Mig 4HD DUAL WIRE FEEDER - ESAB Welding & Cutting equipment/wire feeders/mig 4hd_dual_f... · Mig 4HD DUAL WIRE FEEDER ... AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“

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

INSTRUCTION MANUAL

Mig 4HDDUAL WIRE FEEDER

P/N 37544

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operationand safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practicesfor Arc Welding, Cutting, and Gouging", Form 52-529. Do NOT permit untrained persons to install, operate, ormaintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fullyunderstand these instructions. If you do not fully understand these instructions, contact your supplier forfurther information. Be sure to read the Safety Precautions (Section I) before installing or operating thisequipment.

F15-483-CJul, 2009

Mig 4HD Wire Feeder

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual andaccompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with theinstructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintainedequipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should bereplaced immediately. Should such repair or replacement become necessary, the manufacturer recommendsthat a telephone or written request for service advice be made to the Authorized Distributor from whompurchased.

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 improperuse, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or aservice facility designated by the manufacturer.

TABLE OF CONTENTS

SECTION TITLE PAGE PARAGRAPH

1 SAFETY ............................................................................................................................ 3-6

2 DESCRIPTION AND SPECIFICATION ...................................................................................72.1 Mig 4HD Wire Feeder .............................................................................................72.2 Mig 4HD Wire Feeder Options ................................................................................8

3 EQUIPMENT .........................................................................................................................10

3.1 General .................................................................................................................103.2 Optional Equipment and Accessories ....................................................................103.3 Accessories ..........................................................................................................10

4 INSTALLATION .....................................................................................................................11

4.1 Installation .............................................................................................................11

5 OPERATION .........................................................................................................................135.1 Adjustments and Operation ...................................................................................135.2 Operating Sequence .............................................................................................13

6 SERVICE ..............................................................................................................................136.1 Maintenance .........................................................................................................13

7 REPLACEMENT PARTS .......................................................................................................16

2

3

WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before

performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.

PROTECT YOURSELF AND OTHERS --Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.Training in the proper use of the processes and equip-ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any workarea, even if welding helmets, face shields, and gogglesare also required.

2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc andnot to expose themselves to the rays of the electric-arcor hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing

5. Protect other personnel from arc rays and hot sparkswith a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and ex-plosions. Therefore:

1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.“

3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.

10/98

5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.

6. After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when neces-sary.

7. For additional information, refer to NFPA Standard 51B,"Fire Prevention in Use of Cutting and Welding Pro-cesses", available from the National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.

1. Be sure the power source frame (chassis) is connectedto 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 fatalshock.

4. Use well-maintained equipment. Replace worn or dam-aged 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 fromwork and from ground.

7. Do not stand directly on metal or the earth while workingin tight quarters or a damp area; stand on dry boards oran 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 mistakethe work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —May be dangerous. Electric current flow-ing through any conductor causes lo-calized Electric and Magnetic Fields(EMF). Welding and cutting current cre-ates EMF around welding cables andwelding machines. Therefore:

1. Welders having pacemakers should consult their physi-cian before welding. EMF may interfere with some pace-makers.

2. Exposure to EMF may have other health effects which areunknown.

3. Welders should use the following procedures to minimizeexposure 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.

SECTION 1 SAFETY PRECAUTIONS

4

FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can cause asphyxiation.Therefore:

1. Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel,copper, zinc, lead, beryllium, or cadmium unless positivemechanical ventilation is provided. Do not breathe fumesfrom these materials.

2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene, a highly toxicgas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation is notadequate. Stop work and take necessary steps to im-prove ventilation in the work area. Do not continue tooperate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)for specific ventilation recommendations.

5. WARNING: This product, when used for welding orcutting, produces fumes or gases whichcontain chemicals known to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety Code §25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, ifmishandled, can rupture and violentlyrelease gas. Sudden rupture of cylin-der, valve, or relief device can injure orkill. Therefore:

1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition. Followmanufacturer's operating instructions for mounting regu-lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chainor strap to suitable hand trucks, undercarriages, benches,walls, post, or racks. Never secure cylinders to worktables or fixtures where they may become part of anelectrical circuit.

3. When not in use, keep cylinder valves closed. Havevalve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitablehand 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 inCylinders", which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington,VA 22202.

EQUIPMENT MAINTENANCE -- Faulty orimproperly maintained equipment cancause injury or death. Therefore:

1. Always have qualified personnel perform the installa-tion, troubleshooting, and maintenance work. Do notperform any electrical work unless you are qualified toperform such work.

2. Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.

3. Maintain cables, grounding wire, connections, powercord, and power supply in safe working order. Do notoperate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keepequipment 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 positionand in good repair.

6. Use equipment only for its intended purpose. Do notmodify it in any manner.

ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices for elec-tric arc welding and cutting equipment, askyour supplier for a copy of "Precautions andSafe Practices for Arc Welding, Cutting andGouging", Form 52-529.

The following publications, which are available from theAmerican Welding Society, 550 N.W. LeJuene Road, Mi-ami, 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 Hand-

book.8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have HeldHazardous Substances."

MEANING OF SYMBOLS - As used through-out this manual: Means Attention! Be Alert!Your safety is involved.

Means immediate hazards which, ifnot avoided, will result in immediate,serious personal injury or loss of life.

Means potential hazards which couldresult in personal injury or loss of life.

Means hazards which could result inminor personal injury.

SP98-10

SECTION 1 SAFETY PRECAUTIONS

5

a. Éloigner suffisamment tous les matériaux combus-tibles du secteur où l’on exécute des soudures ou descoupes à l’arc, à moins de les recouvrir complètementd’une bâche non-inflammable. Ce type de matériauxcomprend notamment le bois, les vêtements, la sciure,l’essence, le kérosène, les peintures, les solvants, legaz naturel, l’acétylène, le propane et autres sub-stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-cent peuvent tomber dans des fissures du plancher oudans des ouvertures des murs et y déclencher uneignition lente cachée. Veiller à protéger ces ouverturesdes étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérationsde gougeage ou autres travaux à chaud à la surfacede barils, bidons, réservoirs ou autres contenantsusagés, avant de les avoir nettoyés de toute trace desubstance susceptible de produire des vapeursinflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, ilconvient de disposer d’un matériel d’extinction prêt àservir immédiatement, tel qu’un tuyau d’arrosage, unseau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteurde façon à vous assurer qu’aucune étincelle ou projec-tion de métal incandescent ne risque de provoquerultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arcau plasma exige l’emploi de tensions à viderelativement importantes; or, celles-ci risquent decauser des dommages corporels graves et mêmemortels en cas d’utilisation inadéquate. La gravité duchoc électrique reçu dépend du chemin suivi par lecourant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-sion venir au contact direct de la peau ou devêtements humides. Veillez à porter des gants biensecs.

b. Si vous devez effectuer un travail sur une surfacemétallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secset des chaussures à semelles de caoutchouc et envous tenant sur une planche ou une plate-formesèche.

c. Mettez toujours à la terre le poste de soudage/coupageen le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Nesurchargez jamais le câble. Utilisez toujours unéquipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas enservice. une mise à la masse accidentelle peut eneffet provoquer une surchauffe de l’équipement et undanger d’incendie. Ne pas enrouler ou passer le câbleautour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce enun point aussi proche que possible de la zone detravail. Le branchement des câbles de masse àl’ossature du bâtiment ou en un point éloigné de lazone de travail augmente en effet le risque de pas-sage d’un courant de sortie par des chaînes delevage

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objetd’ assurer votre protection. Veillez à lire et à observer lesprécautions énoncées ci-dessous avant de monter l’équipement ou de commercer à l’utiliser. Tout défautd’observation de ces précautions risque d’entraîner desblessures graves ou mortelles.1. PROTECTION INDIVIDUELLE-- Les brûlures de la

peau et des yeux dues au rayonnement de l’arcélectrique ou du métal incandescent, lors du soudageau plasma ou à l’électrode ou lors du gougeage àl’arc, peuvent s’avérer plus graves que cellesrésultant d’une exposition prolongée au soleil. Aussiconvient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaquesprotectrices et des verres filtrants appropriés afin devous protéger les yeux, le visage, le cou et les oreillesdes étincelles et du rayonnement de l’arc électriquelorsque vous effectuez des soudures ou des coupesou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximitéde façon à ce qu’elles ne regardent pas l’arc et à cequ’elles ne s’exposent pas à son rayonnement, ni àcelui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tuniqueépaisse à manches longues, des pantalons sansrebord, des chaussures à embout d’acier et uncasque de soudage ou une calotte de protection, afind’éviter d’exposer la peau au rayonnement de l’arcélectrique ou du métal incandescent. ll est égalementsouhaitable d’utiliser un tablier ininflammable defaçon à se protéger des étincelles et du rayonnementthermique.

