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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Mig 4500i
The power unit On/Off switch for cooling unit must be in the “I” position (ON) when
connecting a water--cooled welding gun.
6.3 Remote control unit
The program version in U8 should be 1.20 or higher. Machines with intergral control
panels should have program version 1.21 or higher, in order for the remote control to
function correctly.
When the remote control unit is connected, the power source and wire feed unit are
in remote control mode; the buttons and knobs are blocked. The functions can only
be adjusted via the remote unit.
If the remote control unit is not to be used, the remote control unit must be
disconnected from the power source / wire feed unit, as otherwise it will remain in
remote control mode.
When a remote control unit is used to set the voltage, the function will be changed to
the setting of current during MMA welding.
For more information about the operation of the remote control unit, see the
operating instructions for the control panel.
6.4 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder’s pressure rollers. It is important that the
pressure is not too great.
Fig 1 Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against
an insulated object, e.g. a piece of wood.
When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed
rollers should slip.
If you hold the gun approx. 50 mm from the piece of wood, the wire should be
fed out and bend (fig. 2).
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6.5 Changing / loading wire Feed 3004
SOpen the side panel.
SDisconnect the pressure sensor by folding it backwards, the pressure rollers
slide up.
SWind any wire that may be left between the rollers back on to the bobbin and
remove the bobbin.
SStraighten out 10--20 cm of the end of the new wire. File off any burrs from the
end of the wire and then feed it into the feed unit.
SMake sure that the end of the wire is correctly positioned in the groove in the
feed rollers and in the outlet nozzle and wire liner.
STighten the pressure sensor.
SClose the side panel.
6.6 Changing / loading wire Feed 4804
SOpen the side panel.
SPush down the pressure device and pull it towards you and upwards.
SPull out the bogey
SWind any wire that may be left between the rollers back on to the bobbin and
remove the bobbin.
SStraighten out 10--20 cm of the end of the new wire. File off any burrs from the
end of the wire and then feed it into the feed unit.
SMake sure that the end of the wire is correctly positioned in the groove in the
feed rollers and in the outlet nozzle and wire liner.
SReplace the bogey.
SClose the side panel.
6.7 Replacing the Feed 3004 feed rollers
SOpen the side panel.
SDisconnect the pressure sensor (1) by folding it
backwards.
SDisconnect the pressure rollers (2) by turning the
axle (3) 1/4 turn clockwise and pulling out the axle.
The pressure rollers disconnect.
SDisconnect the feed rollers (4) by unscrewing the
nuts (5) and pulling out the rollers.
Reassemble in the reverse order.
Selecting the correct groove in the feed rollers
Turn the feed roller so that the dimension marking of the
required groove is facing you.
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6.8 Replacing the Feed 4804 feed rollers
SOpen the side panel.
SPush down the pressure device (1) and pull it
towards you and upwards.
SPull out the bogey (2).
SRemove the socket--head bolts (3) on the
intermediate nozzle and remove it.
SLoosen the bolt holding the outlet nozzle (4)
and push the nozzle back.
SRemove the socket--head bolt (5) in the centre
SSlacken the two socket--head bolts (6) by half a turn.
SPull out the feed rollers (7).
Reassemble in the reverse order.
Selecting the correct groove in the
feed rollers
Place no, one or two carrier washers
between the outer washer and the feed
rollers. NB: Replace the entire bogey
when changing the pressure rollers (8).
7 MAINTENANCE
Regular maintenance is important in ensuring safe and reliable.
Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
7.1 Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
SCleaning and replacement of the wire feed unit mechanism’s worn parts should
take place at regular intervals in order to achieve trouble--free wire feed. Note
that if pre--tensioning is set too hard, this can result in abnormal wear on the
pressure roller, feed roller and wire guide.
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The brake hub
The hub is adjusted when delivered, if
readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly
slack when wire feed stops.
SAdjusting the braking torque:
STurn the red handle to the locked position.
SInsert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs counterclockwise to increase the braking torque. NB: Turn
both springs through the same amount.
Welding gun
SCleaning and replacement of the welding gun’s wear parts should take place at
regular intervals in order to achieve trouble--free wire feed. Blow the wire guide
clean regularly and clean the contact tip.
8 ORDERING OF SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Feed 3004, Feed 4804 is designed and tested in accordance with the international an
European standards IEC/EN 60974--5 and EN 60974--10.
It is the obligation of the service unit which has carried out the service or repair work
to make sure that the product still conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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Diagram
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Feed 3004, Feed 4804

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Feed 3004, Feed 4804
Edition 071005
Ordering number
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1.
