ESAB | Origo™Feed 304 M13u | Instruction manual | ESAB Origo™Feed 304 M13u User manual

ESAB Origo™Feed 304 M13u User manual
Origo™
Feed 304 M13u
Instruction manual
0461 284 131 US 20181228
Valid for: serial no. 623-xxx-xxxx
TABLE OF CONTENTS
1
USER RESPONSIBILITY ............................................................................
3
2
INTRODUCTION ..........................................................................................
4
3
TECHNICAL DATA ......................................................................................
5
4
INSTALLATION............................................................................................
6
4.1
Lifting instructions .................................................................................
6
OPERATION ................................................................................................
7
5.1
Connections and control devices .........................................................
9
5.2
Starting procedure .................................................................................
9
5.3
Function examples .................................................................................
9
5.4
Wire feed pressure .................................................................................
10
5.5
Changing/loading wire ...........................................................................
11
5.6
Changing the feed rollers ......................................................................
11
MAINTENANCE ...........................................................................................
12
6.1
Inspection and cleaning.........................................................................
12
ORDERING SPARE PARTS ........................................................................
DIAGRAM ............................................................................................................
ORDERING NUMBERS .......................................................................................
WEAR PARTS......................................................................................................
ACCESSORIES ...................................................................................................
14
15
17
18
21
5
6
7
Rights reserved to alter specifications without notice.
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© ESAB AB 2018
1 USER RESPONSIBILITY
1
USER RESPONSIBILITY
CAUTION!
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with
the principles of operation and safe practices for arc welding equipment, we urge you
to read our booklet, "Precautions and Safe Practices for Arc, Cutting and Gouging",
Form 52-529 . Do NOT permit untrained persons to install, operate, or maintain this
equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these
instructions, contact your supplier for further information. Be sure to read the Safety
Precautions before installing or operating this equipment.
This equipment will perform in conformity with the description thereof contained in this
manual and accompanying labels and/or insert when installed, operated, maintained and
repaired in accordance with the instruction provided. This equipment must be checked
periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that
are broken, missing, worn, distorted or contaminated should be replaced immediately. Should
such repair or replacement become necessary, the manufacturer recommends that a
telephone or written request for service advice be made to the Authorised Distributor from
whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of
the manufacturer. The user of this equipment shall have the sole responsibility for any
malfunction which results from improper use, faulty maintenance, damage, improper repair or
alteration by anyone other than the manufacturer or a service facility designated by the
manufacturer.
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2 INTRODUCTION
2
INTRODUCTION
The wire feeders are renamed:
The Feed 304 wire feed unit with control panel M13u is
intended for MIG/MAG-welding together with the infinitely
adjustable welding power sources MTS 3500i and 653
CC/CV.
The wire feed unit is sealed and contains four-wheel drive
wire feed mechanisms as well as control electronics.
It can be used together with wire on ESAB's
MarathonPac, or on wire bobbin (standard Ø 12 in.).
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.
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3 TECHNICAL DATA
3
TECHNICAL DATA
Feed 304
Power supply
42 V, 50-60 Hz
Power requirement
336 VA
Motor current Imax
8A
Settings data
Wire feed speed
6.2-82.0 ft/min (1.9-25.0 m/min)
Burnback time
0–0.5 s
Creep start
OFF or ON
2/4-stroke
2-stroke or 4-stroke
Torch connection
EURO
Max. diameter wire bobbin
11.8 in. (300 mm)
Wire dimension
0.02–0.06 in. (0.6–1.6 mm)
Weight
25.4 lbs (11.5 kg)
Dimensions l × w × h
15.0 × 10.8 × 15.7 in. (380 × 275 × 400 mm)
Operating temperature
14 to 104 °F (-10 to +40 °C)
Operating temperature
-4 to 131°F (-20 to +55°C)
Shielding gas
All types intended for MIG/MAG welding
max pressure
73 PSI (5 bar)
Maximum permissible load at
60% duty cycle
630 A
Enclosure class
IP2X *
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 104 °F (40 °C) or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP2X is intended for indoor use.
* IP23 is valid for optional wire spool cover art. no. 0458 674 880.
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4 INSTALLATION
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
CAUTION!
To avoid personal injury and/or equipment damage, lift using method and attachment
point shown here.
