ESAB Buddy Feed 402 User manual

Buddy

™

Feed 402

Instruction manual

0463 347 074 GB 20120531

Valid for serial no. 210-xxx-xxxx

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1 SAFETY .…………………………………………………………………….. 3

2 INTRODUCTION .………………………………………………………..… 5

3 TECHNICAL DATA …………………………………………………………5

4 INSTALLATION ……………………………………………………………6

5 OPERATION …………………………………………………………………6

5.1 Connections and control devices ………………………………………………….7

5.2 Wire feed pressure..………………………………………………...………………7

5.3 Wire inching…………………………………………………………………………. 7

5.4 Replacing & inserting wire………………………………………………………….8

5.5 Changing rollers ……………...……………………………………………………..8

6 MAINTENANCE ……………………………………………………………. 9

7 ORDERING OF SPARE PARTS .…………………………………………

DIAGRAM …………………………………………………………….……..… 10

ORDERING NUMBERS ………………………………………….……..…… 11

WEAR PARTS ……………………………………………………….……..… 12

ACCESSORIES ……..…………………………………………………………13

Rights reserved to alter specifications without notice.

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1 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following

recommendations should be observed in addition to the standard regulations that apply to the

workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the welding

equipment. Incorrect operation of the equipment may lead to hazardous situations which can result

in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:

●

its operation

●

location of emergency stops

●

its function

●

relevant safety precautions

●

welding

2. The operator must ensure that:

●

no unauthorized person is stationed within the working area of the equipment when it is

started up.

●

no-one is unprotected when the arc is struck

3. The workplace must:

●

be suitable for the purpose

●

be free from drafts

4. Personal safety equipment

●

Always wear recommended personal safety equipment, such as safety glasses, flame-

proof clothing, safety gloves.

●

Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could

become trapped or cause burns.

5. General precautions

●

Make sure the return cable is connected securely.

●

Work on high voltage equipment may only be carried out by qualified electricians.

●

Appropriate fire extinguishing equipment must be clearly marked and close at hand.

●

Lubrication and maintenance must not be carried out on the equipment during operation.

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CAUTION!

Read and understand the instruction manual before

installing or operating.

WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding &

cutting.

Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.

ELECTRIC SHOCK - Can kill

●Install and earth the welding unit in accordance with applicable standards.

●Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

●Insulate yourself from earth and the work-piece.

●Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

●Keep your head out of the fumes.

●Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing

zone and the general area.

ARC RAYS - Can injure eyes and burn skin.

●Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

●Protect bystanders with suitable screens or curtains.

FIRE HAZARD

●Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

●Protect your ears. Use earmuffs or other hearing protection.

●Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

Read and understand the instruction manual before installing or operating.

CAUTION!

This product is solely intended for arc welding only.

ESAB can provide you with all necessary welding protection and accessories.

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2 INTRODUCTION

Feed 402 is a wire feed unit intended for MIG/MAG & FCAW welding when coupled with a Mig

500i power source.

They can be used with wire bobbins up to Ø300mm

ESAB’s accessories for the product can be found on page 13.

2.1 Equipment

The Feed 402 wire feed unit is supplied with

●Instruction manual

●One pressure roller

●Two feed rollers (one Ø1.2/1.6mm V-groove & one Ø1.2/1.6mm Knurled V-groove)

3 TECHNICAL DATA

Feed 402

Power supply

Power requirement

Motor current Imax

Setting range

Wire feed speed

Gun connection

Max. diameter wire bobbin

Wire dimension

Weight

Dimensions lxwxh

Operating temperature

Transportation temperature

Shielding gas

Max pressure

Permissible load at

60% duty cycle

Enclosure class

24 V DC

120 VA

5 A

1.5 - 20.0 m/min

EURO

300 mm

0.8 - 1.6 mm

9 kg

460 x 210 x 330 mm

-10 to +40°C

-20 to +55°C

All types intended for MIG/MAG welding

8 bar

500 A

IP21

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a

certain load without overloading. The duty cycle is valid for temperatures up to 40°C

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid

objects or water. Equipment marked IP21 is designed for indoor use.

