ESAB Origo M11 Feed 302 User manual

GB
Valid for serial no. 620--xxx--xxxx0459 206 101 GB 090325
OrigotM11
Feed 302
Instruction manual

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TOCe
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 6.........................................................
6 OPERATION 7.......................................................
6.1 Connections and control devices 8............................................
6.2 Water connection 8..........................................................
6.3 Function explanations 9......................................................
6.4 Wire feed pressure 10........................................................
6.5 Changing / loading wire 10....................................................
6.6 Changing feed roller 10.......................................................
7 MAINTENANCE 11....................................................
7.1 Inspection and cleaning 11....................................................
8 ORDERING SPARE PARTS 11..........................................
DIAGRAM 12............................................................
ORDERING NUMBER 13.................................................
WEAR PARTS 14........................................................
ACCESSORIES 16.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, declares that Wire feed unit Feed 302
from serial number 620 onwards, conforms to standard IEC/EN 60974--5, in accordance with the re-
quirements of directive (73/23/EEC) and appendix (93/68/EEC) and standard IEC/EN 60974--10 in
accordance with the requirements of directive (89/336/EEC) and appendix (93/68/EEC).
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Kent Eimbrodt
Global Director Equipment and Automation
ESAB AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2006--05--22
2SAFETY
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 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.
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.
Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.
ELECTRIC 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.
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.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
This 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!
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3 INTRODUCTION
The Feed 302 wire feed unit with control panel M11 is
intended for MIG/MAG--welding together with step
controlled welding power sources.
They come in different variants, see the spare parts list on
page 13.
The wire feed units are sealed and contain two--wheel
drive wire feed mechanisms as well as control electronics.
They can be used together with wire on ESAB’s
MarathonPact, or on wire bobbin (standard Ø 300 mm, accessory Ø 440 mm).
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 16.
3.1 Equipment
The Feed 302 wire feed unit is supplied with:
SInstruction manual
SStickers with recommended wear parts.
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
4 TECHNICAL DATA
Feed 302
Power supply 42 V 50 -- 60 Hz
Power requirement 150 VA
Motor current Imax 3.5 A
Settings data
Wire feed speed
Burnback time
Creep start
2/4 stroke
1.9--20.0 m/min
0--0.5 s
OFF or ON
2strokeor4stroke
Welding gun connection EURO
Max. diameter wire bobbin 300 mm (*440mm)
Wire dimension 0.6--1.2 mm
Weight 14.3 kg
Dimensions (l x w x h) 690 x 275 x 420 mm
Shielding gas
max pressure
All types intended for MIG/MAG welding
5 bar
Coolant
max pressure
50% water / 50% glycol
5 bar
Permissible load at
35% duty cycle 400 A
Enclosure class
with wire bobin *440mm
IP23
IP2X
* Accessory, see page 16.
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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 at a cer-
tain 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.
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
5.1 Lifting instructions
Ordering number for the lifting eye can be found on page 16.
Note! If another mounting device is used, this should be insulated from the wire feed
unit.
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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. 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!
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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6.1 Connections and control devices
1Knob for setting burnback time 7Connection for welding gun
2Switch for creep start OFF / ON 8Connection for welding current from power
source, (OKC)
3Knob for setting wire feed speed. 9Connection for control cable from power
source
4Switch for 2--stroke / 4--stroke 10 Connection RED for cooling water to po-
wer source (cooling unit)
5Connection BLUE, with ELP* for cooling
water to the welding gun 11 Connection BLUE for cooling water from power source (cooling unit)
6Connection RED for cooling water from
welding gun 12 Connection for shielding gas
NOTE! Cooling water connections only available on certain models.
* ELP = ESAB Logic Pump, see point 6.2.
6.2 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.
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6.3 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.
2stroke
With 2 stroke, the gas flow and wire feed start when the trigger switch is pressed in
and end when it is released.
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.
Wire feed speed
This sets the required feed speed of the filler wire in m/minute.
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6.4 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).
6.5 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.
6.6 Changing feed roller
SOpen the side panel.
SDisconnect the pressure sensor (1) by folding it
backwards, the pressure rollers slide up.
SCompletely undo the socket head cap screw
(2) in the centre.
SRemove the washer.
SCompletely undo the two outer socket head cap screws
(3).
SPull out the feed rollers (4).
During installation, repeat the above in the reverse order.
Choice of tracks in the feed roller
Turn the feed roller with the dimensioning mark for the required track towards you.
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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.
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
Feed 302 is designed and tested in accordance with the international and European
standards IEC/EN 60974--5 and 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 may be ordered through your nearest ESAB dealer, see the last page of
this publication.
GB

Diagram
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Feed 302
Edition 090325
Ordering number
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1.
OrigotFeed 302, M11 0459 116 781
OrigotFeed 302, M11 with water cooling 0459 116 791
Spare parts list 0459 206 990

