ESAB Origo M 12 Feed 304 User manual

GB
Valid for serial no. 620-xxx-xxxx, 917-xxx-xxxx0459 161 101 GB 20120621
Origo™ M12
Feed 304
Feed 484
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 5...................................................
2.1 Equipment 6................................................................
3 TECHNICAL DATA 6.................................................
4 INSTALLATION 7....................................................
4.1 Lifting instructions 7.........................................................
5 OPERATION 8.......................................................
5.1 Connections and control devices 9............................................
5.2 Water connection 9..........................................................
5.3 Starting procedure 9.........................................................
5.4 Function explanations 10......................................................
5.5 Wire feed pressure 11........................................................
5.6 Changing / loading wire Feed 304 11............................................
5.7 Changing / loading wire Feed 484 11............................................
5.8 Chaning feed rollers on Feed 304 12............................................
5.9 Changing feed rollers on Feed 484 12...........................................
6 MAINTENANCE 13....................................................
6.1 Inspection and cleaning 13....................................................
7 ORDERING SPARE PARTS 13.........................................
DIAGRAM 14............................................................
ORDER NUMBER 19.....................................................
WEAR PARTS 20........................................................
ACCESSORIES 25.......................................................

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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:
its operation
location of emergency stops
its function
relevant safety precautions
welding and cutting
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
3. The workplace must:
be suitable for the purpose
be free from drafts
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 extinquishing equipment must be clearly marked and close at hand.
Lubrication and maintenance must not be carried out on the equipment during operation.
ESAB can provide you with all necessary welding protection and accessories.
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 electromagnetic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
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CAUTION
This product is solely intended for arc welding.
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
Install and earth the unit in accordance with applicable standards.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
Insulate yourself from earth and the workpiece.
Ensure your working stance is safe.
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.
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.
FIRE HAZARD
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
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.
2 INTRODUCTION
The Feed 304 and Feed 484 wire feed units with control
panel M12 are intended for MIG/MAG-
welding together with stepped welding power sources.
They come in different variants, see the spare parts list on
page 19.
The wire feed units are sealed and 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).
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The wire feed unit 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 25.
2.1 Equipment
The Feed 304 wire feed unit is supplied with:
Instruction manual
Stickers with recommended wear parts.
The Feed 484 wire feed unit is supplied with:
Spacer (4)
Hex key wrench (4 mm)
Instruction manual
Stickers with recommended wear parts.
3 TECHNICAL DATA
Feed 304 Feed 484
Power supply 42 V 50 - 60 Hz 42 V 50 - 60 Hz
Power requirement 336 VA 378 VA
Motor current Imax 8 A 9 A
Settings data
Wire feed speed
Burnback time
Creep start
2/4 stroke
1.9-25.0 m/min
0-0.5 s
OFF or ON
2 stroke or 4 stroke
1.9-25.0 m/min
0-0.5 s
OFF or ON
2 stroke or 4 stroke
Welding gun connection EURO EURO
Max. diameter wire bobbin 300 mm (*440mm) 300 mm (*440mm)
Wire dimension 0.6-1.6 mm 0.6-2.4 mm
Weight
basic version
with sealed bobbin holder
11.5 kg
15 kg
14.5 kg
19 kg
Dimensions (l x w x h)
basic version
with sealed bobbin holder
380 x 275 x 400 mm
690 x 275 x 420 mm
380 x 275 x 400 mm
690 x 275 x 420 mm
Shielding gas
max pressure
All types intended for
MIG/MAG welding
5 bar
All types intended for
MIG/MAG welding
5 bar
Coolant
max pressure
50% water / 50% glycol
5 bar
50% water / 50% glycol
5 bar
Permissible load at
60% duty cycle 630 A 630 A
Enclosure class
with wire bobin *440mm
IP23
IP2X
IP23
IP2X
* Accessory, see page 25.
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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. Equipment marked IP23 is designed for indoor and outdoor use.
Equipment marked IP2X is designed for indoor use.
4 INSTALLATION
The installation must be carried out 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
4.1 Lifting instructions
Ordering number for the lifting eye can be found on page 25.
Note! If another mounting device is used, this should be insulated from the wire feed
unit.
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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
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
Risk of crushing when replacing the wire bobbin!
Do not use safety gloves when inserting the welding wire between the feed rollers.
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.
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5.1 Connections and control devices
1Knob for setting burnback time 8Connection for welding gun
2Switch for creep start OFF / ON 9Connection for welding current from power
source, (OKC)
3Knob for setting wire feed speed 10 Connection for control cable from power
source
4Switch for 2-stroke / 4-stroke 11 Connection RED for cooling water to
power source (cooling unit)
5Connection for remote control unit 12 Connection BLUE for cooling water from
power source (cooling unit)
6Connection BLUE, with ELP* for cooling
water to welding gun
13 Connection for shielding gas
7Connection RED for cooling water from
welding gun
NOTE! Cooling water connections only available on certain models.
* ELP = ESAB Logic Pump, see point 5.2.
5.2 Water connection
When connecting a water-cooled welding gun, the power source's main power
supply switch must be in the Off position and the cooling unit switch must be in
position “ELP/0”.
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 Starting procedure
When the wire feed starts, the power source generates welding voltage.
If there is no welding current flow within three seconds, the power source switches the
welding voltage off. The wire feed continues until the welding gun's switch is switched
off.
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5.4 Function explanations
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 solidifying 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 low speed until it comes into electrical
contact with the workpiece and then the speed increases to the set speed.
2 stroke
With 2 stroke, the gas flow and wire feed start when the trigger switch is pressed in
and end when it is released.
4 stroke
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.
Wire feed speed
This sets the required feed speed of the filler wire in m/minute.
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