ESAB Aristo FeedMech 4804 User manual

GB
Valid for serial no. 410-xxx-xxxx0461 066 101 GB 20140625
Aristo®
FeedMech 4804/
FeedControl
Instruction manual

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Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 Equipment 6................................................................
3 TECHNICAL DATA 6.................................................
4 INSTALLATION 7....................................................
4.1 Terminating resistor 7........................................................
4.2 Example of a robotic welding system 8.........................................
5 OPERATION 9.......................................................
5.1 Connections 10..............................................................
5.2 Gas flow guard (if installed) 12.................................................
5.3 Wire feed pressure 13........................................................
5.4 Replacing and inserting wire 13................................................
5.5 Changing feed rollers 13......................................................
6 MAINTENANCE 14....................................................
6.1 Inspection and cleaning 14....................................................
7 ORDERING SPARE PARTS 14.........................................
DIAGRAM 16............................................................
ORDER NUMBER 18.....................................................
WEAR PARTS 20........................................................
ACCESSORIES 22.......................................................
© ESAB AB 2014

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1 SAFETY
Users of ESAB 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 equipment. The following recommendations should be ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
2. The operator must ensure that:
Sno unauthorised person is stationed within the working area of the equipment when it is
started up.
Sno-one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
GB
© ESAB AB 2014

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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 and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION
This product is solely intended for arc welding.
CAUTION
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low-voltage supply system.
There may be potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical and/or
electronic equipment that has reached the end of its life must be disposed of at a
recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain
information on approved collection stations.
For further information contact the nearest ESAB dealer.
GB
© ESAB AB 2014

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CAUTION
Read and understand the instruction manual before
installing or operating.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
The wire feed unit consist of a drive unit (FeedMech 4804) and a separate electronic
unit (FeedControl).
The wire feed unit is intended for MIG/MAG welding along with robotic equipment.
NOTE!
The wire feed unit utilizes the robot's safety system to obtain maximum interference protection.
ESAB's accessories for the product can be found on page 22.
2.1 Equipment
The wire feed unit is supplied with an instruction manual, and the drive unit with a
sticker with recommended wear parts.
3 TECHNICAL DATA
FeedMech 4804 FeedControl
Power supply 42 V 50-60 Hz 42 V 50-60 Hz
Power requirement 378 VA 378 VA
Motor current Imax 9.0 A 9.0 A
Settings data
Wire feed speed 0.8 - 25.0 m/min
Gun connection EURO
Wire dimension
Fe
Ss
Al
Cored wire
0.6-2.4 mm
0.6-2.4 mm
1.0-1.6 mm
0.8-2.4 mm
Operating temperature -10 to + 40°C-10 to + 40°C
Weight 9.7 kg 4.9 kg
Dimensions (l x b x h) 383 x 161 x 287 mm 330 x 118 x 320 mm
Shielding gas
max pressure
Gases for MIG/MAG-welding
5 Bar
Gases for MIG/MAG-welding
5 Bar
Maximum permissible load at
60% intermittens
100% intermittens
500 A
280 A
500 A
280 A
Enclosure class IP2X IP2X
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© ESAB AB 2014

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Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40°C.
The duty cycle is valid for 40°C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Apparatus marked IP2X are intended for indoor use.
4 INSTALLATION
The installation must be carried out by a professional.
Note
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case it
is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distribution network operator if necessary, that the equipment may be connected.
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
4.1 Terminating resistor
The ends of the CAN bus must be fitted with terminating
resistors to avoid communication interference.
The terminating resistor is delivered with the power source.
One end of the CAN bus is at the control panel (U82), which
has an integral terminating resistor.
The other end is at the FeedControl and must be fitted with
the terminating resistor, as shown on the right.
GB
© ESAB AB 2014

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4.2 Example of a robotic welding system
AH 0934
GB
© ESAB AB 2014

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5 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
A
H 0935
WARNING
Rotating parts can cause injury, take great care.
WARNING
Risk of crushing when replacing the wire bobbin!
Do not use safety gloves when inserting the welding wire between the feed rollers.
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© ESAB AB 2014

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5.1 Connections
FeedMech 4804
1Switch for gas purging 9Connection to drive unit, 4 poles
2Switch for reversed wire feed 10 Connection to drive unit, 8 poles
3Switch for cold wire feed 11 Connection for coolant from power source
(cooling unit), BLUE
4Connection for coolant to welding gun,
BLUE
12 Connection for coolant to power source
(cooling unit), RED
5Connection for coolant from welding gun,
RED
13 Inlet connection for spatter removal air
6Outlet connection for spatter removal air 14 Connection for shielding gas in
7Connection for signals to/from robot
welding gun
15 Connection for welding current from
electronic unit (OKC)
8Connection for welding gun 16 Rating plate
GB
© ESAB AB 2014