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

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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 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.......................................................

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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.

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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 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.

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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.

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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

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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.

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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.

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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.

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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.

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6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
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.
6.1 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.
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.
7 ORDERING SPARE PARTS
Feed 3004, Feed 4804 is designed and tested in accordance with the international and
European standards IEC/EN 60974--5 and EN 60974--10. It is the obligation of the servi-
ce 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.

Edition 080110
Diagram
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Feed 3004, Feed 4804
Edition 080110
Ordering number
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Ordering no. Denomination Type
0460 526 887 Wire feed unit OrigotFeed 3004, MA23
0460 526 889 Wire feed unit OrigotFeed 3004, MA24
0460 526 897 Wire feed unit with water OrigotFeed 3004, MA23
0460 526 899 Wire feed unit with water OrigotFeed 3004, MA24
0460 526 987 Wire feed unit OrigotFeed 4804, MA23
0460 526 989 Wire feed unit OrigotFeed 4804, MA24
0460 526 997 Wire feed unit with water OrigotFeed 4804, MA23
0460 526 999 Wire feed unit with water OrigotFeed 4804, MA24
0459 839 017 Spare parts list Feed 3004, Feed 4804
0460 454 Instruction manual OrigotMA23, OrigotMA24
Instruction manuals and the spare parts list are available on the Internet at www.esab.com

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Feed 3004
R0444 408/E080110/P24
Wear parts
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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
HI 15 F102 440 880 Quick connector For Marathon PacTM
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.

Feed 3004
R0444 408/E080110/P24
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Feed 4804
R0444 408/E080110/P24
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Item Ordering no. Denomination Wire type Wire dimensions
HK1 0469 837 880
0469 837 881
0469 837 882
Outlet nozzle
Outlet nozzle
Outlet nozzle
Fe, Ss & cored
Al
Fe, Ss & cored
Ø 2.0 mm steel for 0.6--1.6 mm
Ø 2.0 mm plastic for 1.0--1.6 mm
Ø 3.4 mm steel for 2.0--2.4 mm
Item Ordering no. Denomination Wire type Wire Ø
mm Groove 1 Groove 2 Groove 3 Groove typ Roller / Bogey
mark-
ings
HK2 0366 966 880 Feed Roller Fe, Ss & cored 0.6--1.2 0.6--0.8 0.9--1.0 1.2 V 1
0366 966 881 Feed Roller Fe, Ss & cored 1.4--1.6 1.4--1.6 2.0 2.4 V 2
0366 966 889 Feed Roller Fe, Ss & cored 1.2 .045” / 1.2 .045” / 1.2 .045” / 1.2 V.045 / 7
0366 966 900 Feed Roller Fe, Ss & cored 0.9--1.6 0.9--1.0 1.2 1.4--1.6 V 6
0366 966 882 Feed Roller Cored 1.2--2.0 1.2 1.4--1.6 2.0 V--Knurled 3
0366 966 883 Feed Roller Cored 2.4 2.4 not used not used V--Knurled 4
0366 966 885 Feed Roller Al 1.2 1.2 1.2 1.2 UU2
0366 966 899 Feed Roller Al 1.0--1.6 1.0 1.2 1.6 UU4
Item Ordering no. Denomination Notes
HK3 0156 707 001 Distance washer
HK4 0156 707 002 Adjustment spacer
HK5 Screw M5x20
HK6 Screw M5x16
HD = Heavy Duty
Item Ordering no. Denomination Wire type Wire dimensions Groove
typ Roller / Bogey
markings
HK7 0366 902 880 Bogey (HD)Fe, Ss & cored Ø0.6--1.2mm V 1
0366 902 900 Bogey (HD)Fe, Ss & cored Ø0.9--1.6mm V 6
0366 902 881 Bogey (HD)Fe, Ss & cored Ø1.4--2.4mm V 3
0366 902 894 Bogey (HD)Fe, Ss & cored Ø1.2mm V.045 / 7
0366 902 882 Bogey (HD)Cored Ø1.2--2.0mm V--Knurled 3
0366 902 883 Bogey (HD)Cored Ø2.4mm V--Knurled 4
0366 902 899 Bogey (HD)Al Ø1.0--1.6mm UU4
0366 902 886 Bogey (HD)Al Ø1.2mmx3 U--
Item Ordering no. Denomination Wire type Wire dimensions
HK8 0366 944 001 Washer
HK9 0156 603 001
0156 603 002
0332 322 001
0332 322 002
Intermediate nozzle
Intermediate nozzle
Intermediate nozzle
Intermediate nozzle
Fe, Ss & Al
Fe, Ss & Al
Cored
Cored
Ø 2 mm plastic for 0.6--1.6 mm
Ø 4 mm plastic for 2.0--2.4 mm
Ø 2.4 mm copper for 1.2--2.0 mm
Ø 4 mm copper for 2.4 mm
Item Ordering no. Denomination Note
HK10 0215 702 708 Locking washer
HK11 Nut M10
HK12 0458 748 002 Insulating washer
HK13 0458 748 001 Insulating bushing

Feed 4804
R0444 408/E080110/P24
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Item Ordering no. Denomination Wire type Wire dimensions
HK14 0156 602 001
0156 602 002
0332 318 001
0332 318 002
Inlet nozzle
Inlet nozzle
Inlet nozzle (HD)
Inlet nozzle (HD)
Fe, Ss, Al & Cored
Fe, Ss, Al & Cored
Fe, Ss & Cored
Fe, Ss & Cored
Ø 2 mm plastic for 0.6--1.6 mm
Ø 4 mm plastic for 2.0--2.4 mm
Ø 2.4 mm steel for 1.2--2.0 mm
Ø 4 mm steel for 2.4 mm

Feed 4804
R0444 408/E080110/P24
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R0444 408/E080110/P24
Feed 3004, Feed 4804
Accessories
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1Bobbin cover, plastic 18 kg Ø 300mm ...... 0458 674 880
1Bobbin cover, metal 18 kg Ø 300mm ....... 0459 431 880
1
2
Bobbin holder ...........................
Adapter for 5 kg bobbin ....................
0458 704 880
0455 410 001
1Adapter for 440 mm bobbin ................ 0459 233 880
1
2
Lifting eye ...............................
Quick connector MarathonPact...........
0458 706 880
F102 440 880
1Strain relief forweldinggun ................ 0457 341 881