ESAB Aristo Origo Feed 3004 User manual

GB
Valid for serial no. 620--xxx--xxxx0458 716 201 GB 071005
Feed 3004
Feed 4804
Aristot
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
3.2 Control panel 5.............................................................
4 TECHNICAL DATA 6.................................................
5 INSTALLATION 7....................................................
5.1 Lifting instructions 7.........................................................
5.2 Terminating resistors 8.......................................................
5.3 Connection of multiple wire feed units 8........................................
6 OPERATION 9.......................................................
6.1 Connections and controls 10...................................................
6.2 Water connection 10..........................................................
6.3 Remote control unit 11........................................................
6.4 Wire feed pressure 11........................................................
6.5 Changing / loading wire Feed 3004 12..........................................
6.6 Changing / loading wire Feed 4804 12..........................................
6.7 Replacing the Feed 3004 feed rollers 12.........................................
6.8 Replacing the Feed 4804 feed rollers 13.........................................
7 MAINTENANCE 13....................................................
7.1 Inspection and cleaning 13....................................................
8 ORDERING OF SPARE PARTS 14......................................
DIAGRAM 16............................................................
ORDERING NUMBER 19.................................................
WEAR COMPONENTS 20.................................................
ACCESSORIES 24.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, declares that Wire feed unit Feed
3004/4804 from serial number 620 (2006 w.20) are constructed and tested in compliance with the
standard EN 60974--5 and EN 60974--10 in accordance with the requirements of directive
(2006/95/EC) and (2004/108/EEC).
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Kent Eimbrodt
Global Director
Equipment and Automation
Laxå 2007--03--14
2SAFETY
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 recommen-
dations 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:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized 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.
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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 PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
SInstall and earth the welding 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!
ESAB can provide you with all necessary welding protection and accessories.
WARNING!
Read and understand the instruction manual before installing
or operating.
This product is solely intended for arc welding.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human health!
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3 INTRODUCTION
The Feed 3004 and Feed 4804 wire feed units are intended for use with Mig power
sources.
There are several variants available: see on page 19.
They are totally enclosed, containing four--wheel feeders and the necessary control
electronics.
They are suitable for use with wire on ESAB’s MarathonPact, or on standard
bobbins (standard Ø 300 mm, accessory Ø 440 mm).
The units can be positioned in a choice of ways: on the power source itself, hanging
above the working position, on a support arm or with a wheelset on the floor.
ESAB’s accessories for the product can be found on page 24.
3.1 Equipment
The unit Feed 3004 is supplied with:
SInstruction manual for the wire feed unit.
SInstruction manual for control panel.
SStickers with recommended wear parts.
The unit Feed 4804 is supplied with:
SDistance washer (4 pieces).
SHexagon key (4 mm)
SInstruction manual for the wire feed unit.
SInstruction manual for the control panel.
SStickers with recommended wear parts.
3.2 Control panel
The units are supplied with one of the following control panels:
Empty panel for use with double wire feed units or
with use of control box U8.
MA4 With knobs for setting the voltage and wire feed
speed / current. Other settings by pushbuttons, with
corresponding symbols on the display panel.
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MA6 With knobs for setting the voltage and wire feed
speed / current. Other settings by pushbuttons, with
text indication on the display panel.
U6 With knobs for setting the voltage and wire feed
speed / current. Other settings by pushbuttons, with
text indication on the display panel.
Detailed descriptions of the control panels can be found in separate Instruction
manuals.
4 TECHNICAL DATA
Feed 3004 Feed 4804
Power supply 42 V 50 -- 60 Hz 42 V 50 -- 60 Hz
Power requirement 336 VA 378 VA
Motor current 8A 9A
Wire feed speed 0.8 -- 25 m/min 0.8 -- 25 m/min
Welding gun connection EURO EURO
Max. diameter of wire bobbin 300 mm (*440 mm) 300 mm (*440 mm)
Wire dimension 0.6 -- 1.6 mm 0.6 -- 2.4 mm
Operating temperature -- 1 0 t o + 4 0 ˚C-- 1 0 t o + 4 0 ˚C
Weight
basic unit
with bobbin carrier
with enclosed bobbin carrier
13 kg
16 kg
17.5 kg
18 kg
21 kg
22.5 kg
Dimensions (l x w x h)
basic unit
with bobbin carrier
with enclosed bobbin carrier
380 x 265 x 340 mm
560 x 265 x 350 mm
690 x 285 x 420 mm
380 x 265 x 340 mm
560 x 265 x 350 mm
690 x 285 x 420 mm
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)
Coolant
max pressure
50% water / 50% mono--ethylen
glycol
0.5 MPa (5 bar)
50% water / 50% mono--ethylen
glycol
0.5 MPa (5 bar)
Permissible load at
60% duty cycle 500 A 500 A
Enclosure class
basic unit
with bobbin carrier
with enclosed bobbin carrier
IP23
IP2X
IP23
IP23
IP2X
IP23
* Accessory, see page 24.
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
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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.
Equipment marked IP2X is designed for indoor use.
5 INSTALLATION
The installation must be executed by a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.
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 .
5.1 Lifting instructions
Ordering number for the lifting eye can be found on page 24.
Note! If another mounting device is used, this should be insulated from the wire feed
unit.
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5.2 Terminating resistors
In order to avoid communication interference, the
ends of the CAN bus must be terminated by resistive
loads.
One end of the CAN bus is at the wire feed unit control panel,
which incorporates a terminating resistor. The other end is in
the power source and it must be fitted with a terminating resistor,
as shown in the diagram to the right.
5.3 Connection of multiple wire feed units
When connecting multiple wire feed units (maximum 4), use wire feed units without
control panel and with control box U8.
Two feed units are to be connected according to the picture.
When connecting more than two feed units, an authorised ESAB service technican
must perform the installation.
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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
WARNING!
Assure that the side panels are closed during operation.
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.
WARNING!
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.
When moving the equipment use intended handle. NOTE! Never pull on the gun.
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6.1 Connections and controls
1Control panel
(see respective instruction manual)
6Connection for welding current from the
power source (OKC)
2a
2b
Connection for remote control
Connection for U8.
7Connection for the control cable from the
power source
3Connection with ELP* for cooling water to
the welding gun-- BLUE
8Connection for cooling water to the power
source (cooling unit) -- RED
4Connection for cooling water from the wel-
ding gun -- RED
9Connection for cooling water from the po-
wer source (cooling unit) -- BLUE
5Connection for the welding gun 10 Connection for protection gas
NOTE! Cooling water connections only available on certain models.
* ELP = ESAB Logic Pump, see point 6.2.
6.2 Water connection
The wire feed unit with water connection is equipped with a detection system ELP
(ESAB Logic Pump) which checks that the water hoses are connected.
Mig 4000i and Mig 5000i
The power unit On/Off switch must be in the “0” position (Off) when connecting a
water--cooled welding gun.
If a water--cooled welding gun is connected, the water pump starts automatically
when the main On/Off switch is turned to “START” and/or when welding starts. After
welding, the pump continues to run for 6,5 minutes, and then switches to the
energy--saving mode.
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