ESAB | Feed Airmatic Digital Box | Instruction manual | ESAB Feed Airmatic Digital Box User manual

ESAB Feed Airmatic Digital Box User manual
Feed Airmatic Digital Box
Instruction manual
0463 429 001 GB 20160128
Valid for: serial no. 541-xxx-xxxx
TABLE OF CONTENTS
1
2
SAFETY ................................................................................................................ 4
1.1
Meaning of symbols............................................................................................. 4
1.2
Safety precautions ............................................................................................... 4
INTRODUCTION ................................................................................................... 7
2.1
General.................................................................................................................. 7
2.2
Equipment............................................................................................................. 7
3
TECHNICAL DATA ............................................................................................... 8
4
INSTALLATION..................................................................................................... 9
4.1
General.................................................................................................................. 9
4.2
Fitting the unit on top of the power source .......................................................9
4.2.1
Power sources Mig 3001i and Mig 4001i ......................................................... 10
4.2.2
Power sources Mig 4004i and Mig 5004i ......................................................... 10
5
OPERATION ....................................................................................................... 11
5.1
Connections and control devices..................................................................... 11
6
MAINTENANCE .................................................................................................. 12
7
ORDERING SPARE PARTS ............................................................................... 13
DIAGRAM .................................................................................................................. 14
ORDERING NUMBERS .............................................................................................15
ACCESSORIES .........................................................................................................16
Rights reserved to alter specifications without notice.
0463 429 001
© ESAB AB 2016
1 SAFETY
1
SAFETY
1.1
Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Material Safety Data Sheets (MSDSs).
1.2
Safety precautions
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 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
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 or work is started with the equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
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© ESAB AB 2016
1 SAFETY
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 extinguishing equipment must be clearly marked and close at hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
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 work piece
Ensure your working stance is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
•
•
•
Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
Exposure to EMF may have other health effects which are unknown.
Welders should use the following procedures to minimize exposure to EMF:
○ Route the electrode and work cables together on the same side of your
body. Secure them with tape when possible. Do not place your body
between the torch and work cables. Never coil the torch or work cable
around your body. Keep welding power source and cables as far away
from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the area
being welded.
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
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
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© ESAB AB 2016
1 SAFETY
MOVING PARTS - Can cause injuries
•
•
•
Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
Stop engine before installing or connecting unit. To prevent accidental
starting of equipment during service, disconnect negative (-) battery cable
from battery.
Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
•
Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
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.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/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.
0463 429 001
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© ESAB AB 2016
2 INTRODUCTION
2
INTRODUCTION
2.1
General
The Feed Airmatic Digital Box is a component in ESAB's "push-pull" system and is
intended for use in MIG/MAG welding together with a power source, an Airmatic wire feeder
and a PKB welding torch. The Feed Airmatic Digital Box works as an analogue to digital
converter between the analogue Airmatic wire feeder and ESAB CAN bus power sources for
MIG/MAG welding.
The wire feed unit pushes the wire through the welding hose to the welding torch, after which
the pneumatically-operated motor in the torch piston draws the wire to the contact tip. This
provides an even, interference-free wire feed, which is beneficial when welding with soft
auxiliary material such as aluminium and with thin wires. Feed Airmatic Digital Box is
available in two different versions, one with remote control outlet and one without remote
control outlet.
For description of operation of the U6 control panel, see the U6 instruction manual.
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of this
manual.
2.2
Equipment
The wire feed unit is supplied with:
•
•
An instruction manual for Feed Airmatic Digital Box
An instruction manual for the U6 control panel
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© ESAB AB 2016
3 TECHNICAL DATA
3
TECHNICAL DATA
Technical data Feed Airmatic Digital Box
Supply voltage
42 V AC
Dimensions l × w × h
320 × 220 × 197 mm
Weight
3,9 kg
Enclosure class
IP2X
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.
0463 429 001
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© ESAB AB 2016
4 INSTALLATION
4
INSTALLATION
4.1
General
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
4.2
.
Fitting the unit on top of the power source
WARNING!
A power source equipped with a Feed Airmatic Digital Box, must be fitted on a
trolley.
0463 429 001
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© ESAB AB 2016
4 INSTALLATION
4.2.1
Power sources Mig 3001i and Mig 4001i
4.2.2
Power sources Mig 4004i and Mig 5004i
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© ESAB AB 2016
5 OPERATION
5
OPERATION
5.1
Connections and control devices
1. Display
2. Knob for setting of voltage
3. Knob for setting of wire feed speed and
current
4. Soft pushbuttons (function keys)
0463 429 001
5. MENU button
6. Connection for control cable from power
source
7. Switch for remote control OFF/ON
8. Connection for control cable to wire feeder
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© ESAB AB 2016
6 MAINTENANCE
6
MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
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.
0463 429 001
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© ESAB AB 2016
7 ORDERING SPARE PARTS
7
ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorised ESAB service technician.
Use only ESAB original spare and wear parts.
The Feed Airmatic Digital Box is designed and tested in accordance with international and
european standards IEC/EN 60974-1 and IEC/EN 60974-10. On completion of service or
repair work, it is the responsibility of the person(s) performing the work to ensure that the
product still complies with the requirements of the above standard.
Spare parts may be ordered through your nearest ESAB dealer, see the back cover of this
document. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.
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© ESAB AB 2016
DIAGRAM
DIAGRAM
0463 429 001
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© ESAB AB 2016
ORDERING NUMBERS
ORDERING NUMBERS
Ordering number
Denomination
0464 554 880
Feed Airmatic Digital Box
0464 554 881
Feed Airmatic Digital Box Remote
0463 430 001
Spare parts list
Type
Notes
With remote setting option
Technical documentation is available on the Internet at: www.esab.com
0463 429 001
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© ESAB AB 2016
ACCESSORIES
ACCESSORIES
0464 558 880
Cable set Amphenol 10 pole, 1.0 m
0464 555 880
Mig 3001i/4001i assembly kit
0464 555 881
Mig 4004i/5004i assembly kit
0460 565 880
Trolley
0461 310 880
Trolley adapter kit
for fitting of power sources Mig 4004i and
Mig 5004i to trolley 0460 565 880
0152 700 881
PKB 250 welding torch
straight swan neck
0463 429 001
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© ESAB AB 2016
ACCESSORIES
0152 470 881
PKB 400 welding torch
straight swan neck
0152 470 882
PKB 400 welding torch
curved swan neck 45°
0463 429 001
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© ESAB AB 2016
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 15 25 79 30
Fax: +32 15 25 79 44
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: +359 2 974 42 88
Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
www.esab.com
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting
Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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