Installing wire (R500 WF EUR/EUR+)

This section describes how to install filler wire on the R500 Wire Feeder EUR/EUR+. For the wire feeder part descriptions, refer to R500 Wire Feeder EUR/EUR+ and Wire feed mechanism.

Install the welding torch to the wire feeder before installing the wire.

When changing the wire, remove the remaining filler wire from the welding torch and wire feed mechanism.

Always ensure that the feed rolls are suitable for the filler wire (diameter and material) in question. Refer also to Wire feeder consumables.

1.

Release the filler wire end and cut off any deformed section so that the end is straight.

If using a wire spool, ensure that the filler wire does not unravel from the spool when it is released.

2.

File the tip of the filler wire smooth.

Sharp edges on the filler wire tip may damage the wire liner.

3.

Guide the filler wire through the wire conduit between the wire drum and the wire feeder.

4.

Release the pressure handles.

5.

Guide the filler wire through the inlet guide tube, middle guide tube and into the outlet guide tube, which feeds the filler wire to the welding torch.

 

6.

Push the filler wire by hand through the euro connector.

 

7.

Close the pressure roll locking arms.

8.

Close the pressure handles.

9.

Adjust the pressure of the feed rolls with the pressure adjustment wheels. The pressure is the same for both feed roll pairs.

The graduated scales on the pressure handle indicate the pressure applied to the feed rolls. Adjust the pressure of the feed rolls according to the table below.

Filler wire	Feed roll profile	Filler wire diameter (mm)	Adjustment (x100N)
Fe/Ss solid	V-groove	0.8−1.0	1.5−2.0
		≥ 1.2	2.0−2.5
Metal and flux-cored	V-groove, knurled	≥ 1.2	1.0−2.0
Self-shielded (gasless)	V-groove, knurled	≥ 1.6	2.0−3.0
Aluminum	U-groove	1.0	0.5−1.0
		1.2	1.0−1.5
		1.4	1.5−2.0
		≥ 1.6	2.0−2.5

 

Excessive pressure flattens the filler wire and may damage coated or cored filler wires. Excessive pressure also unnecessarily wears the feed rolls and increases gearbox load.

10.

Press the Wire inch forward button to drive the filler wire into the welding torch. Stop when the wire reaches the welding torch's contact tip.