Control
panel Water cooling
kit
Feeder for
Marathon Pact
Feeder with
open bobbin Feeder with capsuled bobbin
AristotFeed 3004 0458 804 881 0458 805 881 0458 806 881
AristotFeed 3004 W x0458 804 891 0458 805 891 0458 806 891
AristotFeed 3004 MA4 0458 804 884 0458 805 884 0458 806 884
AristotFeed 3004 W MA4 x0458 804 894 0458 805 894 0458 806 894
AristotFeed 3004 MA6 0458 804 886 0458 805 886 0458 806 886
AristotFeed 3004 W MA6 x0458 804 896 0458 805 896 0458 806 896
AristotFeed 3004 U6 0458 804 887 0458 805 887 0458 806 887
AristotFeed 3004 W U6 x0458 804 897 0458 805 897 0458 806 897
AristotFeed 4804 0458 804 981 0458 805 981 0458 806 981
AristotFeed 4804 W x0458 804 991 0458 805 991 0458 806 991
AristotFeed 4804 MA4 0458 804 984 0458 805 984 0458 806 984
AristotFeed 4804 W MA4 x0458 804 994 0458 805 994 0458 806 994
AristotFeed 4804 MA6 0458 804 986 0458 805 986 0458 806 986
AristotFeed 4804 W MA6 x0458 804 996 0458 805 996 0458 806 996
AristotFeed 4804 U6 0458 804 987 0458 805 987 0458 806 987
AristotFeed 4804 W U6 x0458 804 997 0458 805 997 0458 806 997
Spare parts list 0458 716 990 0458 716 990 0458 716 990
Instruction manual MA4 x0458 818 0458 818 0458 818
Instruction manual MA6 x0458 854 0458 854 0458 854
Instruction manual U6 x0459 287 0459 287 0459 287
Instruction manuals and the spare parts list are available on the Internet at www.esab.com

Feed 3004
R0458 716/E071005/P28
Wear components
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Item Ordering no. Denomination Wire type Wire dimensions
HI 1 0455 072 002
0456 615 001 Intermediate nozzle Intermediate nozzle Fe, Ss & cored Al
HI 2 0469 837 880
0469 837 881 Outlet nozzle Outlet nozzle Fe, Ss & cored Al Ø 2.0 mm steel for 0.6--1.6 mm Ø 2.0 mm plastic for 0.8--1.6 mm
HI 3 0191 496 114 Key
HI 4 0215 701 007 Locking washer
HI 5a 0459 440 001 Motor gear euro
Item Ordering no. Denomination Wire type Wire dimensions Groove
typ Roller markings
HI 5b 0459 052 001 Feed/pressure rollers Fe, Ss & cored Ø 0.6 & 0.8 mm V0.6 S2 &0.8S2
0459 052 002 Feed/pressure rollers Fe, Ss & cored Ø 0.8 & 1,0 mm V0.8 S2 &1.2S2
0459 052 003 Feed/pressure rollers Fe, Ss & cored Ø 0.9/1.0 & 1.2 mm V1.0 S2 &1.2S2
0459 052 013 Feed/pressure rollers Fe, Ss & cored Ø 1.4 & 1.6 mm V1.4 S2 &1.6S2
0458 825 001 Feed/pressure rollers Cored Ø 0.9/1.0 & 1.2 mm V--Knurled 1.0 R2 &1.2R2
0458 825 002 Feed/pressure rollers Cored Ø 1.2 & 1.4 mm V--Knurled 1.2 R2 &1.4R2
0458 825 003 Feed/pressure rollers Cored Ø1.6mm V--Knurled 1.6 R2 &2.0R2
0458 824 001 Feed/pressure rollers Al Ø 0.8 & 0.9/1.0 mm U0.8 A2 &1.0A2
0458 824 002 Feed/pressure rollers Al Ø 1.0 & 1.2 mm U1.0 A2 &1.2A2
0458 824 003 Feed/pressure rollers Al Ø 1.2 & 1.6 mm U1.2 A2 &1.6A2
0458 874 002 Feed/pressure rollers Al Ø 1.0 & 1.2 mm U1.0 A2 &1.2A2
Use only pressure and feed rollers marked A2,R2 or S2.
Therollersaremarkedwithwiredimensioninmm,somearealsomarkedwithinch.
Item Ordering no. Denomination Notes
HI 6 Washer Ø 16/5x1
HI 7 Screw M4x12
HI 8 Screw M6x12
HI 9 Washer Ø 16/8.4x1.5
HI 10 0469 838 001 Cover
HI 11 0458 722 880 Axle and Nut
HI 12 0459 441 880 Gear adapter
HI 13 0455 049 001 Inlet nozzle
HI 14 0458 999 001 Shaft
Welding with aluminium wire
In order to weld with aluminium wire, proper rollers, nozzles and liners for aluminium wire MUST be
used, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriate
wear parts.