c. Les étincelles ou les projections de métal incandes-cent risquent de se loger dans des manchesretroussées, des bords relevés de pantalons ou dansdes poches. Aussi convient-il de garder boutonnés lecol et les manches et de porter des vêtements sanspoches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arcélectrique les autres personnes travaillant à proximitéà l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécuritélorsque vous vous trouvez dans un secteur où l’oneffectue des opérations de soudage ou de coupage àl’arc. Utilisez des lunettes de sécurité à écrans ouverres latéraux pour piquer ou meûler le laitier. Lespiquetures incandescentes de laitier peuvent êtreprojetées à des distances considérables. Lespersonnes se trouvant à proximité doivent égalementporter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasmaproduisent un niveau de bruit extrêmement élevé (de100 à 114 dB) et exigent par conséquent l’emploi dedispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections delaitier incandescent ou d’étincelles peuventprovoquer de graves incendies au contact dematériaux combustibles solides, liquides ou gazeux.Aussi faut-il observer les précautions suivantes:

9/97

6

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 detravail, des câbles, du porte-électrode et du poste desoudage/coupage. Réparez immédiatement toutefuite d’eau.

4. VENTILATION-- La respiration prolongée des fuméesrésultant des opérations de soudage/coupage, àl’intérieur, d’un local clos, peut provoquer des mal-aises et des dommages corporels. Aussi convient-ild’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate del’emplacement de travail en maintenant une ventila-tion naturelle ou à l’aide de moyens mécaniques.N’effectuez jamais de travaux de soudage ou decoupage sur des matériaux de zinc, de plomb, deberyllium ou de cadmium en l’absence de moyensmécaniques de ventilation capables d’empêcherl’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou decoupage à proximité de vapeurs d’hydrocarburechloré résultant d’opérations voisines de dégraissageou de pulvérisation. La chaleur dégagée ou lerayonnement de l’arc peut déclencher la formation dephosgène -- gaz particulièrement toxique -- et d’autresgaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de lagorge constatée au cours de l’utilisation del’équipement dénote un défaut de ventilation. Arrêtez-vous de travailler afin de prendre les mesures néces-saires à l’amélioration de la ventilation. Ne poursuivezpas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisationsoù circule de l’hydrogène. L’armoire de commande estmunie d’un ventilateur destiné à empêcher la forma-tion de poches d’hydrogène, lesquelles présentent undanger d’explosion; ce ventilateur ne fonctionne quesi l’interrupteur correspondant du panneau avant setrouve placé en position ON (Marche). Veillez àmanœuvrer cette commande en vérifiant si lecouvercle est bien en place, de façon à assurerl’efficacité de la ventilation ainsi réalisée. Ne jamaisdébrancher le ventilateur.

e. Les fumées produites par l’opération de soudage oude coupage peuvent s’avérer toxiques. Aussi est-ilnécessaire de disposer en permanence d’un dispositifadéquat de ventilation de type aspirant, afin d’élimi-ner du voisinage de l’opérateur tout dégagement defumée visible.

f. Consultez les recommandations particulières enmatière de ventilation indiquées à l’alinéa 6 de lanorme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipemententretenu de façon défectueuse ou inadéquate risquenon seulement de réaliser un travail de mauvaisequalité mais, chose plus grave encore, d’entraîner

des dommages corporels graves, voire mortels endéclenchant 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 postede soudage et de coupage. N’effectuez aucuneréparation électrique sur l’équipement à moins d’êtrequa-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretienquelconque à l’intérieur du poste de soudage/coupage, avant d’avoir débranché l’alimentationélectrique.

c. Maintenez en bon état de fonctionnement les câbles,le câble de masse, les branchements, le cordond’alimentation et le poste de soudage/coupage.N’utilisez jamais le poste ou l’équipement s’il présenteune défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage etdes équipements accessoires. Gardez-les à l’écartdes sources de charleur, notamment des fours, del’humidité, des flaques d’eau maintenez-les à l’abri destraces d’huile ou de graisse, des atmosphères corro-sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tousles panneaux de l’armoire de commande en veillant àles garder en bon état.

