ESAB | RoboFeed 3004HW | Instruction manual | ESAB RoboFeed 3004HW User manual

ESAB RoboFeed 3004HW User manual
Aristo®
RoboFeed 3004HW
FeedControl 3004HW
Instruction manual
0463 280 101 GB 20131011
Valid for: serial no. 325-xxx-xxxx
TABLE OF CONTENTS
1
SAFETY ................................................................................................................ 4
2
INTRODUCTION ................................................................................................... 7
2.1
Equipment............................................................................................................. 7
3
TECHNICAL DATA ............................................................................................... 8
4
INSTALLATION..................................................................................................... 9
5
6
4.1
Terminating resistor............................................................................................. 9
4.2
Example of a robotic welding system ................................................................9
OPERATION ....................................................................................................... 10
5.1
Connection and control devices....................................................................... 11
5.2
Replacing and inserting wire ............................................................................ 13
5.3
Changing feed rollers ........................................................................................ 13
5.4
Pressure guard................................................................................................... 13
5.5
Wire feed pressure............................................................................................. 13
MAINTENANCE .................................................................................................. 15
6.1
7
Inspection and cleaning .................................................................................... 15
ORDERING SPARE PARTS ............................................................................... 16
DIAGRAM .................................................................................................................. 17
WEAR PARTS............................................................................................................19
ORDERING NUMBERS .............................................................................................21
ACCESSORIES .........................................................................................................22
Rights reserved to alter specifications without notice.
0463 280 101
© ESAB AB 2013
1 SAFETY
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 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 equpment
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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© ESAB AB 2013
1 SAFETY
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 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. Protect your ears.
Use earmuffs or other hearing protection
Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Read and understand the instruction manual before
installing or operating.
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© ESAB AB 2013
1 SAFETY
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 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.
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© ESAB AB 2013
2 INTRODUCTION
2
INTRODUCTION
The RoboFeed 3004HW and FeedControl 3004HW wire feed unit is intended for MIG/MAG
welding with robotic equipment.
The wire feed unit consists of a drive unit (RoboFeed 3004HW) and a separate electronic
unit (FeedControl 3004HW).
NOTE!
The wire feed unit utilizes the robot's safety system to obtain maximum
interference protection.
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1
Equipment
The wire feed unit is supplied with an instruction manual and a quick connection for
Marathon Pac™ .
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© ESAB AB 2013
3 TECHNICAL DATA
3
TECHNICAL DATA
RoboFeed 3004HW
FeedControl 3004HW
Power supply
-
42 V 50 - 60 Hz
Power requirement
-
378 VA
Motor voltage
60 VDC PWM (Pulse Width
Modulation)
-
Motor current Imax
8.0 A
8.0 A
Wire feed speed
0.8 - 30.0 m/min
-
Torch connection
EURO
-
- Steel (Fe)
0.8 - 1.6 mm
-
- Stainless steel (Ss)
0.8 - 1.6 mm
-
- Aluminum (Al)
1.0 - 1.6 mm
-
- Cored wire (FCW)
0.8 - 1.6 mm
-
Operating temperature
-10 to +40°C
-10 to +40°C
Transport temperature
-20 to +55°C
-20 to +55°C
Weight
5.4 kg
4.9 kg
Dimensions (l × b × h)
251 × 182 × 221 mm
330 × 118 × 320 mm
Shielding gas
Gases for MIG/MAG welding
Gases for MIG/MAG welding
- max pressure
0.5 Mpa (5 bar)
0.5 Mpa (5 bar)
Coolant
-
ESAB's ready-mixed coolant
- max pressure
-
0.5 Mpa (5 bar)
Wire dimension
Maximum permissible load at
- 60% duty cycle
500 A
500 A
- 100% duty cycle
280 A
280 A
Enclosure class
IP2X
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 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 IP2X is intended for indoor use.
Coolant
It is very important to use the ESAB ready-mixed coolant! If other coolants are used the
equipment could be damaged or in worst case the chassis could become live. You can find
the ordering number of ESAB's ready-mixed coolant in the "ACCESSORIES" chapter of the
instruction manual.
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© ESAB AB 2013
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
.
Terminating resistor
The ends of the CAN bus must be fitted with terminating
resistors to avoid communication interference.
The terminating resistor is delivered with the power source.