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4 INSTALLATION

The installation must be executed by a professional

WARNING!

When welding in an environment with increased electrical danger, only power

sources intended for this environment may be used. These power sources are

marked with the symbol

5 OPERATION

General safety regulations for the handling of the equipment can be found

on page 3. Read through before you start using the equipment!

NOTE! When moving the equipment use intended handle. Never pull on the gun.

WARNING!

To prevent the reel from sliding off the hub, lock the reel in place by slotting the

locking lever in the correct position.

WARNING!

Rotating parts can cause injury, take great care.

WARNING!

Risk of crushing! Do not use safety gloves when replacing wire, feed rollers and

wire bobbins.

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1Connection for welding gun (Euro)

2Knob for setting wire feed speed

3Button for wire inching

4Knob for setting the voltage

5 Brake hub

6Connection for welding current from

power source

7Connection for control cable from

power source

8Connection for shielding gas

9Wire spool cover

5.1 Connections and control devices

5.2 Wire feed pressure

Start by making sure that the wire moves smoothly through the wire guide. Then set the pressure

of the wire feeder's pressure rollers. It is important that the pressure is not too great.

To check that the feed pressure is set correctly, you can feed out the wire against an insulated

object, e.g. a piece of wood.

When you hold the gun approx. 0.5 mm from the piece of wood (Fig. 1) the feed rollers should slip.

If you hold the gun approx. 50 mm from the piece of wood, the wire should be fed out and bend

(Fig. 2)

5.3 Wire inching

Wire inching is used to feed wire without welding voltage and gas flow. The wire is fed as

long as the button is depressed.

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5.4 Replacing and inserting wire

●Disconnect the pressure locking device by folding it forward, slide the

pressure roller up.

●If necessary, roll back the wire and remove the wire bobbin.

●Straighten out 10-20 cm of the new wire. File away burrs and sharp edges

from the end of the wire before inserting it into the wire straightener & feed

unit.

●Make sure that the wire goes properly into the feed roller's track and into

the outlet nozzle & wire straightener’s grooves.

●Secure the pressure locking device & tighten the wire straightener slightly.

5.5 Changing rollers

●Disconnect the pressure locking device (1) by folding it forward.

●Disconnect the pressure roller (2) by turning the axle (3) counter-clockwise

using a screwdriver and pulling out the axle.

The pressure roller is disconnected.

●Disconnect the feed roller (4) by unscrewing the nut (5) and pulling out the

rollers. (Take note of the woodruff key that is used to turn the feed roller)

●During installation, repeat the above in reverse order.

Choice of track in the feed roller

Turn the feed roller with the dimensioning mark for the required track towards you.

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6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Only those persons who have appropriate electrical knowledge (authorized

personnel) may remove the machine cover.

Wire feed unit

Check regularly that the wire feed unit is not clogged with dirt.

●Cleaning and replacement of the wire feed unit mechanism's worn parts

should take place at regular intervals in order to achieve trouble-free wire

feed. Note that if pre-tensioning is set too hard, this can result in abnormal

wear on the pressure roller, feed roller and wire guide.

The brake hub

The hub is adjusted when delivered, if readjustment is required, follow the

instructions below. Adjust the brake hub so that wire is slightly slack when wire

feed stops.

●

Adjusting the braking torque

- Remove the spool locking lever by turning it counter-clockwise.

- Insert an allen key into the bolt in the hub.

- Turn the springs counter-clockwise to reduce the braking torque

- Turn the springs clockwise to increase the braking torque.

Welding gun

●Cleaning and replacement of the welding gun's wear parts should take

place at regular intervals in order to achieve trouble-free wire feed. Blow the

wire guide clean regularly and clean the contact tip.

CAUTION!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any faults.

7 ORDERING SPARE PARTS

Use only ESAB original spare and wear parts.

To find the required spare part, please refer to the Spare Parts List as shown on page 11.

Spare parts may be ordered through your nearest ESAB dealer. See the last page of this publication

to find the nearest ESAB office or dealers.

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Feed 402

Diagram

Table of contents

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