ESAB Origo Feed 30 User manual

Valid for serial no. 6380349 301 132 070426
Feed 30
Feed 30w
Origo



Instruction manual

ENGLISH
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TOCe
1 SAFE Y 4...........................................................
2 IN RODUC ION 6...................................................
2.1 Equipment 6................................................................
3 ECHNICALDA A 6.................................................
4 INS ALLA ION 7....................................................
5 OPERA ION 8.......................................................
5.1 Connectionandcontroldevices .............................................
5.2 Functionexplanation 10.......................................................
5.3 Wirefeedpressure 11........................................................
5.4 Changing/loadingwire 11....................................................
5.5 Flux--coredwireswelding 11..................................................
5.6 Aluminiumwirewelding 12....................................................
6 MAIN ENANCE 12....................................................
6.1 Inspectionandcleaning 12....................................................
7 FAUL RACING 13...................................................
8 ORDERINGOFSPAREPAR S 13......................................
DIAGRAM 14............................................................
WEARCOMPONEN S 16.................................................
ACCESSORIES 18.......................................................

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document

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DECLARA ION OF CONFORMI Y
ESAB Welding Equipment AB, S--695 1 Laxå, Sweden, declares that Wire feed unit OrigoTM Feed
30w from serial number 63 onwards, conforms to standard EN 60974--5, in accordance with the re-
quirements of directive (73/23/EEC) and appendix (93/6 /EEC) and standard EN 60974--10 in accord-
ance with the requirements of directive ( 9/336/EEC) and appendix (93/6 /EEC).
--------------------------------------------------------------------------------------------------------------------------------------
Kent Eimbrodt
Global Director Equipment and Automation
ESAB AB
695 1 LAXÅ
SWEDEN Tel: + 46 5 4 1000 Fax: + 46 5 4 411924
Laxå 2007--04--23
1 SAFE Y
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 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 draughts
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.
GB

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WARNING
READ AND UNDERS AND HE INS RUC ION MANUAL BEFORE INS ALLING OR OPERA ING.
ARC WELDING AND CU ING CAN BE INJURIOUS O YOURSELF AND O HERS. AKE PRECAU-
IONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFE Y PRAC ICES WHICH SHOULD BE
BASED ON MANUFAC URERS’ HAZARD DA A.
ELEC RIC 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.
MALFUNC ION -- Call for expert assistance in the event of malfunction.
PRO EC YOURSELF AND O HERS!
WARNING!
Read and understand the instruction manual
before installing or operating.
Do not use the power source for thawing frozen pipes.
WARNING!
his product is solely intended for arc welding.
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!
GB

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2 IN RODUC ION
The OrigoTM Feed 30, Feed 30w wire feed unit is intended for MIG/MAG welding
together with step controlled welding power sources, with solid steel, stainless steel,
aluminium wire and flux--cored wires.
ESAB’s accessories for the product can be found on page 18.
2.1 Equipment
The wire feed unit is supplied with:
SMarathon PAC bracket
SReel adaptors
SInstruction manual
3 ECHNICAL DA A
Origo M Feed 30, Feed 30w
Power supply 42V, 1∼
∼∼
∼50/60 Hz
Power requirement 420 VA
Welding current @60% duty cycle 500 A
Settings data
Wire feed speed 1,5--25 m/min
Burnback time 0,0--0,7 sec
Spot welding time 0,2--5,0 sec
Welding gun connection EURO
Wire dimension range 0, --1,6 (Fe,SS);
1,0--1,6 ( Al);
1,0--1,6 (FCW)
Shielding gas All types for MIG/MAG -- max 5 bar
Max diam. / weight of wire bobin 300 mm / 1 kg
Dimensions lxwxh 700x255x420
Weight 14, kg (Feed 30)
with cooling liquid system 15,0 kg (Feed 30w)
Operating temperature --10 to +40oC
Enclosure class IP 23 (wire bobbin -- IP 2X)
Application classification
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.
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.
GB

