ESAB Buddy Feed 402 User manual

GB
Buddy
™
Feed 402
Instruction manual
0463 347 074 GB 20120531
Valid for serial no. 210-xxx-xxxx

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GB
© ESAB AB2012
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 .………………………………………… 9
DIAGRAM …………………………………………………………….……..… 10
ORDERING NUMBERS ………………………………………….……..…… 11
WEAR PARTS ……………………………………………………….……..… 12
ACCESSORIES ……..…………………………………………………………13
Rights reserved to alter specifications without notice.

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© ESAB AB2012
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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© ESAB AB2012
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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© ESAB AB2012
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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© ESAB AB2012
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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© ESAB AB2012
1Connection for welding gun (Euro)
2Knob for setting wire feed speed
3Button for wire inching
4Knob for setting the voltage
5 Brake hub
1
2
3
4
5
6
7
8
9
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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© ESAB AB2012
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.
1
2
3
4
5

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© ESAB AB2012
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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© ESAB AB2012
Feed 402
Diagram