Order number for lifting eyelet can be found in chapter "ACCESSORIES".
NOTE!
If another mounting device is used, this must be electrically insulated from the wire
feed unit.
CAUTION!
If equipment is placed on a surface that slopes more than 10°, toppling over may
occur. Personal injury and/or significant damage to equipment is possible.
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5 OPERATION
5
OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
WARNING!
To avoid shock, do not touch electrode wire or parts in contact with it, or uninsulated
cable or connection.
WARNING!
Make sure 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.
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5 OPERATION
WARNING!
Risk of crushing when replacing the wire bobbin!
Do not use safety gloves when inserting the
welding wire between the feed rollers.
WARNING!
Before making any connections between the wire feeder and the welding power
source, turn off power to the welding power source and the wire feeder.
WARNING!
Be sure to properly insulate this connection before applying power to the power
source. Uninsulated cable and parts can arc when contacting a grounded surface.
The arc may damage eyes or start a fire. Body contact with an uninsulated weld cable
connector, or uncovered conductor can shock, possibly fatally.
WARNING!
Unless starting to weld, do not allow the welding wire to touch a grounded metal
surface. The welding wire becomes electrically hot when the secondary contact is
closed. Keep fingers clear of the drive rolls; they will start turning when the torch
trigger is pressed.
WARNING!
When the power switch is on, and torch trigger is depressed, the electrode wire
becomes electrically hot and the wire feed rolls are activated. Do not touch the wire as
it may cause a possibly fatal shock. Unless welding, do not allow wire to touch a
grounded metal surface as it will cause an arc flash. Keep clear of feed rolls and drive
gears.
WARNING!
Prior to welding, it is imperative that proper protective clothing (welding coat and
gloves) and eye protection (glasses and/or welding helmet) be put on. Failure to
comply may result in serious injury.
WARNING!
Failure to shut off shield gas in a confined space may result in a build-up of fumes,
displacing oxygen.
CAUTION!
Do not terminate the arc by removing the torch from the weld area. Release the torch
trigger to stop welding before removing the torch.
NOTE!
When moving the equipment, use the handle intended for transportation. Never pull
the equipment by the welding torch.
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5 OPERATION
5.1
Connections and control devices
1. Knob for setting the voltage
2. Switch for inching/gas purge
3. Switch for creep start OFF/ON
4. Knob for setting wire feed speed
5. Connection for welding torch
6. Switch for 2-stroke/4-stroke
7. Knob for setting burnback time
8. Connection for welding current from power
source (OKC)
9. Connection for control cable from power
source
10. Connection for shielding gas
CAUTION!
Make sure the torch chosen is of the proper rating for the welding current to be used,
has the proper size and type of liner, the proper contact tip and the proper guide tube.
5.2
Starting procedure
When the wire feed starts, the power source generates the welding voltage.
If there is no welding current flow within three seconds, the power source switches the
welding voltage off. The wire feed continues until the welding torch's switch is switched to off.
5.3
Function examples
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 a
burnback time results in a long wire stickout after finishing the welding, with a
risk of the wire catching 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.
Inching
Used when wire is to be fed without switching on the welding voltage.
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5 OPERATION
Gas purging
Used to measure the 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.
2-stroke
With 2-stroke gas, pre-flow (if used) starts when the welding torch trigger switch
is pressed. The welding process then starts. Releasing the trigger switch stops
welding entirely and starts gas post-flow (if selected).
4-stroke
With 4 stroke, the gas pre-flow starts when the welding torch trigger switch is
depressed and the wire feed starts when it is released. The welding process
continues until the switch is pressed in again, the wire feed then stops and when
the switch is released the gas post-flow starts (if selected).
Creep start
Creep start feeds out the wire at 50% of the set speed, until it makes electrical
contact with the workpiece.
Wire feed speed
This sets the required feed speed of the filler wire in m/minute.
5.4
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.
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 torch approx. 0.2 in. (5 mm) from the piece of wood (fig. 1), the feed
rollers should slip.
If you hold the torch approx. 2 in. (50 mm) from the piece of wood, the wire should be fed out
and bend (fig. 2).
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5 OPERATION
5.5
•
•
•
•
•
•
Changing/loading wire
Open the side panel.
Disconnect the pressure sensor by folding the pressure sensor backward.
