ESAB Aristo Origo Feed 4804 User manual

Aristo®, Origo™
Instruction manual
0444 408 201 GB 20171124 Valid for: serial no. 745-, 910-, 236-, 540-, 628-xxx-xxxx
Feed3004, Feed4804

TABLE OF CONTENTS
0444 408 201 © ESAB AB 2017
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 8
2.1 Equipment............................................................................................... 8
2.2 Control panel .......................................................................................... 8
3TECHNICAL DATA ...................................................................................... 10
4INSTALLATION............................................................................................ 11
4.1 Lifting instructions ................................................................................. 11
5OPERATION ................................................................................................ 12
5.1 Connections and control devices ......................................................... 13
5.2 Water connections ................................................................................. 13
5.3 Wire feed pressure ................................................................................. 13
5.4 Replacing and inserting Feed 3004 wire .............................................. 14
5.5 Replacing and inserting Feed 4804 wire .............................................. 14
5.6 Changing feed rollers on Feed 3004..................................................... 15
5.7 Changing feed rollers on Feed 4804..................................................... 15
6MAINTENANCE........................................................................................... 16
6.1 Inspection and cleaning......................................................................... 16
7ORDERING SPARE PARTS ........................................................................ 17
DIAGRAM ............................................................................................................. 18
WEAR PARTS....................................................................................................... 20
ORDERING NUMBERS........................................................................................ 28
ACCESSORIES .................................................................................................... 29
Rights reserved to alter specifications without notice.

1 SAFETY
0444 408 201 -4- © ESAB AB 2017
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2 Safety precautions
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 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
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 or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0444 408 201 -5- © ESAB AB 2017
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 extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Wire feeders are intended to be used with power sources in MIG/MAG mode
only.
If used in any other welding mode, such as MMA, the welding cable between wire
feeder and power source must be disconnected, or else the wire feeder becomes
live or energized.
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
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

1 SAFETY
0444 408 201 -6- © ESAB AB 2017
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
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
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.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/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.

1 SAFETY
0444 408 201 -7- © ESAB AB 2017
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0444 408 201 -8- © ESAB AB 2017
2 INTRODUCTION
The wire feed unit Feed 3004 with control panel U6,MA23,MA24 or MA25 Pulse is
intended for MIG/MAG welding together with 400A, 500A and 600A CAN welding power
sources.
The wire feed unit Feed 4804 with control panel U6,MA23 or MA24 is 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 in chapter "ACCESSORIES" of this
manual.
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 Internet:
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.
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.

2 INTRODUCTION
0444 408 201 -9- © ESAB AB 2017
MA25
Pulse
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
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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 8 A 9 A
Wire feed speed 0.8 - 25.0 m/min 0.8 - 25.0 m/min
Torch connection EURO EURO
Max. diameter wire bobbin 300 mm (*440 mm) 300 mm (*440 mm)
Wire dimension
Fe 0.8 - 1.6 mm 0.8 - 2.4 mm
Ss 0.8 - 1.6 mm 0.8 - 2.4 mm
Al 1.0 & 1.6 mm 1.0 & 2.4 mm
Cored wire 0.9 - 1.6 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 All types intended for
MIG/MAG welding
All types intended for
MIG/MAG welding
max pressure 0.5 MPa ( 5 bar) 0.5 MPa ( 5 bar)
Coolant ESAB's ready mixed coolant ESAB's ready mixed coolant
max pressure 0.5 MPa ( 5 bar) 0.5 MPa ( 5 bar)
Maximum permissible load at
60% duty cycle 630 A 630 A
100% duty cycle 500 A 500 A
Enclosure class IP23 IP23
*Accessories can be found in the "ACCESSORIES" chapter.
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/104°F, or below.
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 intended for indoor and outdoor use.

4 INSTALLATION
0444 408 201 - 11 - © ESAB AB 2017
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 in chapter "ACCESSORIES".
NOTE!
If another mounting device is used, this must be electrically insulated from the
wire feed unit.

5 OPERATION
0444 408 201 - 12 - © ESAB AB 2017
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
NOTE!
When moving the equipment, use handle intended for transportation. Never pull
the equipment by the welding torch.
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.
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 OPERATION
0444 408 201 - 13 - © ESAB AB 2017
5.1 Connections and control devices
1Control panel, (see separate instruction
manual)
6Connection for welding current from
power source, (OKC)
2a Connection for remote control unit 7Connection for control cable from power
source or cooling unit
2b Connection for U82
3Connection BLUE, with ELP* for coolant
to the welding torch
8Connection RED, for coolant to cooling
unit
4Connection RED, for coolant from
welding torch
9Connection for shielding gas
5Connection for welding torch 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 section "WATER CONNECTION".
5.2 Water connections
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 torch, the water pump starts.
Detection only works with power sources that are equipped with ELP.
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.