f. Utilisez le poste de soudage/coupage conformément àson usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVESÀ LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur lesrègles de sécurité à observer pour le montage etl’utilisation d’équipements de soudage et de coupageélectriques et sur les méthodes de travailrecommandées, demandez un exemplaire du livret N°52529 “Precautions and Safe Practices for Arc Weld-ing, Cutting and Gouging” publié par ESAB. Nousconseillons également de consulter les publicationssui-vantes, tenues à votre disposition par l’AmericanWelding Society, 550 N.W. LeJuene Road, Miami, FL32126:

a. “Safety in Welding and Cutting” AWS Z49.1b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.d. “Recommended Safe Practices for Plasma Arc Cut-

ting” AWS-A6. 3.e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

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PRÉCAUTIONS DE SÉCURITÉ

SECTION 2 DESCRIPTION

7

Table 2-1. Mig 4HD Specifications

Input Power Required ..........................................42 V ac, 5A, 50/60 Hz, 1-phaseWire Feed Speed Range ..................................... 50-750 in./min. (1.3-19 m/min.)Wire Sizes Accommodated:

Hard/Soft ............................................... .023 thru 1/16 in. (0.6 thru 1.6 mm)Flux Cored ............................................. .035 thru 3/32-in. (0.9 thru 2.4 mm)

Length ...................................................................................................................Width ....................................................................................................................Height* ..................................................................................................................Weight (approx**) .................................................................................................

*Add 2-3/4-in. (7 cm) for spindle and spindle arm.**8-ft (2.4m) control cable and hose included in specified weight.

2.1 Mig 4HD Dual Wire Feeder

The Mig 4HD Dual Wire Feeder (Figure 2-1 and Table2-1) described in this manual is designed for shortarc, spray arc or cored wire welding with a constantpotential (MIG) welding power source.

Secondary input from the Power Source can be DC"+" or DC "-" depending on the requirements of thewire type being used.

Mig spot welding can be done with the Mig 4HD Dualif it is equipped with Option Kit (P/N 37799).

The Mig 4HD Dual uses drive motors designed tofeed wires from .023 to 3/32-inches diameter. Rate ofwire feed (50-750 inches per minute) is preciselycontrolled by a solid-state, Pulse Width Modulated(PWM) governor printed circuit board housed in thecontrol assembly. The Gun Switch is energized by 12volts DC for operator safety.

The Mig 4HD Dual Wire Feeder is designed to sit onflat surfaces such as the top of the Power Source orCart. The standard features of the Mig 4HD Dual WireFeeder include:

• 4-roll drive stands, each with two driven rollsand two pressure rolls

• 2 Internal gas solenoids• 8-foot (2.4m) control cable w/19-pin amphenol

style plug (factory installed)• "Euro" style torch connections• Power ON/OFF switch• 2 Weld Schedules per gun• 2 Wire feed speed potentiometers per gun• 2 Voltage control potentiometers per gun• Gas purge/Jog switch• Remote power source voltage control• Right/Left side "Active" lights• Push-Pull Torch Control Receptacle


8

2.2 Optional Accessories. The followingoptions are available from ESAB or your sup-plier.

• Spot/Burnback/Pre-postflow/Trigger LockModule (P/N 37799). Easy to install kit permitsthe operator to set times for spot welding (0-5sec), wire burnback (0-0.6 sec), gas preflow(0-1.5 sec) and gas postflow (0-7.5 sec). Thismodule also includes trigger lock which allowsthe welder to make long welds without continu-ously depressing the gun trigger. Includesmodule and current detector.

• Digital Meter/Preset Module (P/N 34180).Easy to install kit provides a digital display ofwire feed speed (ipm or m/min) and voltage.This option also enables the welder to presetwire feed speed. The meter automatically dis-

plays the setting for the "Active" side of thefeeder.

• Remote Schedule Selector Switch12-1/2 ft. .............................. P/N 2310218525 ft. .................................... P/N 23102187

Torch mounted, two position switch providesremote schedule selection (A or B). Feeder "A/B Switch" must be in the "B" position for remoteswitch to operate.

• Water Kit (P/N 37801). Convenient way ofusing water cooled guns. Kit consists of inlet/outlet fittings, mounting hardware, quick actionconnectors for the gun hoses with "B" sizewater fittings for connecting to the Cooler/Recirculator.


9

FRONT VIEW

REAR VIEW

Figure 2-1. Mig 4HD Dual Wire Feeder

JOG PURGE

SCHEDULE SCHEDULE

A AB B

VOLTS VOLTSPOWER

1

0

LEFT RIGHT POWER INDICATOROPTIONAL

DIGITALMETER

KIT

PUSHPULLGUN

REMOTESELECT

B

REMOTESELECT

B

GUNCONNECTOR

WATERKIT

OPTION

SPINDLEASSEMBLY

4 ROLLDRIVE STAND

POWER BLOCK

WATERKIT

OPTION

WATERKIT

OPTION

S/N PLATE RATING LABEL

IPM IPM

REMOTE SCHEDULEA - B SELECT

WELD SCHEDULESELECT SWITCH

RIGHT/LEFT WIRE FEED SPEED CONTROLRIGHT SIDE SCHEDULE A & B

WIRE FEED SPEED CONTROLLEFT SIDE SCHEDULE A & B

OUTPUT VOLTAGE CONTROLLEFT SIDE SCHEDULE A & B

OUTPUT VOLTAGE CONTROLRIGHT SIDE SCHEDULE A & B

WATERKIT

OPTION

POWERON/OFF

(Has to be in "B" Positionto Operate Remotely)

