DuraDrive 4-30 Wire Feeder Instruction Literature ESAB Item No.
Be sure this information reaches the operator. You can get extra copies through your supplier. caution 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.
TABLE OF CONTENTS SECTION SECTION PAGE 1 DESCRIPTION ............................................................................................................................................................................17 2 INSTALLATION ............................................................................................................................................................................25 3 OPERATION ........................................................................
TABLE OF CONTENTS 4
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 installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
safety precautions 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 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. 2. Connect the workpiece to a good electrical ground. B. Never coil the torch or work cable around your body. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. C.
safety precautions 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.) 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2.
safety precautions 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances." Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
sEGURIDAD La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora. 1.2 Safety - Spanish ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad".
sEGURIDAD 3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF: 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.
sEGURIDAD 5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.) 1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo. 2.
sEGURIDAD SIGNIFICADO DE LOS sImbolOs -- Según usted avanza en la lectura de este folleto: Los Símbolos Significan ¡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.
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 : AVERTISSEMENT : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires.
sÉCURITÉ 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 endommagés. 5.
sÉCURITÉ 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 considéres 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.) 1. 2. MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz.
sÉCURITÉ SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu. DANGER Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles. AVERTISSEMENT Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles. ATTENTION Signifie un danger qui peut entraîner des blessures corporelles mineures.
SECTION 1 DESCRIPTION 1.0 SAFETY REFERENCES Before the DuraDrive 4-30 wire feeder is put into operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper installation. 1.1 DESCRIPTION AND SPECIFICATIONS The DuraDrive 4-30 is a 4 roll drive 42 vac wire feeder with the ability to meet immediate and long term welding requirements of any weld shop.
SECTION 1 DESCRIPTION C. Modular MMI (Man/Machine Interface) Panel System Introduction The interchangeable control panels (MMI) are available in 4 different models depending on the needs of the welding operator and the welding application. The panels are designed for easily removal and replacement. The following describes the functions and capability of each MMI panel.
SECTION 1 DESCRIPTION NOTE Either the 4-in-1 Option Module or the Pulse Selection Option Module can be installed NOT BOTH Digital Dual Schedule MMI Panel The Digital Dual Schedule MMI panel has all the capability of the Basic Dual Schedule panel with the addition of a digital WFS and VOLT meter. The digital WFS meters adds digital presettability to the wire feed speed.
SECTION 1 DESCRIPTION NOTE A continuous water supply or re-circulator is required when using a water cooled MIG gun. D. Front Panel Components 1. Modular MMI panel 2. Power On/Off Switch Controls the 42 vac power from the power source. 3. Wire Jog Switch Used to safely thread the wire through the gun liner without applying welding power to the wire or gun assembly. 4. Gas Purge Switch Used to preset the shield gas flowrate without applying welding power to the wire or gun assembly. 5.
SECTION 1 DESCRIPTION MODULAR MMI (MAN/MACHINE INTERFACE) PANEL WIRE FEED SPEED AND VOLTAGE* MIG TORCH CONNECTOR RECEPTACLE POWER "ON/OFF" SWITCH WIRE JOG AND GAS PURGE MIG TORCH TRIGGER RECEPTACLE FRONT VIEW GAS CONNECTION 5 A CIRCUIT BREAKER SPOOL/REEL SPINDLE POST WIRE SPOOL HUB OPTION MODULE PANEL BURNBACK ADJUSTMENT WATER IN (WATER KIT INSTALLED) SLOW RUN-IN SWITCH CONTROL CABLE RECEPTACLE REAR VIEW Figure 1-1.
SECTION 1 DESCRIPTION B. Control Cable Assembly: For connection of the DuraDrive 4-30 to ESAB power sources with a 19‑pin receptacle, the following control cable assemblies are available: 8-foot (2.5m) - PN 0558002358 30‑foot (9.
SECTION 1 DESCRIPTION 2. Digital Dual Schedule MMI Panel (PN 0558001912) This easy to install MMI panel provides digital meters to preset wire feed speed and display both wire feed speed and average arc voltage while welding. Both wire feed speed (IPM) and arc voltage are displayed for 10 seconds after the weld is completed for easy viewing and recording of weld parameters. Two welding schedules can be preset and switched during welding by using the MIG gun trigger. 3.
SECTION 1 DESCRIPTION NOTE If the Trigger Lock option has been installed and set to the "ON" position, the trigger switch lever can be released when the arc has been struck. Depress the trigger lever a second time to stop the arc. If the gun is withdrawn from the workpiece during welding, the arc will be interrupted and wire feeding will stop automatically. NOTE A continuous water supply or re-circulator is required when using a water cooled MIG gun. 5.
SECTION 2 INSTALLATION 2.0 INSTALLATION After checking to be sure you have all required components and accessories (see Section II), proceed as follows: A. HOSE AND ELECTRICAL CONNECTIONS 1. Connect shielding gas supply hose to the rear panel of the feeder. 2. Connect the 19-pin control cable between the DuraDrive rear panel and power source wire feeder connection. 3. Connect suitably sized power cable between the power source and the power block at the rear base of the feeder. B.
