ESAB Aristo RoboFeed 3004w User manual

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Valid for serial no. 745-xxx-xxxx0461 165 001 GB 20120808
Aristo®
RoboFeed 3004w
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 Equipment 6................................................................
3 TECHNICAL DATA 6.................................................
4 INSTALLATION 7....................................................
4.1 Terminating resistor 7........................................................
4.2 Example of a robotic welding system 7.........................................
5 OPERATION 8.......................................................
5.1 Connection and control devices 9.............................................
5.2 Water connection 10..........................................................
5.3 Gas flow guard (if installed) 10.................................................
5.4 Wire feed pressure 11........................................................
5.5 Replacing and inserting wire 11................................................
5.6 Changing feed rollers 11......................................................
6 MAINTENANCE 12....................................................
6.1 Inspection and cleaning 12....................................................
7 ORDERING OF SPARE PARTS 12......................................
DIAGRAM 14............................................................
ORDER NUMBER 16.....................................................
WEAR PARTS 18........................................................
ACCESSORIES 20.......................................................

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1 SAFETY
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 ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
2. The operator must ensure that:
Sno unauthorised 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 precautions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the 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
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.
CAUTION
Read and understand the instruction manual before
installing or operating.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/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.
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© ESAB AB 2008
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CAUTION
This product is solely intended for arc welding.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
The RoboFeed 3004w wire feed unit is intended for MIG/MAG welding along with
robotic equipment.
2.1 Equipment
The wire feed unit is supplied with an instruction manual and a sticker with
recommended wear parts.
3 TECHNICAL DATA
RoboFeed 3004w
Power supply 42 V 50-60 Hz
Power requirement 147 VA
Motor current Imax 8 A
Wire feed speed 0.8-30.0 m/min
Gun connection EURO
Wire dimension
Fe
Ss
Al
Cored wire
0.6-1.6 mm
0.6-1.2 mm
1.0-1.6 mm
0.8-1.6 mm
Weight 7.3 kg
Dimensions (l x b x h) 362 x 246 x 235 mm
Shielding gas
max pressure
Gases for MIG/MAG welding
5 bar
Coolant
max pressure
50% water / 50% mono-ethylene glycol
5 bar
Maximum permissible load at
60% duty cycle
100% duty cycle
500 A
280 A
Enclosure class IP2X
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.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Apparatus marked IP2X are intended for indoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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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 Terminating resistor
The ends of the CAN bus must be fitted with terminating
resistors to avoid communication interference.
The terminating resistor is delivered with the power source.
One end of the CAN bus is at the control panel, which
has an integral terminating resistor. The other end is at
the wire feed unit and must be fitted with the
terminating resistor, as shown on the right.
4.2 Example of a robotic welding system
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5 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
WARNING
Assure that the side panels are closed during operation.
WARNING
Rotating parts can cause injury, take great care.
A
H 0935
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5.1 Connection and control devices
1White indicating lamp – Power supply ON 9Connection for coolant from power source
(cooling unit), BLUE
2Switch for gas purging 10 Inlet connection for spatter removal air
3Switch for reversed wire feed 11 Connection for coolant to power source
(cooling unit), RED
4Switch for cold wire feed 12 Quick connector MarathonPact
5Connection for signals to/from robot
welding gun
13 Connection for shielding gas
6ELP* - Connection for coolant to welding
gun BLUE and from welding gun RED
14 Connection for welding current from power
source, (OKC)
7Outlet connection for spatter removal air 15 Connection for terminating resistor or
forwarding to next wire feed unit
8 Connection for welding gun (EURO) 16 Connection for control cable from power
source
* ELP = ESAB Logic Pump, see 5.2
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Symbol and function explanations
Inlet spatter removal air (10)
Shielding gas (13)
Outlet spatter removal air (6)
Used for spray-cleaning the contact tip on the welding gun.
Gas purging (2)
Used to measure the gas flow or to flush the gas hoses to clean them of any air and
moisture before commencing welding. Gas purging is carried out with the voltage
and wire feed switched off.
Reversed wire feed (3)
Used to reverse the wire, for example when replacing the wire bobbin.
Inching (4)
Used when wire is to be fed without switching on the welding voltage.
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.
5.3 Gas flow guard (if installed)
The gas flow monitor interrupts the ongoing welding process if the gas flow drops
below 3.5 l/min. When this occurs, an error message is displayed via the control unit.
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