01/2007 - Numerous updates, complete replacement of section 3 & 4, numerous updates in 3. replacement parts, updated schematics and wiring diagrams. Same changes as in F15-610-H.

03 / 2008 - Updated pictures and updated Replacement Parts section per CN#083002.4.

reVIsIon hIstorY

0558005327 03/2008

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