LOCATION FOROPTIONAL PANEL

SECTION 3 EQUIPMENT

10

3.1 General

This section describes the Mig 4HD Dual Wire Feederand recommended equipment and accessories.

3.2 Equipment and Accessories

A. Constant potential Mig power source. Use theMig 4HD with power sources such as: 352cv,452cv, SVI-450i cvcc, 652 cvcc, 350mpi, MTS-3500i.

B. Extension Cables. Multi-conductor cable with19-pin amphenol plug and receptacle. Used toextend 8-ft (2.4m) cable supplied with wire feeder.

• 30-foot (9.1 m) P/N 34378• 60-foot (18.3 m) P/N 34377

C. Shielding gas regulator/flowmeter and fitted hoseis supplied to bring gas from flowmeter to wirefeeder. Such as:

Regulator/Flowmeters:R-5007 Argon/Helium/Nitrogen, P/N 998124.R-5008 CO2, P/N 998125.

D. Drive Roll and Guide Tube. (Refer to Table 1):The Mig 4HD wire feeder comes equipped witha drive roll and a guide tube for wire sizes .035to .045 (0.9 to 1.2 mm). Select other size driverolls from Table 1 for the wire size and type to beused.

3.3 Accessories

A. Wire Reel Adapter (P/N 34323). Use with 60 or65-lbs. (27 or 30 kg) coils.

B. Spool Spacer (P/N 34330). For adapting 10-in(25.4 cm) spools.

Table 1. Drive Roll & Guide Tube Selection

Upper Outlet Center InletWire Type / Lower Pressure Guide Guide GuideDiameter Drive Roll Roll Tube Tube Tube

Hard Wires (“V” groove)

.023 in.(0.6mm) 21155 2361 2397 21163 34612 34615

.030 in.(0.8mm) 21155 2361 2397 21164 34612 34615

.035 in.(0.9mm) 21156 2361 2397 21165 34612 34615

.040 in.(1.0mm) 21156 2361 2397 21165 34612 34615

.045 in.(1.2mm) 21156 2361 2397 21165 34612 34615

.052 in.(1.4mm) 21157 2361 2397 21166 34612 34615

1/16 in.(1.6mm) 21157 2361 2397 21166 34612 34615

Soft (aluminum) Wires (“U” groove)

.030 in.(0.8mm) 21158 2361 2397 21167 34612 34615

.035 in.(0.9mm) 21158 2361 2397 21168 34612 34615

3/64 in.(1.2mm) 21159 2361 2397 21168 34612 34615

1/16 in.(1.6mm) 21159 2361 2397 34612 34615

Top and Bottom Grooved- Aluminum

.035 in.(0.9mm) 36860 36860 21167 34612 34615

3/64 in.(1.2mm) 36860 36860 21168 34612 34615

1/16 in.(1.6mm) 36861 36861 34612 34615

Cored Wires (Serrated “V” groove)

.030 in.(0.8mm) 21160 2361 2369 21164 34612 34615

.035 in.(0.9mm) 21160 2361 2369 21165 34612 34615

.040 in.(1.0mm) 21161 2361 2369 21165 34612 34615

.045 in.(1.2mm) 21161 2361 2369 21165 34612 34615

.045 in.(1.2mm)† 37319 37319 21165 34612 34615

.052 in.(1.4mm) 21161 2361 2369 21166 34612 34615

.052 in.(1.4mm)† 37319 37319 21166 34612 34615

1/16 in.(1.6mm) 21161 2361 2369 21166 34612 34615

1/16 in.(1.6mm)† 37320 37320 21166 34612 34615

5/64 in.(2.0mm) 21162 2361 2369 21166 34613 34616

5/64 in.(2.0mm)† 37320 37320 21166 34613 34616

† Recommended for use with soft cored wires that are easy to flat-ten. Order both lower drive roll and upper pressure roll.

Requires Support Tube, P/N 21169.

Call Factory for current recommendation.

