ESAB Aristo Origo Feed 3004 Bedienungsanleitung

Valid for serial no. 745-xxx-xxxx, 910-xxx-xxxx0444 408 101 GB 20120621

Aristo Origo™

Feed 3004

Feed 4804

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

2.1 Equipment 6................................................................

2.2 Control panel 6.............................................................

3 TECHNICAL DATA 7.................................................

4 INSTALLATION 8....................................................

4.1 Lifting instructions 8.........................................................

5 OPERATION 9.......................................................

5.1 Connections and control devices 10............................................

5.2 Water connection 11..........................................................

5.3 Wire feed pressure 11........................................................

5.4 Replacing and inserting Feed 3004 wire 11......................................

5.5 Replacing and inserting Feed 4804 wire 12......................................

5.6 Changing feed rollers on Feed 3004 12..........................................

5.7 Changing feed rollers on Feed 4804 12..........................................

6 MAINTENANCE 13....................................................

6.1 Inspection and cleaning 13....................................................

7 ORDERING SPARE PARTS 13.........................................

DIAGRAM 14............................................................

ORDER NUMBER 16.....................................................

WEAR PARTS 18........................................................

ACCESSORIES 22.......................................................

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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.

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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 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!

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.

CAUTION

This product is solely intended for arc welding.

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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.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

The wire feed units Feed 3004 / Feed 4804 with control panel U6, MA23 or MA24

are intended for MIG/MAG welding together with 400A, 500A and 600A CAN

welding power sources.

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 MarathonPac, or on wire bobbin

(standard Ø 300 mm, accessory Ø 440 mm).

The wire feed unit can be installed either on the power source trolley, 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 22.

2.1 Equipment

The wire feed unit is supplied with:

instruction manual for the wire feed unit

instruction manual in English for the control panel

Instruction manuals in other languages can be downloaded from the website,

www.esab.com.

decal with recommended wear parts.

2.2 Control panel

The wire feed unit is supplied with one of the following control panels:

Empty panel for use with double wire feed units or with

use of control box U82.

Knobs for setting the voltage and the wire feed speed /

current. Other parameters are controlled by

pushbuttons, with text in the display panel.

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MA23 Knobs for setting the voltage and the wire feed speed /

current. Other settings with push buttons.

MA24 Knobs for setting the voltage / QSetand the wire feed

speed / current. Other settings with push buttons.

See the separate instruction manual for a detailed description of the control panels.

3 TECHNICAL DATA

Feed 3004 Feed 4804

Mains voltage 42 V 50-60 Hz 42 V 50-60 Hz

Power requirement 336 VA 378 VA

Motor current Imax 8 A 9 A

Wire feed speed 0.8 - 25.0 m/min 0.8 - 25.0 m/min

Gun connection EURO EURO

Max. diameter wire bobbin 300 mm (*440 mm) 300 mm (*440 mm)

Wire dimension

Cored wire

0.8 - 1.6 mm

1.0 & 1.6 mm

0.9 - 1.6 mm

0.8 - 2.4 mm

1.0 & 2.4 mm

0.9 - 2.4 mm

Weight 15 kg 19 kg

Dimensions (l x w x h) 690 x 275 x 420 mm 690 x 275 x 420 mm

Operating temperature -10 to +40°C-10 to +40°C

Shielding gas

max pressure

All types intended for

MIG/MAG welding

0.5 MPa ( 5 bar)

All types intended for

MIG/MAG welding

0.5 MPa ( 5 bar)

Type of cooling

max pressure

50 % water /

50 % mono-ethylene glycol

0.5 MPa ( 5 bar)

50 % water /

50 % mono-ethylene glycol

0.5 MPa ( 5 bar)

Maximum permissible load at

60% duty cycle

100% duty cycle

630 A

500 A

630 A

500 A

Enclosure class IP23 IP23

* Accessories, see page 22.

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.

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4 INSTALLATION

The installation must be carried out by a professional.

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

Order number for lifting eyelet can be found on page 22.

NOTE! If another mounting device is used, this must be electrically 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!

NOTE: When moving the equipment use intended handle. Never pull on the gun.

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.

5.1 Connections and control devices

1Control panel,

(see separate instruction manual)

6Connection for welding current from power

source, (OKC)

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! Display (digital instrument) and coolant connections only available on certain models.

* ELP = ESAB Logic Pump, see point 5.2.

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