SECTION 2 INSTALLATION PRESSURE ROLL BOGEY PRESSURE ADJUSTMENT UPPER ROLL RETAINING KNOB cENTER GUIDE LOCKING KNOB cENTER GUIDE GUN LOCKING KNOB INLET GUIDE LOCKING KNOB OUTLET GUIDE OUTLET GUIDE LOCKING KNOB INLET GUIDE GEAR PIN AXLE LOWER ROLL RETAINING NUTS Figure 2-1 DuraDrive 4-30 Drive Stand NOTE The top roll arms are designed to equalized the pressure of each driven feed roll in order to optimize wire feeding performance.
SECTION 2 5. 6. INSTALLATION Thread wire to gun as follows: a. Round off the free end of the welding wire with a file. b. Release the tension lever to relieve pressure on the feed rolls. Rotate pressure adjusting knob off the pressure roll bogey and lift bogey upward to access the feed rolls. c. Thread the wire through the inlet guide, over the feed roll grooves in the feed rolls, and into the outlet guide. d.
SECTION 2 INSTALLATION 28
SECTION 3 OPERATION 3.0 ADJUSTMENTS AND OPERATION Make sure safety glasses with side shields are worn when handling or changing wire, or clipping wire off at the spool or at the end of the gun‑serious eye injury can result due to the springiness of the wire which quickly unravels, or a cut wire end which may shoot across the room. NOTE If the Trigger Lock option has been installed and set to the "ON" position, the trigger switch lever can be released when the arc has been struck.
SECTION 3 OPERATION To change the wire speed range to 350 to 999 IPM refer to Figures 3-1 & 3-2: 1. Turn the power "OFF" to the wire feed by moving the main power toggle switch of the front panel of the DuraDrive feeder to the "OFF" position. 2. Remove the right side panel of the DuraDrive Control cabinet. 3. Locate switch SW-1 on the DuraDrive Control PCB. 4. Move dip switch S2 to the "ON" (CLOSED) position. Dip switches S1 & S3 should remain in the "OFF" position. 5.
SECTION 3 OPERATION Do not allow metal‑to‑metal contact between the wire feeder chassis and a metal surface connected in any way to a welding ground. With such contact, a poor welding ground connection may create a difference in potential that sends part of the welding current through the safety ground wiring in the control cable and wire feeder, resulting in burnout of that wiring and/or damage to wire feeder circuitry.
SECTION 3 OPERATION 32
SECTION 4 MAINTENANCE 4.0 MAINTENANCE If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts. A. GENERAL MAINTENANCE Little maintenance is required to keep the wire feeder in top operating condition.
SECTION 4 MAINTENANCE 34
SECTION 5 TROUBLESHOOTING 5.0 TROUBLESHOOTING Refer to the troubleshooting Chart Table 5-1.
D-0558002964-C DuraDrive 4-30 Schematic Diagram SECTION 5 TROUBLESHOOTING 36
D-0558002965-B DuraDrive 4-30 Wiring Diagram SECTION 5 TROUBLESHOOTING 37
SECTION 5 TROUBLESHOOTING 38
SECTION 6 REPLACEMENT PARTS 6.0 SPARE AND REPAIR PARTS Replacement Parts are illustrated on the following pages. When ordering replacement parts, order by part number and part name, as illustrated on the figure Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 6.1 ORDERING To assure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment.
SECTION 6 REPLACEMENT PARTS 122 18, 24 24, 93 22, 69, 80 98 89 86, 87 79 40
SECTION 6 REPLACEMENT PARTS 25, 28 84, 85 31, 32 10, 11 9, 82 4 71 26 8, 9 13 12, 30 41 6 12, 30 18, 24
SECTION 6 REPLACEMENT PARTS 75 29 16 104 92 67 119 1 105 3, 66, 83 5 42 2
SECTION 6 REPLACEMENT PARTS 81 2 15 78 74 23 100 99 112 102 2 96 103 95 91 20 101 111 21 73 17 33 34 76, 77, 90 19 97 94 14 7 43 7, 109 78
SECTION 6 REPLACEMENT PARTS 950626 13.
SECTION 6 REPLACEMENT PARTS Items marked with * are: Screw, .375-16 x 1.00" Lg., RH and Washer, .
SECTION 6 REPLACEMENT PARTS 46
SECTION 6 REPLACEMENT PARTS 47
SECTION 6 REPLACEMENT PARTS 48
SECTION 6 REPLACEMENT PARTS 6 4 2 3 5 1 7 NOTE: For replacement of new module include Item 8.
Notes
Revision History 1. Revision “A” edition (1/2002) of the manual covers the following changes: Updated and corrected Optional Accessories listed on page 16. 2. Revision "B" edition (2/2002) of the manual covers the following changes: Updates images on page 21 to show a better view of switch settings. 3. Revision "C" edition (3/2002) of this manual covers the following changes: Updates Accessories listing on page 16 and Replacement Parts listing on page 31. Updated Replacement Parts section. 4.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C.