ESAB OrigoFeed 30-4 Bedienungsanleitung

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

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

* 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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