ESAB Feed L302 Origo M08 User manual

GB
Valid for serial no. 620-xxx-xxxx0459 508 101 GB 110203
Origo™ M08, Origo™ M09
Feed L302
Feed L304
Instruction manual

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Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Lifting instructions 7.........................................................
6 OPERATION 7.......................................................
6.1 Connections and control devices 8............................................
6.2 Explanation of function 10.....................................................
6.3 Wire feed pressure 11........................................................
6.4 Replacing and inserting wire 11................................................
6.5 Changing feed roller Feed L302 12.............................................
6.6 Changing feed roller Feed L304 12.............................................
7 MAINTENANCE 12....................................................
7.1 Inspection and cleaning 12....................................................
8 ORDERING SPARE PARTS 13.........................................
DIAGRAM 14............................................................
ORDERING NUMBER 16.................................................
WEAR PARTS 17........................................................
ACCESSORIES 21.......................................................

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1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE-695 81 Laxå, Sweden, declares that Wire feed unit Feed
L302/Feed L304 from serial number 620 are constructed and tested in compliance with the standard
EN 60974-5 and EN 60974-10 (Class A) in accordance with the requirements of directive
(2006/95/EC) and (2004/108/EEC).
--------------------------------------------------------------------------------------------------------------
Kent Eimbrodt
Global Director
Equipment and Automation
Laxå 2007-03-14
2SAFETY
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 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. Note! Do not use safety gloves when replacing wire.
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 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!
ESAB can provide you with all necessary welding protection and accessories.
WARNING
Do not use the power source for thawing frozen pipes.
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.
CAUTION
Read and understand the instruction manual before
installing or operating.
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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.
3 INTRODUCTION
The Feed L302 with control panel M08 and Feed L304 with control panel M09 wire
feed units are intended for MIG/MAG welding with the Mig L405 power source.
They come in different variants, see page 16.
The feed units can be used together with wire on ESAB's MarathonPact, or on wire
bobbin Ø 300 mm.
They can be installed either at the power source, suspended above the workplace,
on a support arm or on the floor with or without wheel set.
ESAB's accessories for the product can be found on page 21.
3.1 Equipment
The wire feed units are supplied with an instruction manual and stickers.
4 TECHNICAL DATA
Feed L302 Feed L304
Power supply 42 V 50-60 Hz 42 V 50-60 Hz
Power requirement 150 VA 150 VA
Motor current Imax 3.5 A 3.5 A
Settings data
Wire feed speed
Burnback time
Spot welding time
1.5-22.0 m/min
0-0.7 s
-
1.5-22.0 m/min
0-0.7 s
0.2-5 s
Gun connection EURO EURO
Max. diameter wire bobbin 300 mm 300 mm
Wire dimension
Fe
Ss
Al
Cored wire
0.6-1.2 mm
0.6-1.2 mm
1.0-1.2 mm
0.8-1.2 mm
0.6-1.6 mm
0.6-1.2 mm
1.0-1.6 mm
0.8-1.6 mm
Weight 12.6 kg 13.2 kg
Dimensions (l x b x h) 569 x 259 x 355 mm 569 x 259 x 355 mm
Operating temperature -10 to +40°C-10 to +40°C
Shielding gas
max pressure Gases for MIG/MAG welding 5 bar Gases for MIG/MAG welding 5 bar
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Feed L304Feed L302
Coolant
max pressure - -50% water / 50% glycol 5 bar
Maximum permissible load at
60% duty cycle
100% duty cycle 365 A
280 A 365 A 280 A
Enclosure class
basic version
with sealed bobbin holder*
with MarathonPact
IP2X
IP23
IP23
IP2X
IP23
IP23
* Accessories, see page 21.
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.
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.
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.
5 INSTALLATION
The installation must be executed by a professional.
CAUTION
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
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5.1 Lifting instructions
Order number for lifting eyelet can be found on page 21.
Note! If another mounting device is used, this should be insulated from the wire feed
unit.
6OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
A
H 0935
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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.
NOTE: When moving the equipment use intended handle. Never pull on the gun.
6.1 Connections and control devices
Connecting control cable
When connecting the control cable, it is
important to secure the cable with the