One end of the CAN bus is at the control panel (U82), which
has an integral terminating resistor.
The other end is at the FeedControl and must be fitted with the
terminating resistor, as shown on the right.
If U82 is used together with W82, the terminal resistor in the
W82 must be disconnected, see the instruction manual for the
W82.
4.2
Example of a robotic welding system
NOTE!
A mounting kit and a cable kit are required for mounting to a robot, please contact
your local ESAB dealer for more information.
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© ESAB AB 2013
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!
Assure that the side panels are closed during operation.
WARNING!
Rotating parts can cause injury, take great care.
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© ESAB AB 2013
5 OPERATION
5.1
Connection and control devices
RoboFeed 3004HW
1. Outlet for connection to the drive unit from
the electronic unit
2. Connection for shielding gas, in
3. Connection for the welding cable or the
return cable.
4. Connection for welding torch (EURO)
0463 280 101
5. Rating plate
6. Push button for inching
7. Push button for gas purging
8. Quick connector Marathon Pac™
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© ESAB AB 2013
5 OPERATION
FeedControl
1. White indicating lamp – Power supply ON
2. Connection from electronic unit to drive
unit - pulse signal encoder
3. Connection from electronic unit to drive
unit - 42V power
4. Connection for spatter removal air, out
5. Connection for coolant to welding torch,
BLUE
6. Connection for welding current from drive
unit (OKC)
7. Connection for coolant from welding torch,
RED
8. Connection for shielding gas, out
9. Rating plate
10. Connection for terminating resistor or
forwarding to next wire feed unit
11. Connection for control cable from power
source
12. Connection for shielding gas, in
13. Connection for spatter removal air, in
14. Connection for coolant from power source
(cooling unit), BLUE
15. Connection for welding current from power
source (OKC)
16. Connection for coolant to power source
(cooling unit), RED
Symbol and function explanations
Inlet spatter removal air
Shielding gas
Outlet spatter removal air
Used for spray-cleaning the contact tip on the welding torch.
0463 280 101
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© ESAB AB 2013
5 OPERATION
Gas purging
Gas purging is used when measuring the gas flow or to flush any air or moisture
from the gas hoses before welding starts. Gas purging occurs for as long as the
button is held depressed and occurs without voltage or wire feed starting.
Wire inching
Wire inching is used when one needs to feed wire without welding voltage being
applied. The wire is fed as long as the button is depressed.
Shielding gas out
5.2
•
•
•
•
•
•
Replacing and inserting wire
Open the side panel.
Disconnect the pressure sensor by folding it backwards, the pressure rollers slide up.
Straighten out the new wire 10-20 cm. File off any burrs and sharp edges from the end of
the wire before inserting it into the wire feed unit.
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.
WARNING!
Risk of crushing when replacing the wire bobbin! Do not use safety gloves when
inserting the welding wire between the feed rollers.
5.3
Changing feed rollers
1. Open the side panel.
2. Disconnect the pressure sensor (A) by folding it backwards.
The pressure rollers slide up.
3. Disconnect the pressure rollers (B) by turning the axle (C)
1/4 turn clockwise and pulling out the axle.
The pressure rollers disconnect.
4. Disconnect the feed rollers (D) by unscrewing the nuts (E)
and pulling out the rollers.
Install the new feed rollers, by repeating the above-mentioned
steps in the reverse order.
5.4
Pressure guard
The pressure guard interrupts the ongoing welding process if the gas flow drops below
5.0 l/min (approximately 0.2 bar pressure). When this occurs, an error message is displayed
via the control unit.
5.5
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 high.
0463 280 101
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© ESAB AB 2013
5 OPERATION
Figure A
Figure B
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 welding torch approximately 5 mm from the piece of wood (figure A) the
feed rollers should slip.
If you hold the welding torch approximately 50 mm from the piece of wood, the wire should
be fed out and bend (figure B).
0463 280 101
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© ESAB AB 2013
6 MAINTENANCE
6
MAINTENANCE
NOTE!
Regular maintenance is important for safe, 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.
6.1
Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
•
Cleaning 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.
Welding torch
•
The wear parts of the welding torch should be cleaned and replaced at regular intervals in
order to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the
contact tip.
0463 280 101
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© ESAB AB 2013
7 ORDERING SPARE PARTS
7
ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
RoboFeed 3004HW 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 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 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.