SECTION 4 INSTALLATION

11

4.1 Installation

A. Connect the 19 pin control cable to the PowerSource.

B. Hose and Electrical Connections. Connectshielding gas supply hose. Connect secondarypower cable to power block and power supply.

C. Attach a Mig Gun with "EURO" style connectorto the mating receptacles on the feeder frontpanel.

D. Wire Spool.

As with any work area, make sure safety glasseswith side shields are worn when handling orchanging wire or clipping wire off at the spool orat the end of the torch. Hold onto the wire comingoff the spool with one hand before clipping.Serious eye injury can result due to the resilienceof the wire which can quickly unravel, or a cutwire end which may shoot across the room.

Install a spool of welding wire on the hub as follows:

1. Remove "hairpin" clip from spindle.2. Position the spool of wire so that when it is

placed on the spindle, wire will be drawn tothe feed roll from the bottom of the spool.The spool should be held so that the indexhole on the back will engage the lug on thespindle.

3. Slide the spool onto the spindle until itengages the lug. Lock in place with thehairpin clip.

4. When wire coils are to be used instead ofspools, reposition the spindle to the highestposition and mount wire reel on spindle asthough it were a spool (see 1 and 3 above).Remove thumbnuts and cover plate fromreel. Remove coil from its package, but donot remove its binding wires. Slide coil ontoreel so that wire will be drawn from bottomof coil (starting end for a coil is always theouter end). Replace reel cover plate andthumbnuts. Cut off coil tie wires and anykinked wire.

E. Drive Rolls. The drive roll has two grooves; thesmaller groove feeds 0.035 in. diameter wire,

the larger groove feeds 0.045 in. wire. Thegroove nearer the gear motor feeds the wire. Ifthe required groove is not correctly positioned,perform the following:

1. Release the pressure drive roll levers andlift the assemblies upward.

2. Remove shoulder screw holding each driveroll to the gear.

3. Reverse the drive roll on the drive roll shaft.4. Replace the shoulder screws and tighten.5. Secure the pressure drive roll assembly.

E. Threading Wire.

1. Release pressure drive roll assembly andlift upward. Check that proper wire diam-eter groove is in the inner position.

Before threading welding wire through liner, makesure chisel point and burrs have been removedfrom wire end to prevent wire from jamming ingun or liner.

2. Feed the wire from the spool through theinlet guide, across the drive roll groove andinto gun outlet guide.

Make sure that the proper "outlet guidetube" is inserted into the front-panel gunfitting for the size and type of wire beingused.

3. Lower pressure roll assembly and secure.Apply power to the feeder. Momentarilydepress and release the torch trigger forthe desired "Active" side (Left/Right).

4. Feed wire through to gun tip using the JOGswitch located on the front panel.

5. To ensure proper wire feeding, it is impor-tant that the wire be kept clean and that thedrive rolls be periodically cleaned of anychips or scale that might be carried into thegun liner and cause clogging.

F. Brake Drag Adjustment. Loosen the brakescrew in the center of the spindle hub, thentighten it just enough to prevent coasting of thespool when wire is drawn from it. Too muchpressure will load the wire feed motor unneces-sarily. Too little pressure will permit the spool tooverrun, causing the wire to kink and tangle.

SECTION 5 OPERATION

12

5.1 Adjustments and Operation

A. Selecting the "Active" side (Left/Right).

1. Apply power to wire feeder by turning onthe power source and the power switch onthe 4HD front panel.

2. When power is applied to the feeder thedefault "Active" side is the right side (asviewed from the front of the feeder). Thisshould be indicated by the right "Active"pilot light being illuminated. If the desiredactive side is the Left, momentarily depressand released the Left gun trigger. The Right"Active" light will extinguish and the Left"Active" light will be illuminated. The Leftside will remain the "Active" side until theRight gun trigger is depressed. When ei-ther gun trigger is depressed that sideautomatically becomes the "Active" sideand the gun trigger for the opposite side isdisabled until the "Activated" gun trigger isreleased.

B. Control Setting.

1. Set the wire feed rate and voltage by ad-justing the WIRE FEED SPEED and VOLTScontrol knobs on the front panel.

2. Optional BURNBACK control: sets to thedesired setting (0-0.6 seconds), depend-ing on the amount of burnback desired.The higher the setting, the greater theamount of time that the contactor is held into allow the wire to burn back out of thepuddle, after releasing the torch switch.

If spot welding is to be performed, set rear-panel switch to "SPOT" position, set spot-welding potentiometer for time period(range: 0 to 5 seconds).

