ESAB Aristo Origo Feed 3004 User manual

GB
Valid for serial no. 745--xxx--xxxx0444 408 001 GB 080110
Origot
Feed 3004,
Feed 4804
Instruction manual

-- 2 --
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 6....................................................
5.1 Lifting instructions 7.........................................................
6 OPERATION 7.......................................................
6.1 Connections and control devices 8............................................
6.2 Water connection 8..........................................................
6.3 Wire feed pressure 9........................................................
6.4 Replacing and inserting Feed 3004 wire 9......................................
6.5 Replacing and inserting Feed 4804 wire 9......................................
6.6 Changing feed rollers on Feed 3004 10..........................................
6.7 Changing feed rollers on Feed 4804 10..........................................
7 MAINTENANCE 11....................................................
7.1 Inspection and cleaning 11....................................................
8 ORDERING SPARE PARTS 11..........................................
DIAGRAM 12............................................................
ORDERING NUMBER 13.................................................
WEAR PARTS 15........................................................
ACCESSORIES 20.......................................................

-- 3 --
bm50d1ea
1SAFETY
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.

-- 4 --
bm50d1ea
WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions 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!
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 electromagnic
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.

-- 5 --
bm50d1ea
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!
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
The wire feed units Feed 3004 / Feed 4804 with control panel 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 MarathonPact, 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 20.
2.1 Equipment
The wire feed unit is supplied with:
Sinstruction manual for the wire feed unit
Sinstruction manual in English for the control panel
Sdecal with recommended wear parts.
2.2 Control panel
The wire feed unit is supplied with one of the following control panels:
MA23 Knobs for setting the voltage and the wire feed speed /
current. Other settings with push buttons.
MA24 Knobs for setting the voltage / QSettand the wire feed
speed / current. Other settings with push buttons.
See the separate instruction manual for a detailed description of the control panels.

-- 6 --
bm50d1ea
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 8A 9A
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 -- 1 0 t o + 4 0 ˚C-- 1 0 t o + 4 0 ˚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 500 A 500 A
Enclosure class IP23 IP23
* Accessories, see page 20.
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.
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.
4 INSTALLATION
The installation must be executed 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

-- 7 --
bm50d1ea
4.1 Lifting instructions
Order number for lifting eyelet can be found on page 20.
NOTE! If another mounting device is used, this must be electrically insulated from
the wire feed unit.
5 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
When moving the equipment use intended handle. NOTE! Never pull on the gun.
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.
WARNING!
Rotating parts can cause injury, take great care.

-- 8 --
bm50d1ea
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.
5.1 Connections and control devices
1Control panel,
(see separate instruction manual)
6Connection for welding current from power
source, (OKC)
2Connection for remote control unit 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.
5.2 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. When
connecting a water--cooled welding gun, the water pump starts.
Detection only works with power sources that are equipped with ELP.

-- 9 --
bm50d1ea
5.3 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).
5.4 Replacing and inserting Feed 3004 wire
SOpen the side panel.
SDisconnect the pressure sensor by folding it backwards, the pressure rollers
slide up.
SIf necessary, roll back the wire and remove the wire bobbin.
SStraighten out the new wire 10--20 cm. File away burrs and sharp edges from the
end of the wire before inserting it into the wire feed unit.
SMake sure that the wire goes properly into the feed roller’s track and into the
outflow nozzle or wire guide.
SSecure the pressure sensor.
SClose the side panel.
5.5 Replacing and inserting Feed 4804 wire
SOpen the side panel.
SPress down and pull the pressure device towards you and up.
SPull out the bogie.
SIf necessary, roll back the wire and remove the wire bobbin.
SStraighten out the new wire 10--20 cm. File away burrs and sharp edges from the
end of the wire before inserting it into the wire feed unit.
SMake sure that the wire goes properly into the feed roller’s track and into the
outflow nozzle or wire guide.
SReinstall the bogie.
SClose the side panel.

-- 1 0 --
bm50d1ea
5.6 Changing feed rollers on Feed 3004
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.
During installation, repeat the above in reverse order.
Choice of track in the feed rollers
Turn the feed roller with the dimensioning mark for the
required track towards you.
5.7 Changing feed rollers on Feed 4804
SOpen the side panel.
SPress down and pull the pressure device (1) towards
you and up.
SPull out the bogie (2).
SUndo the socket head cap screws (3) on the holder
for the intermediate nozzle and remove it.
SUndo the screw for the outflow nozzle (4) and
push back the nozzle.
SCompletely undo the socket head cap screw (5) in the
centre.
SUndo the two outer socket head cap screws (6) 1/2 a
turn.
SPull out the feed rollers (7).
During installation, repeat the above in reverse order.
Choice of track in the feed rollers
Place no, one or two driving washers
between the outer washer and the feed
roller. NOTE! When replacing the
pressure rollers (8), the entire bogie is
replaced.