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Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
4 INS ALLA ION
The installation must be executed by a professional.
WARNING!
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 .
a. Connect the wire feeder with the welding rectifier. Temporary keep the
current cable disconnected.
b. Connect the wire feeder to gas regulator by means of gas hose.
Attention: Use gas heater only for pure CO2.
c. Connect a welding torch. If it is liquid--cooled, connect its hoses to
appropriate connectors, turning aside an arm of the pump switch (ELP).
Hoses and appropriate connectors are marked in red and blue.
d. Install the bobbin with electrode wire.
e. Input the wire between the rolls and further to the torch connector, at least
for 20cm inside. Type of the rolls should match the side and the type of used
electrode wire. Take in account, that for convenience, marking on the side of
the rolls corresponds the size of the groove on the opposite side.
f. Close the rolls and adjust an optimal radial pressure by means of knobs.
Setting recommendation is placed on the inner side of the cover.
g. Set braking force of the wire bobbin by means the bolt placed inside the
bobbin holder.
Attention! Keep attention during replacement of the bobbin. Don’t use gloves
while installing the bobbin and inputting the wire into the torch.
h. Set mode selector (2) in position (inching). Press the torch switch and let
the wire go through the torch up to its appearance out of the torch.
i. Set mode selector (2) in position (gas purge). Press the torch switch and
adjust the gas flow.
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j. Connect current cables. Set voltage in the welding rectifier. Switch the
rectifier on. The machine is ready for welding.
The wire feeder is factory -- equipped with insulating feet that allow to put the feeder
on top of power source or directly on the ground.
Feeder can optionally be equipped with accessory wheel set (see page 1 ).
5 OPERA ION
General safety regulations for the handling of 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.
To prevent the reel 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!
When moving the equipment use intended handle. NOTE Never pull on the gun.
5.1 Connection and control devices
1Power ON indicator 7Cooling liquid connectors with pump switch
(Feed 30w)
2Wire feeder speed knob 8Torch connector
3Mode selector (see table below) 9Control cable terminal
4Burn--back time knob 10 Gas inlet
5Spot welding time knob 11 Current terminal (from power source)
6Creep speed knob 12 Cooling liquid connectors (Feed 30w)
Symbols explanation:
wire feeding / inching gas purge
2--stroke burn--back
4--stroke creep speed
spot welding / spot
welding time
GB

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GB

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5.2 Function explanation
5.2.1 2--stroke mode
Set the 2--stroke mode by means of the knob (3). Set required wire speed by means
of the knob (2). The creep speed option can be set by means of the knob (6). If
creep speed is chosen the wire speed before the actual start of welding is reduced
by two. The creep speed is not recommended for speed setting close to the minimal.
The burn--back time should set by means of the knob (4). This setting should be
chosen experimentally, starting from the lowest values.
Pressing the torch switch opens the gas valve and then switching the power source
on and feeding the wire. Releasing the torch switch stops the wire feeding. After
delay proportional to burn--back time setting the power is switched off. Eventually
the gas is cut off too.
5.2.2 4--stroke mode
Set the 4--stroke mode by means of the knob (3). Other settings as for 2--stroke
mode.
This mode could be described as follows:
1. switch pressed -- gas starts to flow,
2. switch released -- power source is switched and wire is fed, the actual start of
welding,
3. switched pressed again -- stop of welding, gas remains flowing,
4. switch released -- cut off the gas.
5.2.3 Burnback time
Burnback time is a delay between the time when the wire starts to brake 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.
5.2.4 Creep start
Creep start means that the wire is fed at reduced speed within 1 sec after welding
torch trigger is pressed, and then the speed increases to the set speed.
5.2.5 Inching and gas purge modes
Set the required mode by means of the knob (3). Inching or gas purge is started by
means of the torch switch.
5.2.6 Wire feed speed
This sets the required feed speed of the filler wire in m/minute.
5.2.7 Spot welding
Set the spot welding mode by means of the knob (3). Set the required time of the
spot welding by means of the knob (5). Other settings as for previously described
modes. The control sequence is similar to 2--stroke mode sequence. The difference
is that the welding is stopped automatically after particular time. The torch switch
must be pressed up to the end of welding. Releasing the torch switch enables the
next spot welding cycle.
GB

