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Thread: ESB Pulse Mig

  1. #1
    Join Date
    Nov 2009
    Location
    Penshurst
    Posts
    1

    Default ESB Pulse Mig

    Have the possibility to purchase a used ESB Pulse Mig. The only thing is that something seems to be wrong with the wire feed.

    The wire feed is not constant and slows down / speeds up randomly.

    Hope it would only be an easy fix... any hint where to start looking for a solution to this?

    Cheers,
    Daniel

  2. #2
    Join Date
    Dec 2008
    Location
    Eastern Australia
    Posts
    43

    Default

    I fixed one of those, normally the drive board is quite simple, but the usual fault is people pulse the wire feed and the motor dont like it. From memory I replaced an SCR a chip and several other bits, I bought 2 of each for the guy as spares because the postage at $9. 50 was the expensive part. He bought the motor which from memory was $50 or so bucks. That was 2 years ago its still welding now and he welds as a trade.

  3. #3
    Join Date
    Jan 2004
    Location
    Mackay North Qld
    Posts
    6,446

    Default

    There are 2 possibilities there,
    99% of mig problems are mechanical.Look for the simple things first.

    1. Examine the wire spool and check it for surface rust.If rusty its likely that as the spool is pulled around by the wire drives, that the top rusty surfaces slip somewhat. When the the bottom surface goees through the drive where the is less rust, it goes faster as there is more grip.

    2.The other possible cause is there is a switch control somewhere that turns of the drive for a set time and turns it on again. Different switches on different places on diffrent machines ,so you will have to look carefully.

    Can't recall the layout for ESB but it will be there if its a pulsed machine.
    The setting may even be electronically adjusted,I do not know for sure on that one.
    Get the model and do a search on the net for a downloadable manual.

    Grahame

  4. #4
    Join Date
    Dec 2009
    Location
    broadford
    Age
    63
    Posts
    213

    Default

    here is my two bobs worth,the first thing you look at is the liner in the gun lead,if it is in need of replacement it will bind up the wire with the slightest of movement of the gun.classic symptom is thwire feed slows and regains speed and slows again causing backburn and tip fusion.a cheap and easy maintenance issue that needs to be done sooner or later anyway????

  5. #5
    Join Date
    Jan 2004
    Location
    Mackay North Qld
    Posts
    6,446

    Default

    If the coil of wire is contaminated with grinding dust or rust its a waste of time just changing a liner as it wont be long until ther replacement is as bad as the original.

    Alternately ,the wire can have a wiper placed on it. A simple trick is an ear plug(old E.A.R. brand ones work best ) with a razor slit lengthways and placed over the outgoing wire prior to the wire drive.

    Cleaning the mig liner rather than replacing it,is acheived by rinsing it in kerosine , then methylated spirits to dry off the kerosine.

    For those of us that live in humid areas ,the wire if left on the machine will rust within a week, particularly with a coating of metallic dust (from the grinder ) coating it.

    When not using your mig put a garbage bag over the wire with some desscicant in the bag.
    I hope this helps you.

    Grahame

  6. #6
    Join Date
    Dec 2009
    Location
    broadford
    Age
    63
    Posts
    213

    Default

    another trick is to fold a piece of felt over the wire between spool roll and wirefeed motor inlet guide and place a clothespeg on the felt under the wire,it hangs nicely.we will have to agree to disagree on washing out liners graham,ive never seen anything that will succesfully remove the crud/copperwash from a mig liner and put liner back into viable service,especially when a replacement part is often only $25-$35 dollars and will last one to two years on an industrially used machine

  7. #7
    Join Date
    Jan 2004
    Location
    Mackay North Qld
    Posts
    6,446

    Default

    Daniel,
    All I can say the process worked for me.I was a shift welder in the nickel pipe welding bay at QAL Gladstone for a few years.

    This was a procedure in the time that I was there.
    I cleaned my liner every couple of days before the crud got a grip.

    All I tended to forcefully inform anyone -who pointed their grinder stream at my wire feeder- of the error of their ways. Units with uncovered spools tend to cop it as the hot sparks imbed in the wire coating.

    Migs are mechanical more than electrical in their failures. Too many operators machines (see inside of their wirefeeders) are like pigsties. No wonder they have problems.

    Nickel pipe butt joints were fully certified pressure vessel joints and as such each one was radiographed.

    I never failed a single joint in the three hundred or so that I welded.
    I have also used the same procedure for LW1 GMAW wire in certified carbon alloy pipework and had no problems.

    Most liners in my experience were replaced due to some wally kinking the liner by dropping something on it.

    I did not mention that the air was used to blast through the liner in the direction of wire feed after the kero,then again after the metho.
    Liner cleaning should be a maintainence procedure not a repair procedure and must be done on a regualr basis.

    Having said that I always kept a set of spares in my tool locker, liners,insulators, gas diffusers shrouds and most importantly spare contact tips.

    Cheers
    Grahame

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