load-removing grommet.
Ensure that the cover is properly screwed
into place.
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Feed L302
1Knob for setting wire feed speed 4Connection for welding gun
2Knob for setting burnback time 5Connection for welding current from power
source, (OKC)
3Switch for 2-stroke / 4-stroke 6Connection for shielding gas
7Connection for control cable from power
source
Feed L304
1Knob for setting wire feed
speed 7Connection RED for cooling water from welding gun
2Switch for activation of 2/4 stroke, spot
welding, cold wire feed or gas purging 8Connection BLUE, for cooling water to welding gun
3Knob for setting spot welding time 9Connection for welding current from power
source, (OKC)
4Knob for setting burnback time 10 Connection for shielding gas
5Switch for creep start OFF / ON 11 Connection for control cable from power
source
6Connection for welding gun
NOTE! Cooling water connections only available on certain models.
10
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6.2 Explanation of function
Wire feed speed
This sets the required feed speed of the filler wire in m/minute.
2stroke
With 2-stroke, the gas flow starts followed by the wire feed when the trigger switch is
pressed in. The welding process is concluded when the trigger switch is released,
the wire feed stops and the gas stops flowing.
4stroke
With 4 stroke, the gas flow starts when the trigger switch is pressed in and the wire
feed starts when it is released. The welding process continues until the switch is
pressed in again, the wire feed stops and when the switch is released the gas stops
flowing.
Spot welding
Spot welding is used when you want to weld on short, repeated occasions with a
pre-set time.
When the trigger switch is pressed in, the gas flow starts for a period of time
governed by the printed circuit board. After this the welding process starts for the set
time. When the welding process is complete, the gas flow stops.
Cold wire feed
Cold wire feed is used to feed wire without welding voltage and gas flow.
Activation of cold wire feed: press in the trigger switch and the wire feed starts.
Gas purging
Gas purging is used to measure that 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.
Activation of gas purging: press in the trigger switch and gas purging starts.
Burnback time
Burnback time is a delay between the time when the wire brakes until the time when
the power source switches off the welding voltage. Too short burnback time results
in a long wire stickout after completion of welding, with a risk of the wire being
caught in the weld pool. Too long a burnback time results in a shorter stickout, with
increased risk of the arc striking back to the contact tip.
Creep start
Creep start means that the wire is fed at 50% lower speed until it comes into
electrical contact with the workpiece, at which point the speed increases to the set
speed.
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6.3 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).
6.4 Replacing and inserting wire
WARNING
Risk of crushing! Do not use safety gloves when replacing wire, feed rollers
and wire bobbins.
SOpen the side panel.
SDisconnect the pressure sensor by folding it backwards, the pressure arm is
folded up.
SStraighten out 10-20 cm of the new wire. 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.
SFold down the pressure arm and secure it to the pressure sensor.
SClose the side pannel.
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6.5 Changing feed roller Feed L302
SOpen the side panel.
SDisconnect the pressure sensor (1) by folding it
backwards.
SDisconnect and remove the Allen screw (2) and the
washer.
SPull out the feed roller (3).
During installation, repeat the above in the reverse
order.
Choice of track in the feed roller
Turn the feed roller with the dimensioning mark for the
required track towards you.
6.6 Changing feed roller Feed L304
SOpen the side panel.
SDisconnect the pressure sensor (1) by folding it
backwards.
SDisconnect the feed rollers (2) by unscrewing the
nuts (3) and pulling out the rollers.
During installation, repeat the above in the reverse
order.
Choice of track in the feed roller
Turn the feed roller with the dimensioning mark for the
required track towards you.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION
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 SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Feed L302 / Feed L304 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 pro-
duct 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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Edition 110203
Diagram
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Feed L302

Edition 110203
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Feed L304

Feed L302, Feed L304
Edition 110203
Ordering number
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Ordering no. Denomination Type
0459 495 782 Wire feed unit OrigotFeed L302, M08
0459 495 882 Wire feed unit OrigotFeed L304, M09
0459 495 892 Wire feed unit OrigotFeed L304, M09 with water
cooling
0459 508 990 Spare parts list