The pressure rollers slide up.
Straighten out the new wire 4–8 in.
Before inserting the new wire into the wire feed unit, file away burrs and sharp edges
from the end of the wire.
Make sure that the wire goes properly into the feed roller's track and into the outflow
nozzle or wire guide.
Secure the pressure sensor.
Close the side panel.
5.6
•
•
•
•
Changing the feed rollers
Open the side panel.
Disconnect the pressure
sensor (1) by folding the
pressure sensor backward.
The pressure rollers slide up.
Disconnect the pressure rollers
(2) by turning the axle (3) 1/4
turn clockwise and pulling out
the axle.
The pressure rollers
disconnect.
Disconnect the feed rollers (4)
by unscrewing the nuts (5) and
pulling out the feed rollers.
During installation, repeat the above
in reverse order.
Choice of track in the feed rollers
Turn the feed roller with the dimensioning mark for the required track toward you.
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6 MAINTENANCE
6
MAINTENANCE
WARNING!
Be sure the branch circuit or main disconnect switch is off or electrical input circuit
fuses are removed from the power source main supply before attempting any
inspection or work on the inside of the wire feeder. Placing the power switch on the
welding machine in the off position does not remove all power from inside of the
equipment.
WARNING!
Inspection, troubleshooting, and repair of this equipment should be undertaken by a
competent individual having at least general experience in the maintenance and repair
of semi-conductor electronic equipment. Maintenance or repair should not be
undertaken by anyone without such qualifications.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.
NOTE!
Regular maintenance is important for safe and reliable operation.
6.1
Inspection and cleaning
WARNING!
If uninsulated cable and parts are not replaced, an arc caused by a bare cable or part
touching a grounded surface may damage unprotected eyes or start a fire. Body
contact with bared cable, connector, or uncovered conductor can shock, possibly
fatally.
Wire feed unit
Regularly check that the wire feed unit is not clogged with dirt.
•
Cleaning and replacement of worn parts in the mechanism of the wire feed should take
place at regular intervals in order to achieve trouble-free wire feeding.
NOTE!
If pre-tensioning is set too hard, this can result in abnormal wear on the pressure
roller, feed roller and wire guide.
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6 MAINTENANCE
The brake hub
The hub is adjusted when delivered, if
readjustment is required, follow the
instructions below. Adjust the brake hub so
the wire is slightly slack when the wire feed
stops.
Adjusting the braking torque:
•
•
•
•
Turn the red handle to the locked
position.
Insert a screwdriver into the springs in
the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs counter-clockwise to increase the braking torque.
NOTE!
Turn both springs the same amount.
Welding torch
•
The wear parts of the welding torch should be cleaned and replaced at regular intervals
in order to achieve trouble-free wire feeding. Regularly blow the wire guide clean and
clean the contact tip.
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© ESAB AB 2018
7 ORDERING SPARE PARTS
7
ORDERING SPARE PARTS
CAUTION!
Do not make any repairs to the equipment unless you are fully qualified, as described
in the maintenance section.
Feed 3004 is designed and tested in accordance with the international and European
standards IEC/EN 60974-5 and IEC/EN 60974-10. It is the obligation of the service unit
that carried out the service or repair work to make sure that the product still
conforms to said standard.
When ordering replacement parts, order by part number and part name, as illustrated on the
figure. Always provide the series or serial number on the unit in which the parts will be used.
The serial number is stamped on the rating plate.
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© ESAB AB 2018
DIAGRAM
DIAGRAM
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© ESAB AB 2018
DIAGRAM
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© ESAB AB 2018
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
Type
0459 115 860
Wire feed unit
Origo Feed 304, M13u
0459 839 060
Spare parts list
Feed 304
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© ESAB AB 2018
WEAR PARTS
WEAR PARTS
Item Ordering no. Denomination
Notes
Wire type
HI1 0455 072 002 Intermediate nozzle
Wire dimensions
Fe, Ss & cored
0456 615 001 Intermediate nozzle
Al
HI2 0469 837 880 Outlet nozzle
Fe, Ss & cored Ø 2.0 mm (0.080 in.)
steel for 0.6–1.6 mm
(0.023–0.063 in.)
0469 837 881 Outlet nozzle
Al
Ø 2.0 mm (0.080 in.)
plastic for 0.8–1.6 mm
(0.030–0.063 in.)