Feed 302
R0459 206/E090325/P20
Wear parts
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Item Ordering no. Denomination Wire type Groove
type Wire dimensions Notes
HK1 0455 889 001* Insert tube Fe, Ss & cored
0455 894 001* Insert tube Al
HK2 0455 886 001* Outlet nozzle Fe, Ss & cored
0455 885 001* Outlet nozzle Al
HK3 0369 716 001 Feed roller geared
HK4 0369 557 001 Feed roller Fe, Ss & cored VØ0.6--0.8mm
0369 557 002 Feed roller Fe, Ss & cored VØ0.8--1.0mm
0369 557 003 Feed roller Fe, Ss & cored VØ 1.0/1.2 & 1.4/1.6 mm
0369 557 004 Feed roller Cored V--Knurled Ø1.0--1.2mm
0369 557 011 Feed roller Al UØ0.8--0.9mm
0369 557 006 Feed roller Al UØ1.0--1.2mm
HK5 0193 104 002 Washer
HK6 0455 898 001
0215 201 202 Screw O--ring (M5x12)
HK7 0455 881 001 Cover plate
HK8 Screw M4x12
HK9 Screw M3x16
HK10 0466 074 001 Insert tube
HK11 0369 728 001 Pressure roller Flat
0466 262 001 Pressure roller Knurled
HK12 0455 053 880 Geared adapter
HK13 Locking washer SGA D8
HK14 Holder
HK15 Shaft
HK16 0455 896 001 Spring
HK17 Nut M10
HK18 0458 748 002 Insulating washer
HK19 0458 748 001 Insulating bushing
HK20 0156 602 001
0332 318 001 Inlet nozzle Inlet nozzle Fe, Ss, Al & Cored Fe, Ss & Cored Ø 2 mm plastic for 0.6--1.6 mm Ø 2.4 mm steel for 1.2--2.0 mm
HK21 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
HK100 0469 833 880 Pressure arm complete Includes items HK11 (flat pressure roller), HK12, HK13, HK14 and HK15
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 302
R0459 206/E090325/P20
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R0459 206/E090325/P20
Feed 302
Accessories
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1Bobbin cover, plastic 18 kg Ø 300mm ...... 0458 674 880
1Bobbin cover, metal 18 kg Ø 300mm ....... 0459 431 880
1
2
Bobbin holder ...........................
Adapter for 5 kg bobbin ....................
0458 704 880
0455 410 001
1Adapter for 440 mm bobbin ................ 0459 233 880
1
2
Lifting eye ...............................
Quick connector MarathonPact...........
0458 706 880
F102 440 880

R0459 206/E090325/P20
Feed 302
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1
2
3
Turning piece ............................
Guide pin ................................
Quick connector MarathonPact...........
0458 703 880
0156 654 883
F102 440 880
1Wheel kit ................................ 0458 707 880
1Strain relief for welding gun .............. 0457 341 881
Strain relief bracket for connection set .... 0459 234 880
Push button for cold wire feed or gas purging 0459 465 880

R0459 206/E090325/P20
Feed 302
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Counter balance device ..................
(includes mast and counter balance)
0458 705 880
Connection set for 400 A power sources
1.7m ....................................
5m......................................
10m.....................................
15m.....................................
25m.....................................
35m.....................................
1.7m,water ..............................
5m,water................................
10m,water...............................
15m,water...............................
25m,water...............................
35m,water...............................
0469 836 880
0469 836 981
0469 836 881
0469 836 882
0469 836 883
0469 836 884
0469 836 885
0469 836 983
0469 836 886
0469 836 887
0469 836 888
0469 836 889
Connection set for 500 A power sources
1.7m ....................................
10m.....................................
15m.....................................
25m.....................................
35m.....................................
1.7m,water ..............................
10m,water...............................
15m,water...............................
25m,water...............................
35m,water...............................
0469 836 890
0469 836 891
0469 836 892
0469 836 893
0469 836 894
0469 836 895
0469 836 896
0469 836 897
0469 836 898
0469 836 899

R0459 206/E090325/P20
Feed 302
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Welding gun with EURO connection
Self cooled
Type Ordering no. Max welding current Wire dimensions
Hose length
3m Hose length 4.5 m CO2Mix Ar Fe Ss Cored Al
PSF 250 0368 100 882 0368 100 883 250A 60% 225A 60% 0.6 -- 1.0 0.6 -- 1.0 1.0 1.0
PSF 305 0458 401 880 0458 401 881 315A 60& 285A 60% 0.8 -- 1.2 0.8 -- 1.2 1.0 -- 1.2 1.0 -- 1.2
PSF 405 0458 401 882 0458 401 883 380A 60% 325A 60% 0.8 -- 1.6 0.8 -- 1.2 1.0 -- 1.6 1.0 -- 1.6
PSF 505 0458 401 884 0458 401 885 475A 60% 410A 60% 1.0 -- 2.4 1.0 -- 1.6 1.0 -- 2.4 1.2 -- 2.4
Water cooled
Type Ordering no. Max welding current Wire dimensions
Hose length
3m Hose length 4.5 m CO2Mix Ar Fe Ss Cored Al
PSF 410W 0458 400 882 0458 400 883 425A 100% 400A 100% 0.8 -- 1.6 0.8 -- 1.2 1.0 -- 1.6 1.0 -- 1.6
PSF 510W 0458 400 884 0458 400 885 500A 100% 440A 100% 1.0 -- 2.4 1.0 -- 1.6 1.0 -- 2.4 1.2 -- 2.4

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]
www.esab.com
081016
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]
DENMARK
Aktieselskabet ESAB
Herlev
Tel:[phone]
Fax:[phone]
FINLAND
ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]
GERMANY
ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]
ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]
HUNGARY
ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]
NORWAY
AS ESAB
Larvik
Tel:[phone]
Fax:[phone]
POLAND
ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]
PORTUGAL
ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]
ESAB international AB
Gothenburg
Tel:[phone]
Fax:[phone]
SWITZERLAND
ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]
BRAZIL
ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]
INDIA
ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]
JAPAN
ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: [phone]
Fax: [phone]
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel:[phone]
Fax: [phone]
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: [phone]
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: [phone]
RUSSIA
LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]
LLC ESAB
St Petersburg
Tel: [phone]
Fax: [phone]
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com