Feed L302
R0459 508/E110203/P24
Wear parts
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Item Ordering no. Denomination Notes
HM1 0455 889 001* Insert tube For Fe, Ss & cored wire
0455 894 001* Insert tube For Al wire
HM2 0455 886 001* Outlet nozzle For Fe, Ss & cored wire
0455 885 001* Outlet nozzle For Al wire
HM3 0455 898 001
0215 201 202 Screw O-ring (M5x12)
HM4 0455 881 001 Cover plate
HM5 Screw M4x12
HM6 0193 104 002 Washer Ø16/5x1
HM7 0367 556 001 Feed roller For Fe, Ss & cored wire, Ø 0.6 - 0.8 mm, V groove
0367 556 002 Feed roller For Fe, Ss & cored wire, Ø 0.8 - 1.0 mm, V groove
0367 556 003 Feed roller For Fe, SS & cored wire Ø 1.0 - 1.2 mm, V groove
0367 556 004 Feed roller For Al wire, Ø 1.0 - 1.2 mm, U groove
HM8 0466 074 001 Insert tube
HM9 0455 906 001 Spacer sleeve Included in item HM100
HM10 0455 907 001 Pressure roller Flat, Included in item HM100
HM11 Nut M8, Included in item HM100
HM12 0469 835 001 Pressure arm Included in item HM100
HM13 0456 088 001 Shaft Included in item HM100
HM14 0455 896 001 Spring
HM15 Nut M10
HM16 0458 748 002 Insulating washer
HM17 0458 748 001 Insulating bushing
HM18 0156 602 001
0332 318 001 Inlet nozzle Inlet nozzle For Fe, Ss, Al & Cored wire, Ø 2 mm plastic for 0.6-1.6 mm For Fe, Ss & Cored wire, Ø 2.4 mm steel for 1.2-2.0 mm
HM19 0191 496 114 Woodruff wedge
* Insert tube 0455 889 001 and outlet nozzle 0455 886 001 must be used together.
Insert tube 0455 894 001 and outlet nozzle 0455 885 001 must be used together.
PARTS SET
Item Ordering no. Denomination Notes
HM100 0367 529 001 Pressure arm compl. Includes item HM9, HM10, HM11, HM12 and HM13
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 L302
R0459 508/E110203/P24
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Feed L304
R0459 508/E110203/P24
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HD = Heavy Duty
Item Ordering no. Denomination Notes
HN1 0455 072 002
0456 615 001 Intermediate nozzle Intermediate nozzle For Fe, Ss & cored wire For Al Wire
HN2 0469 837 880
0469 837 881 Outlet nozzle Outlet nozzle For Fe, Ss & cored wire, Ø 2.0 mm steel for 0.6-1.6 mm For Al wire, Ø 2.0 mm plastic for 0.8-1.6 mm
HN3 0191 496 114 Woodruff wedge
HN4 0459 440 001 Motor gear euro
HN5 Washer Ø 16/5x1
HN6 Screw M4x12
HN7 Screw M6x12
HN8 Washer Ø 12/6.4x1.5
HN9 0469 838 001 Cover
HN10 0458 722 880 Axle and Nut
HN11 0369 557 001 Feed roller For Fe, Ss & cored wire, Ø 0.6 & 0.8 mm, V groove
0369 557 002 Feed roller For Fe, Ss & cored wire, Ø 0.8 & 1.0 mm, V groove
0369 557 003 Feed roller For Fe, Ss & cored wire, Ø 1.0 & 1.2 mm, V groove
0369 557 004 Feed roller For Cored wire, Ø 1.0 & 1.2 mm, V-Knurled groove
0369 557 013 Feed roller For Cored wire, Ø 1.4 & 1.6 mm, V-Knurled groove
0369 557 011 Feed roller For Al wire, Ø 0.8 & 0.9 mm, U groove
0369 557 006 Feed roller For Al wire, Ø 1.0 & 1.2 mm, U groove
HN12 0459 441 880 Gear adapter
HN13 0455 049 001 Inlet nozzle
HN14 0455 906 001 Spacer sleeve
HN15 0455 907 001 Pressure roller Flat
HN16 0215 702 708 Locking washer
HN17 0459 518 001 Axel pressure roll
HN18 Nut M10
HN19 0458 748 002 Insulating washer
HN20 0458 748 001 Insulating bushing
HN21 0156 602 001
0332 318 001 Inlet nozzle Inlet nozzle (HD)For Fe, Ss, Al & Cored wire, Ø 2 mm plastic for 0.6-1.6 mm For Fe, Ss & Cored wire, Ø 2.4 mm steel for 1.2-2.0 mm
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 L304
R0459 508/E110203/P24
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