0463 280 101
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© ESAB AB 2013
DIAGRAM
DIAGRAM
0463 280 101
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© ESAB AB 2013
DIAGRAM
0463 280 101
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© ESAB AB 2013
WEAR PARTS
WEAR PARTS
Item
Denomination
Wire type
Intermediate
nozzle
Fe, Ss &
cored
0456 615 001
Intermediate
nozzle
Al
0469 837 880
Outlet nozzle
Fe, Ss &
cored
0469 837 881
Outlet nozzle
HJ 3
0191 496 114
Key
HJ 4
0215 701 007
Locking washer
HJ 5a
0459 440 001
Motor gear
euro, drive gear
Item
Ordering
number
HJ 1
HJ 2
HJ
5b
Ordering no.
0455 072 002
Denomination
Wire dimensions
Ø 2.0 mm steel for 0.6-1.6 mm
Al
Wire
type
Ø 2.0 mm plastic for 0.8-1.6 mm
Wire dimensions (mm)
Groove
type
Roller
markings
0459 052 001 Feed/pressure rollers Fe, Ss Ø 0.6 & 0.8
& cored
V
0.6 & 0.8 S2
0459 052 002 Feed/pressure rollers Fe, Ss Ø 0.8 & 1.0
& cored
V
0.8 & 1.0 S2
0459 052 003 Feed/pressure rollers Fe, Ss Ø 0.9/1.0 & 1.2
& cored
V
1.0 & 1.2 S2
0459 052 013 Feed/pressure rollers Fe, Ss Ø 1.4 & 1.6
& cored
V
1.4 & 1.6 S2
0458 825 001 Feed/pressure rollers Cored
Ø 0.9/1.0 & 1.2
V1.0 & 1.2 R2
knurled
0458 825 002 Feed/pressure rollers Cored
Ø 1.2 & 1.4
V1.2 & 1.4 R2
knurled
0458 825 003 Feed/pressure rollers Cored
Ø 1.6
V1.6 & 2.0 R2
knurled
0458 824 001 Feed/pressure rollers Al
Ø 0.8 & 0.9/1.0
U
0.8 & 1.0 A2
0458 824 002 Feed/pressure rollers Al
Ø 1.0 & 1.2
U
1.0 & 1.2 A2
0458 824 003 Feed/pressure rollers Al
Ø 1.2 & 1.6
U
1.2 & 1.6 A2
0458 874 002 Feed/pressure rollers Al
Ø 1.0 & 1.2 mm
U
1.0 A2 & 1.2
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.
Item
Ordering no.
Denomination
Notes
HJ 6
Washer
Ø 16/5x1
HJ 7
Screw
M4x12
HJ 8
Screw
M6x12
HJ 9
Washer
Ø 16/8.4x1.5
HJ 10
0469 838 001 Cover
HJ 11
0458 722 880 Axle and Nut
0463 280 101
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© ESAB AB 2013
WEAR PARTS
Item
Ordering no. Denomination
Notes
HJ 12
0459 441 880 Gear adapter
HJ 12
0455 053 881 Gear adapter
Heavy duty with needle bearing
HJ 13
0465 129 001 Inlet nozzle
Ø 3 mm for 0.6–1.6 mm Fe, Ss, Al and cored wire
HJ 14
0458 999 001 Shaft
HJ 15
F102 440 880 Quick connector For Marathon Pac™
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 long welding torch for aluminium wire,
equipped with appropriate wear parts.
Rights reserved to alter specifications without notice.
0463 280 101
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© ESAB AB 2013
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
Type
0465 040 880
Drive unit
Aristo® RoboFeed 3004HW
0461 080 881
Feed Box
Aristo® Feed Control 3004HW
0465 113 880
Cable and Bracket unit
Aristo® RoboFeed 3004HW
0459 839 070
Spare parts list
Aristo® Robo Feed 3004HW &
Aristo® Feed Control
Technical documentation is available on the Internet at www.esab.com
0463 280 101
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© ESAB AB 2013
ACCESSORIES
ACCESSORIES
F102 440 880
Quick connector
MarathonPac™
0007 810 012
ESAB's ready mixed coolant
(10 l)
0463 280 101
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© ESAB AB 2013
ACCESSORIES
0463 280 101
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© ESAB AB 2013
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.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
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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