ESAB Aristo Origo Feed 3004 User manual

GB
Valid for serial no. 745-xxx-xxxx, 910-xxx-xxxx0444 408 101 GB 20120621
Aristo Origo™
Feed 3004
Feed 4804
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 Equipment 6................................................................
2.2 Control panel 6.............................................................
3 TECHNICAL DATA 7.................................................
4 INSTALLATION 8....................................................
4.1 Lifting instructions 8.........................................................
5 OPERATION 9.......................................................
5.1 Connections and control devices 10............................................
5.2 Water connection 11..........................................................
5.3 Wire feed pressure 11........................................................
5.4 Replacing and inserting Feed 3004 wire 11......................................
5.5 Replacing and inserting Feed 4804 wire 12......................................
5.6 Changing feed rollers on Feed 3004 12..........................................
5.7 Changing feed rollers on Feed 4804 12..........................................
6 MAINTENANCE 13....................................................
6.1 Inspection and cleaning 13....................................................
7 ORDERING SPARE PARTS 13.........................................
DIAGRAM 14............................................................
ORDER NUMBER 16.....................................................
WEAR PARTS 18........................................................
ACCESSORIES 22.......................................................

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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:
its operation
location of emergency stops
its function
relevant safety precautions
welding and cutting
2. The operator must ensure that:
no unauthorised 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 a qualified electrician.
Appropriate fire extinquishing 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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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
Install and earth the 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 workpiece.
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!
CAUTION
Read and understand the instruction manual before
installing or operating.
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.
CAUTION
This product is solely intended for arc welding.
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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.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
The wire feed units Feed 3004 / Feed 4804 with control panel U6, MA23 or MA24
are intended for MIG/MAG welding together with 400A, 500A and 600A CAN
welding power sources.
The wire feed units contain four-wheel drive wire feed mechanisms as well as control
electronics.
They can be used together with wire on ESAB's MarathonPac, or on wire bobbin
(standard Ø 300 mm, accessory Ø 440 mm).
The wire feed unit can be installed either on the power source trolley, suspended above
the workplace, on a counter balance device or on the floor with or without wheel set.
ESAB's accessories for the product can be found on page 22.
2.1 Equipment
The wire feed unit is supplied with:
instruction manual for the wire feed unit
instruction manual in English for the control panel
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
decal with recommended wear parts.
2.2 Control panel
The wire feed unit is supplied with one of the following control panels:
Empty panel for use with double wire feed units or with
use of control box U82.
U6
Knobs for setting the voltage and the wire feed speed /
current. Other parameters are controlled by
pushbuttons, with text in the display panel.
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MA23 Knobs for setting the voltage and the wire feed speed /
current. Other settings with push buttons.
MA24 Knobs for setting the voltage / QSetand the wire feed
speed / current. Other settings with push buttons.
See the separate instruction manual for a detailed description of the control panels.
3 TECHNICAL DATA
Feed 3004 Feed 4804
Mains voltage 42 V 50-60 Hz 42 V 50-60 Hz
Power requirement 336 VA 378 VA
Motor current Imax 8 A 9 A
Wire feed speed 0.8 - 25.0 m/min 0.8 - 25.0 m/min
Gun connection EURO EURO
Max. diameter wire bobbin 300 mm (*440 mm) 300 mm (*440 mm)
Wire dimension
Fe
Ss
Al
Cored wire
0.8 - 1.6 mm
0.8 - 1.6 mm
1.0 & 1.6 mm
0.9 - 1.6 mm
0.8 - 2.4 mm
0.8 - 2.4 mm
1.0 & 2.4 mm
0.9 - 2.4 mm
Weight 15 kg 19 kg
Dimensions (l x w x h) 690 x 275 x 420 mm 690 x 275 x 420 mm
Operating temperature -10 to +40°C-10 to +40°C
Shielding gas
max pressure
All types intended for
MIG/MAG welding
0.5 MPa ( 5 bar)
All types intended for
MIG/MAG welding
0.5 MPa ( 5 bar)
Type of cooling
max pressure
50 % water /
50 % mono-ethylene glycol
0.5 MPa ( 5 bar)
50 % water /
50 % mono-ethylene glycol
0.5 MPa ( 5 bar)
Maximum permissible load at
60% duty cycle
100% duty cycle
630 A
500 A
630 A
500 A
Enclosure class IP23 IP23
* Accessories, see page 22.
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.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
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4 INSTALLATION
The installation must be carried out 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
4.1 Lifting instructions
Order number for lifting eyelet can be found on page 22.
NOTE! If another mounting device is used, this must be electrically insulated from
the wire feed unit.
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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!
NOTE: When moving the equipment use intended handle. Never pull on the gun.
A
H 0935
WARNING
Assure that the side panels are closed during operation.
WARNING
To prevent the reel from sliding off the hub: Lock the
reel in place by turning the red knob as shown on the
warning label attached next to the hub.
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WARNING
Rotating parts can cause injury, take great care.
WARNING
There is a risk of tipping if the wire feed unit is fitted with a counterbalance arm.
Secure the equipment, especially if used on an uneven or sloping surface.
WARNING
Risk of crushing when replacing the wire bobbin!
Do not use safety gloves when inserting the welding wire between the feed rollers.
5.1 Connections and control devices
1Control panel,
(see separate instruction manual)
6Connection for welding current from power
source, (OKC)
2a
2b
Connection for remote control unit
Connection for U82
7Connection for control cable from power
source or cooling unit
3Connection BLUE, with ELP* for coolant to
the welding gun
8Connection RED, for coolant to cooling
unit
4Connection RED, for coolant from welding
gun
9Connection for shielding gas
5Connection for welding gun 10 Connection BLUE, for coolant from cooling
unit
NOTE! Display (digital instrument) and coolant connections only available on certain models.
* ELP = ESAB Logic Pump, see point 5.2.
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