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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 insolated 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 Changing / loading wire
SOpen the side panel.
SDisconnect the pressure sensor by folding it backwards, the pressure rollers
slide up.
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 Flux -- cored wires welding
A set of special feeding rolls (2 pcs.) for 1,0; 1,2 mm or 1,6 mm wire diameter should
be used for flux--cored wires.
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5.6 Aluminium wire welding
In case of aluminium wires welding, appropriate equipment is to be used.
1. Replace the set of 4 feeding rolls with aluminium intended ones for appropriate
wire diameter.
2. Replace steel nozzle in the torch connector with plastic nozzle for aluminium
wire.
3. Apply the torch armed for aluminium wire of particular wire diameter.
4. Release the roll closer to the torch connector and input the wire guide as close to
roll as possible. Tighten the torch and close the roll.
Attention! Exclusively inert gases can be used for aluminium welding thus
appropriate pressure reductor/regulator should be applied.
6 MAIN ENANCE
Regular maintenance is important for safe, reliable operation.
Note
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any ork 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.
he 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 anticlockwise to increase the braking torque. NB: Turn both
springs through the same amount.
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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 FAUL RACING
Try these recommended checks and inspections before sending for an authorised service technican.
ype of fault Actions
No arc SCheck that the mains power supply switch is turned on.
SCheck that the welding current supply and return cables are
correctly connected.
SCheck the main power supply fuses
Welding current is interrupted
during welding
SCheck whether the thermal overload trip has operated
(indicated by the orange lamp on the power source).
SCheck the main power supply fuses.
Poor welding performance SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct welding wires are being used.
SCheck the main power supply fuses.
8 ORDERING OF SPARE PAR S
Origo M Feed 30, Feed 30w is designed and tested in accordance with the international
and European standard IEC/EN 60974--5. 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 may be ordered through your nearest ESAB dealer, see the last page of
this publication.
GB

Diagram
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dOF30
Origo M Feed 30w

Origo
T
M
Feed 30, Feed 30w
Edition 070426
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oOF302
Valid for serial no. 638--XXX--XXXX
Ordering numbers
0349 304 39 OrigoTM Feed 30w 42V 1∼
∼∼
∼50/60Hz
0349 304 40 OrigoTM Feed 30 42V 1∼
∼∼
∼50/60Hz

Origo
T
M
Feed 30, Feed 30w
Edition070426
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wOF302
Wear components
(W. F. Mechanism 0349 484 083)
Item Denomination Ordering no. Notes
AFeed / pressure roller
0349 4 4 335
0349 4 4 339
0349 4 4 342
0349 4 4 341
0349 4 4 33
0349 4 4 340
Ø 0. --1.0mm Fe, Ss, cored wire, V--groove.
Ø 1.2--1.6mm Fe, Ss, cored wire, V--groove.
Ø 1.0--1.2mm cored wire, V--groove, knurled.
Ø 1.2--1.6mm cored wire, V--groove, knurled.
Ø 1.0--1.2mm Al, U--groove.
Ø 1.2--1.6mm Al, U--groove.
BGear adapter 0349 4 4 355
CDrive gear 0349 4 4 356
DPressure roller 0349 4 4 346 Fe, Ss, cored wire, Al
EInlet nozzle 0349 30 000 Fe, Ss, cored wire, Al
FIntermediate nozzle 0349 4 4 344 Fe, Ss, cored wire, Al
GOutlet nozzle 0349 304 793
0349 305 0 9 Ø 2.0 steel for Fe, Ss, cored wire Ø 2.0 plastic for Al
HLiner 0349 496 716 Fe, Ss, cored wire, Al
The rollers are marked with wire dimension in mm, some are also marked with inch.
Welding with aluminium wires.
In order to weld with aluminium wires, proper rollers, nozzles and liners for
aluminium wires MUST be used. It is recommended to use 3m long welding gun for
aluminium wires, equipped with appropriate wear parts.

Origo
T
M
Feed 30, Feed 30w
Edition070426
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wOF302

Origo
T
M
Feed 30, Feed 30w
Edition 070426
Accessories
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aOF302
raction kit Ø 100 (wheels set) . . . . . . . . . . . 0349 493 925
raction kit Ø 120 (wheels set) . . . . . . . . . . . 0349 493 903

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]
www.esab.com
070514
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Tel: [phone]
Fax: [phone]
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Tel: [phone]
Fax: [phone]
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Tel: [phone]
Fax: [phone]
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Tel:[phone]
Fax:[phone]
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Fax:[phone]
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Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com