5 OPERATION
0444 408 201 - 14 - © ESAB AB 2017
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 torch approx. 5 mm from the piece of wood (fig. 1) the feed rollers should
slip.
If you hold the torch 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
• Open the side panel.
• Disconnect the pressure sensor by folding it backwards, the pressure rollers slide up.
• If necessary, roll back the wire and remove the wire bobbin.
• Straighten 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.
• Make sure that the wire goes properly into the feed roller's track and into the outflow
nozzle or wire guide.
• Secure the pressure sensor.
• Close the side panel.
5.5 Replacing and inserting Feed 4804 wire
• Open the side panel.
• Press down and pull the pressure device towards you and up.
• Pull out the bogie.
• If necessary, roll back the wire and remove the wire bobbin.
• Straighten 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.
• Make sure that the wire goes properly into the feed roller's track and into the outflow
nozzle or wire guide.
• Reinstall the bogie.
• Close the side panel.

5 OPERATION
0444 408 201 - 15 - © ESAB AB 2017
5.6 Changing feed rollers on Feed 3004
• Open the side panel
• Disconnect the pressure sensor
(1) by folding it backwards.
• Disconnect the pressure rollers
(2) by turning the axle (3) 1/4 turn
clockwise and pulling out the
axle.
The pressure rollers disconnect.
• Disconnect 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
• Open the side panel.
• Press down and pull the pressure device
(1) towards you and up.
• Pull out the bogie (2).
• Undo the socket head cap screws (3) on
the holder for the intermediate nozzle and
remove it.
• Undo the screw for the outflow nozzle (4)
and push back the nozzle.
• Completely undo the socket head cap
screw (5) in the centre.
• Undo the two outer socket head cap
screws (6) 1/2 a turn.
• Pull 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.
Groove 1 Groove 2 Groove 3
NOTE!
When replacing the pressure rollers (8), the entire bogie is replaced.

6 MAINTENANCE
0444 408 201 - 16 - © ESAB AB 2017
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1 Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
• Cleaning 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!
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.
Adjusting the braking torque:
• Turn the red handle to the locked
position.
• Insert a screwdriver into the springs in the
hub.
• Turn the springs clockwise to reduce the braking torque
• Turn the springs counter-clockwise to increase the braking torque.
NOTE!
Turn both springs the same amount.
Welding torch
• The welding torch's wear parts should be cleaned and replaced 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
0444 408 201 - 17 - © ESAB AB 2017
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 IEC/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 and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.

DIAGRAM
0444 408 201 - 18 - © ESAB AB 2017
DIAGRAM

DIAGRAM
0444 408 201 - 19 - © ESAB AB 2017

WEAR PARTS
0444 408 201 - 20 - © ESAB AB 2017
WEAR PARTS
Feed 3004
Item Ordering no. Denomination Notes Wire type Wire dimensions
HI1 0455 072 002 Intermediate nozzle Fe, Ss & cored
0456 615 001 Intermediate nozzle Al
HI2 0469 837 880 Outlet nozzle Fe, Ss & cored Ø 2.0 mm steel for
0.6-1.6 mm
0469 837 881 Outlet nozzle Al Ø 2.0 mm plastic for
0.8-1.6 mm
HI3 0191 496 114 Key
HI4 0215 701 007 Locking washer
HI5a 0459 440 001 Motor gear euro Drive gear
Item Ordering
number
Denomination Wire
type
Wire dimen-
sions (mm)
Groove
type
Roller
markings
HI5b 0459 052 001 Feed/pressure rollers Fe, Ss
& cored
Ø 0.6
&0.8mm
V 0.6 S2 &0.8S2
0459 052 002 Feed/pressure rollers Fe, Ss
& cored
Ø 0.8
&1.0mm
V 0.8 S2 &1.0S2
0459 052 003 Feed/pressure rollers Fe, Ss
& cored
Ø 0.9/1.0
&1.2mm
V 1.0 S2 &1.2S2
0459 052 013 Feed/pressure rollers Fe, Ss
& cored
Ø 1.4
&1.6mm
V 1.4 S2 &1.6S2
0458 825 001 Feed/pressure rollers Cored Ø 0.9/1.0
&1.2mm
V-
Knurled
1.0 R2
&1.2R2
0458 825 010 Feed/pressure rollers Cored Ø 1.2/1.2 mm V-
Knurled
1.2 R2
&1.4R2
0458 825 002 Feed/pressure rollers Cored Ø 1.2
&1.4mm
V-
Knurled
1.2 R2
&1.2R2
0458 825 003 Feed/pressure rollers Cored Ø 1.6 mm V-
Knurled
1.6 R2
&2.0R2
0458 824 001 Feed/pressure rollers Al Ø 0.8
&0.9/1.0mm
U 0.8 A2
&1.0A2
0458 824 002 Feed/pressure rollers Al Ø 1.0
&1.2mm
U 1.0 A2
&1.2A2
0458 824 003 Feed/pressure rollers Al Ø 1.2
&1.6mm
U 1.2 A2
&1.6A2
Only use pressure and feed rollers marked A2,R2 or S2.
The rollers are marked with wire dimension in mm, some are also marked with inch.