ESAB Aristo Series User manual

GB
Valid for serial no. 613-xxx-xxxx0459 813 101 GB 110308
Aristo®/ Origo™
Feed L3004
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Control panel 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Lifting instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Connections and control devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Water connection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Wire feed pressure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Replacing and inserting wire 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Changing feed rollers 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Inspection and cleaning 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING SPARE PARTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE-695 81 Laxå, Sweden, declares that Wire feed unit Feed L3004
from serial number 613 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
2 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:
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.
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.
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for arc welding.
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.
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3 INTRODUCTION
The wire feed units Feed L3004 with control panels U6, MA23 or MA23A are
intended for MIG/MAG welding with the Mig L3000i power source.
They come in different variants, see page 14.
The wire feed units contain four-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 trolley for the power source, suspended
above the workplace, on a counter balance device or on the floor with or without
wheel set.
ESAB's accessories for the product can be found on page 18.
3.1 Equipment
The wire feed unit is supplied with:
Sinstruction manual for the wire feed unit
Sinstruction manual in english for the control panel
Sdecal with recommended wear parts.
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
3.2 Control panel
The units are supplied with one of the following control panels:
U6
With knobs for setting the voltage and wire feed speed /
current. Other settings by pushbuttons, with text
indication on the display panel.
MA23 With knobs for setting the voltage and wire feed speed /
current. Other settings by pushbuttons.
MA23A With knobs for setting the voltage / QSettand wire feed
speed / current. Other settings by pushbuttons.
Detailed descriptions of the control panels can be found in separate Instruction
manual.
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4 TECHNICAL DATA
Feed L3004
Power supply 42 V 50-60 Hz
Power requirement 180 VA
Motor current Imax 3.5 A
Wire feed speed 0.8 - 25.0 m/min
Gun connection EURO
Max. diameter wire bobbin 300 mm (*440 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
Weight 15 kg
Dimensions (l x w x h) 690 x 275 x 420 mm
Operating temperature -10 to +40°C
Shielding gas
max pressure
All types intended for MIG/MAG welding
0.5 MPa (5 bar)
Type of cooling
max pressure
50% water / 50% mono-ethylen glycol
0.5 MPa (5 bar)
Maximum permissible load at
60% duty cycle 365 A
Enclosure class
with sealed bobbin holder
without sealed bobbin holder
IP23
IP2X
* Accessories, see page 18.
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.
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.
5 INSTALLATION
The installation must be executed by a professional.
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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
Order number for lifting eyelet can be found on page 18.
Note! If another mounting device is used, this must be electrically 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!
NOTE: When moving the equipment use intended handle. Never pull on the gun.
A
H 0935
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.
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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.
WARNING
Risk of crushing when replacing the wire bobbin!
Do not use safety gloves when inserting the welding wire between the feed rollers.
6.1 Connections and control devices
1Control panel,
(see separate instruction manual)
6Connection for welding current from power
source, (OKC)
2a
2b
Connection for remote control unit
Connection for U82
7Connection for control cable from power
source or cooling unit
3Connection BLUE, with ELP* for coolant to
the welding gun
8Connection RED, for coolant to cooling
unit
4Connection RED, for coolant from welding
gun
9Connection for shielding gas
5Connection for welding gun 10 Connection BLUE, for coolant from cooling
unit
Note! Coolant connections only available on certain models.
* ELP = ESAB Logic Pump, see point 6.2.
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6.2 Water connection
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.
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).
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6.4 Replacing and inserting 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
outlet nozzle and the wire guide.
SSecure the pressure sensor.
SClose the side panel.
6.5 Changing feed rollers
SOpen the side panel.
SDisconnect the pressure sensor (1) by folding it
backwards, the pressure rollers slide up.
SDisconnect the pressure rollers (2) by turning the
axle (3) 1/4 turn clockwise and pulling out the axle.
The pressure rollers disconnect.
SDisconnect the feed rollers (4) by unscrewing the
nuts (5) and pulling out the rollers.
GB