C. Feeding Wire. Thread wire through torch andcontact tip as directed in Section 4, cut off wire,so that the wire extends about 1/2-inch beyondthe end of the torch nozzle.

D. Shielding Gas Flow Rate. Operate PURGEswitch and set desired gas flow rate at theshielding gas regulator-flowmeter. Activateswitch for at least 15 seconds to insure ad-equate purging of gas hose and torch.

Optional Spot/Burnback/Pre-Postlfow/TriggerLock Module: set pre and postflow potentiom-eters for the desired preflow interval (range: 0 -1.5 seconds) and postflow interval (range: 0 to7.5 seconds).

E. Making the Weld. Start to weld by pressing thegun switch lever to actuate the torch switch.This closes the welding contactor, and startswire feed and gas flow. The trigger must bedepressed for the duration of the weld. Weldingaction will be stopped and all services discontin-ued when the lever is released and returned toits original position. If the gun is withdrawn fromthe workpiece during welding, the arc will beinterrupted, but shielding gas flow and weldingwire feed will continue until the trigger lever isreleased.

Do not allow metal-to-metal contact between thewire feeder chassis and a metal surface con-nected in any way to a welding ground.

5.2 Operating Sequence.

A. Normal.

1. Close Gun switch.-- Gas solenoid opens, weld contactorcloses, wire feed motor runs.

2. Release Gun switch.-- Wire feed motor deenergized, brakecircuit effective.-- Burnback circuit energized.

3. Burnback circuit times out (delay deter-mined by setting of Burnback potentio-meter).-- Weld contactor opens.-- Gas solenoid valve closes.

B. Spot Weld.

1. Close Gun switch.-- Gas solenoid, weld contactor, wire feedmotor energized.-- Spotweld timing circuit energized.

SECTION 5 OPERATION

13

2. Spotweld circuit times out (interval estab-lished by setting of spotweld potentiom-eter).-- Wire feed motor deenergized, brakecircuit effective.-- Burnback circuit energized.

3. Burnback circuit times out (interval estab-lished by setting of burnback potentiom-eter).-- Weld contactor opens.

4. Release torch switch.-- Gas solenoid valve closes.

C. Pre-flow/Post-Flow Options. Contactor and wirefeed motor are energized only after intervalestablished by setting of preflow potentiometer.When torch switch is opened, gas solenoidvalve remains energized until interval estab-lished by setting of postflow potentiometer haselapsed.

SECTION 6 SERVICE

If it should become necessary to replace the 5amp wire feeder circuit breaker or any othercircuit breaker/fuse in the welding machine, en-sure that the proper size is used as a replace-ment.

The 42-volt circuit is protected by a 5 amp circuitbreaker located at the rear of the wire feeder.Failure of this circuit breaker will shut off thecontactor, shielding gas, and wire feeder. Thecircuit breaker must cool before it can be reset.If the breaker trips, wait before resetting.

B. Wire Feeder. As soft wire is fed, the drive rollsmay pick up metal from the wire surface. Accu-mulation on the rolls may score the wire withresulting unwanted friction and improper feed-ing.

Inspect the rolls regularly and clean them with afine-wire power brush. Avoid roughening, orremoving the hardness of groove surfaces ingrooved rolls. Any roughening may score thewire, just as the accumulation being removedmay do.

6.1 Maintenance.

If this equipment does not operate properly, stopwork immediately and investigate the cause ofthe malfunction. Maintenance work must be per-formed by an experienced person, and electricalwork by a trained electrician. Do not permit un-trained persons to inspect, clean, or repair thisequipment. Use only recommended replacementparts.

Little maintenance is required to keep the wire feederin top operating condition. It is important, however,that moving parts such as feed and pressure rolls,wire feed motor, etc., be kept clean and free of dustor dirt. Cleaning is best accomplished by regularlyblowing off these parts with dry compressed air. Thisshould be done once for every eight hours of operat-ing time, more often if necessary.