HI3 0191 496 114 Key
HI4 0215 701 007 Locking washer
HI5a 0459 440 001 Motor gear euro
Item Ordering no.
Denomination
Drive gear
Wire
type
Wire dimensions Groove Roller
type markings
HI5b 0459 052 001 Feed/pressure rollers Fe, Ss Ø 0.6 & 0.8 mm
& cored (0.023 & 0.030 in.)
V
0.6 S2
& 0.8 S2
0459 052 002 Feed/pressure rollers Fe, Ss Ø 0.8 & 1.0 mm
& cored (0.030 & 0.039 in.)
V
0.8 S2
& 1.0 S2
0459 052 003 Feed/pressure rollers Fe, Ss Ø 0.9/1.0 & 1.2 mm
& cored (0.035/0.039 &
0.045 in.)
V
1.0 S2
& 1.2 S2
0459 052 013 Feed/pressure rollers Fe, Ss Ø 1.4 & 1.6 mm
& cored (0.055 & 0.063 in.)
V
1.4 S2
& 1.6 S2
0458 825 001 Feed/pressure rollers Cored
Ø 0.9/1.0 & 1.2 mm
V1.0 R2
(0.035/0.039 &
Knurled & 1.2 R2
0.045 in.)
0458 825 010 Feed/pressure rollers Cored
Ø 1.2 & 1.2 mm
(0.045 & 0.045 in.)
V1.2 R2
Knurled & 1.2 R2
0458 825 002 Feed/pressure rollers Cored
Ø 1.2 & 1.4 mm
(0.045 & 0.055 in.)
V1.2 R2
Knurled & 1.4 R2
0458 825 003 Feed/pressure rollers Cored
Ø 1.6 mm
(0.063 in.)
V1.6 R2
Knurled & 2.0 R2
0458 824 001 Feed/pressure rollers Al
Ø 0.8 & 0.9/1.0 mm
(0.030 &
0.035/0.039 in.)
U
0.8 A2
& 1.0 A2
0458 824 002 Feed/pressure rollers Al
Ø 1.0 & 1.2 mm
(0.039 & 0.045 in.)
U
1.0 A2
& 1.2 A2
0458 824 003 Feed/pressure rollers Al
Ø 1.2 & 1.6 mm
(0.045 & 0.063 in.)
U
1.2 A2
& 1.6 A2
Only use pressure and feed rollers marked A2, R2 or S2.
The rollers are marked with wire dimension in mm, some are also marked with inch.
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WEAR PARTS
Item Ordering no.
Denomination
Notes
HI6
Washer
Ø 16/5×1
HI7
Screw
M4×12
HI8
Screw
M6×12
HI9
Washer
Ø 16/8.4×1.5
HI10 0469 838 001 Cover
HI11 0458 722 880 Axle and Nut
HI12 0459 441 880 Gear adapter
HI13 0455 049 001 Inlet nozzle
Ø 3 mm (0.12 in.) for 0.6-1.6 mm (0.023–0.063 in.)
Fe, Ss, Al and cored wire
HI14 0458 999 001 Shaft
HI15
Nut
M10
HI16 0458 748 002 Insulating washer
HI17 0458 748 001 Insulating bushing
Item Ordering no.
Denomination
HI18 0156 602 001 Inlet nozzle
Wire type
Wire dimensions
Fe, Ss, Al & cored Ø 2 mm (0.080 in.) plastic for
0.6–1.6 mm (0.023–0.063 in.)
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 (10 ft) long welding torch for aluminium wire,
equipped with appropriate wear parts.
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WEAR PARTS
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© ESAB AB 2018
ACCESSORIES
ACCESSORIES
0458 674 880
1 Bobbin cover, plastic Ø 12 in. (300 mm)
0459 233 880
1 Adapter for 17.3 in. (440 mm) bobbin
0458 706 880
1 Lifting eye
F102 440 880
2 Quick connector Marathon Pac™
0458 707 880
1 Wheel kit for feed
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© ESAB AB 2018
ACCESSORIES
0457 341 881
1 Strain relief for welding torch
0458 705 880
Counter balance device
(includes mast and counter balance)
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© ESAB AB 2018
ACCESSORIES
0461 284 131
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© ESAB AB 2018
For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
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