ESAB OrigoFeed 30-4 User manual

GB
Valid for serial no. 418--xxx--xxxx0459 508 001 GB 040507
OrigoFeed 30- 4
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 4...................................................
3.1 Equipment 4................................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 5....................................................
5.1 Lifting instructions 6.........................................................
6 OPERATION 6.......................................................
6.1 Connections and control devices 7............................................
6.2 Explanation of function 8.....................................................
6.3 Wire feed pressure 9........................................................
6.4 Replacing and inserting wire 9................................................
6.5 Changing feed roller OrigoFeed 30--4 9........................................
7 MAINTENANCE 10....................................................
7.1 Inspection and cleaning 10....................................................
8 ORDERING SPARE PARTS 10..........................................
DIAGRAM 11............................................................
ORDERING NUMBER 13.................................................
WEAR COMPONENTS 14.................................................
ACCESSORIES 16.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, SE--695 81 Laxå, Sweden, declares that Wire feed unit OrigoFeed
30--4 from serial number 418 onwards, conforms to standard IEC/EN 60974--5, in accordance with the
requirements 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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Henry Selenius
Managing Director
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2004--04--20
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.
WARNING!
Read and understand the instruction manual before installing
or operating.
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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 PRECAU-
TIONS 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.
Do not use the power source for thawing frozen pipes.
WARNING!
This product is solely intended for arc welding.
3 INTRODUCTION
The OrigoFeed 30--4 wire feed units are intended for MIG/MAG welding with the
OrigoMig 405 power source.
They come in different variants, see page 13.
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 16.
3.1 Equipment
The wire feed units are supplied with an instruction manual and stickers.
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4 TECHNICAL DATA
OrigoFeed 30--4
Power supply 42 V 50--60 Hz
Power requirement 336 VA
Motor current Imax 3.5 A
Settings data
Wire feed speed
Burnback time
Spot welding time
1.5--22.0 m/min
0--0.7 s
0.2--5 s
Gun connection EURO
Max. diameter wire bobbin 300 mm
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 13.2 kg
Dimensions (l x b x h) 569 x 259 x 355 mm
Shielding gas
max pressure
Gases for MIG/MAG welding
5 bar
Maximum permissible load at
60% duty cycle
100% duty cycle
365 A
280 A
Enclosure class
basic version
with sealed bobbin holder*
with MarathonPact
IP2X
IP23
IP23
* Accessories, see page 16.
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 at a cer-
tain load without overloading.
5 INSTALLATION
The installation must be executed by a professional.
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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 .
5.1 Lifting instructions
Order number for lifting eyelet can be found on page 16.
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!
WARNING!
Assure that the side panels are closed during operation.
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!
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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.
When moving the equipment use intended handle. NOTE! 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.
OrigoFeed 30--4
1Knob for setting wire feed
speed 6Connection for welding gun
2Switch for activation of 2/4 stroke, spot
welding, cold wire feed or gas purging 7Connection for welding current from power source, (OKC)
3Knob for setting spot welding time 8Connection for shielding gas
4Knob for setting burnback time 9Connection for control cable from power
source
5Switch for creep start OFF / ON
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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 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).
6.4 Replacing and inserting wire
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.
6.5 Changing feed roller OrigoFeed 30--4
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.
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7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Note!
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
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
OrigoFeed 30--4 is designed and tested in accordance with the international and Euro-
pean standards IEC/EN 60974--5 and EN 50199. 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.
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Edition 040507
Diagram
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OrigoFeed 30--4

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page

OrigoFeed 30- 4
Edition 040507
Ordering number
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Ordering no. Denomination Type
0459 495 882 Wire feed unit OrigoFeed 30--4
0459 508 990 Spare parts list OrigoFeed 30--2 / OrigoFeed 30--4

OrigoFeed 30- 4
Edition 040507
Wear components
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S= Standard, HD = Heavy Duty
Item Ordering no. Denomination Notes
HN1 0455 072 002
0456 615 001 Intermediate nozzle (S) Intermediate nozzle For Fe, Ss & cored wire For Al Wire
HN2 0469 837 880
0469 837 881 Outlet nozzle (S) 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 (S)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 & 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 (S) 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.

OrigoFeed 30- 4
Edition 040507
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Edition 040507
OrigoFeed 30- 4
Accessories
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1Bobbin cover, plastic Ø 300mm ........... 0458 674 880
1Adapter for 5 kg bobbin .................... 0455 410 001
Lifting eye ............................... 0458 706 880
1
2
Turning piece ............................
Quick connector MarathonPact...........
0458 703 880
F102 440 880
1Wheel kit ................................ 0458 707 880

Edition 040507
OrigoFeed 30- 4
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1Strain relief for welding gun .............. 0457 341 881
Strain relief bracket for connection set .... 0459 234 880
Counter balance device ...................
(includes mast and counter balance)
0458 705 880
Water kit................................. 0459 564 880
Connection set
Connection set 1.7 m ......................
Connection set 5 m ........................
Connection set 10 m .......................
0459 532 880
0459 532 881
0459 532 882

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]
www.esab.com
031021
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.
Prague
Tel: [phone]
Fax: [phone]
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
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.
Utrecht
Tel: [phone]
Fax: [phone]
NORWAY
AS ESAB
Larvik
Tel:[phone]
Fax:[phone]
POLAND
ESAB Sp.z.o.o
Warszaw
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.
Alcobendas (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]
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax: [phone]
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]
SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: [phone]
Fax: [phone]
UNITED ARAB EMIRATES
ESAB Middle East
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--CIS
ESAB Representative Office
Moscow
Tel:[phone]
Fax: [phone]
ESAB Representative Office
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