A. 42 Volt Wire Feeder and Control Circuits.

14

SECTION 6 SERVICE

Figure 6-1 - Schematic Diagram - 4HD Dual Wire Feeder

D-37633

15

SECTION 6 SERVICE

Figure 6-2 - Wiring Diagram - 4HD Dual Wire Feeder

D-37634

16

SECTION 7 REPLACEMENT PARTS

View 1 of 37544 Bill of Materials

17




19




20



21



22



23




24




26


62 2062161 1 CIRCUIT BREAKER 5A63 92040101 2 SCR RND HD .375-16 X .7565 99512203 4 SPACER .26 ID X .5 OD X .13 L PLST66 04S04010 4 SCR RND HD M04-.70 X 1067 04W01044 4 WASHER FLAT M468 04W10041 4 WASHER LOCK M470 32300GY 1 PANEL FRONT71 34141GY 1 PANEL COVER FRONT72 37638GY 1 BASE73 37639YL 1 DOOR ASSY LEFT74 37640YL 1 DOOR ASSY RIGHT75 37641GY 1 PANEL REAR76 37642GY 1 PANEL CENTER77 37644GY 1 PAN LOWER78 37795YL 1 TOP COVER79 37796GY 2 PANEL BLANKING80 37797GY 1 REEL STAND81 96W85 1 STRAIN RELIEF

ITEM PART ORNO. CODE NO. QTY. DESCRIPTION

37544 - Bill of Materials4HD Dual Wire Feeder (Cont'd)

27

Figure 7-1 4-roll Drive stand, p/n 952940 - Mid 1999 - current

Item Qty. PartNo. Rec. No. Description

952940 4 ROLL GEARED WIRE DRIVE SYSTEM, CONSISTS OF: 91 1 23612459 PRESSURE ARM COMPLETE, REAR (incls. 96, 102, 103, 104, 113) 92 1 952704 PRESSURE ARM COMPLETE, FRONT(incls. 96, 102, 103, 104, 113) 93 1 23612460 PRESSURE DEVICE WITH SCALE 94 1 34614 FEED PLATE, 4DR. 95 2 23612470 LOCATING PIN,PRESSURE DEVICE 96 2 23612475 PRESSURE ARM 97 2 23612473 LOCATING PIN, PRESSURE ARM 98 4 23612472 Cl RCLIP, LOCATING PIN, PRESSURE ARM 99 2 23612662 SPACER TUBE, PRESSURE ARM 100 1 34607 SPRING, PRESSURE ARM 101 4 0459441880 GEARED ADAPTOR, PRESSURE & DRIVE ROLLS 102 2 23612477 AXLE, PRESSURE ROLL 103 2 23612474 NUT, AXLE, PRESSURE ROLL 104 2 23612368 PRESSURE ROLL, PLAIN 105 1 34615 INLET GUIDE, .023" - .062" WIRE 105A (OPT-1) 34616 INLET GUIDE, .063" - .093" WIRE 106 1 34612 INTERMEDIATE GUIDE, .023" - .062" WIRE 106A (OPT-1) 34613 INTERMEDIATE GUIDE, .062" - .093" WIRE 107 2 34611 AXLE SHAFT, DRIVE ROLL 108 2 34608 WASHER, RETAINING SCREW 109 2 952925 RETAINING SCREW, DRIVE ROLL 110 1 34610 MAIN GEAR DRIVE 111 3 952927 SCREW, THUMB M6X12 112 1 36881 PROTECTIVE GUARD (Not Shown) 113 4 23612476 SPACER, PRESSURE ROLL

sectIon 7 replaceMent parts

95

91

96 113104103102

(2)

96 113104103102

(2)

99

COMPLETE

COMPLETE

28

7

1, 3, 4

8

6 5

Mig 4HD Wire Feeder Wire Spool Hub Assembly

ItemNo.

QtyReq.

PartNo. Description

Ckt.Symbol

123456789

101112

111112111111

920440466343479205600705580033209482589482553675623600982633001366430203764304125613411330558005764

SCREW R.H.M. 3/8-16X1.00* CLIP, HITCHWASHER, FLAT 3/8"* WASHER, D-TYPE* SPINDLE, MOLDED* PAD, BRAKING"D" SHAFTSPRINGNUT, HEX 3/8-16WASHER, LOCK 3/8WASHER, FLAT 3/8SCREW, HHM 3/8-16 X 1.00spInDle replaceMent KItincludes items marked *

9, 10, 11, 12

sectIon 7 replaceMent parts

2

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

A. CUSTOMER SERVICE QUESTIONS:Order Entry Product Availability Pricing DeliveryOrder Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548

Central Distribution Center Telephone: (800)783-5360 / Fax: (800) 783-5362

Western Distribution Center Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM ESTWarranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM ESTPerformance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:Telephone: (843)664-4428 / Fax: (843) 679-5864Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

ESAB Welding & Cutting Products, Florence, SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES

Documents

Mig 4HD DUAL WIRE FEEDER - ESAB Welding & Cutting equipment/wire feeders/mig 4hd_dual_f... · Mig 4HD DUAL WIRE FEEDER ... AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“