ESAB FeedMech 4804 User manual

GB

Valid for serial no. 606-xxx-xxxx0461 066 001 GB 20120828

Aristo

®

FeedMech 4804/

FeedControl

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

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

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

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

3 TECHNICAL DATA 6.................................................

4 INSTALLATION 7....................................................

4.1 Terminating resistor 7........................................................

4.2 Example of a robotic welding system 8.........................................

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

5.1 Connections 10..............................................................

5.2 Gas flow guard (if installed) 12.................................................

5.3 Wire feed pressure 13........................................................

5.4 Replacing and inserting wire 13................................................

5.5 Changing feed rollers 13......................................................

6 MAINTENANCE 14....................................................

6.1 Inspection and cleaning 14....................................................

7 ORDERING SPARE PARTS 14.........................................

DIAGRAM 16............................................................

ORDER NUMBER 18.....................................................

WEAR PARTS 20........................................................

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:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S 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

S Install and earth the unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

S Keep your head out of the fumes.

S 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.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION

This product is solely intended for arc welding.

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.

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.

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CAUTION

Read and understand the instruction manual before

installing or operating.

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

2 INTRODUCTION

The wire feed unit consist of a drive unit (FeedMech 4804) and a separate electronic

unit (FeedControl).

The wire feed unit is intended for MIG/MAG welding along with robotic equipment.

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 on page 22.

2.1 Equipment

The wire feed unit is supplied with an instruction manual, and the drive unit with a

sticker with recommended wear parts.

3 TECHNICAL DATA

FeedMech 4804 FeedControl

Power supply 42 V 50-60 Hz 42 V 50-60 Hz

Power requirement 378 VA 378 VA

Motor current I

max

9.0 A 9.0 A

Settings data

Wire feed speed 0.8 - 25.0 m/min

Gun connection EURO

Wire dimension

Fe

Ss

Al

Cored wire

0.6-2.4 mm

1.0-1.6 mm

0.8-2.4 mm

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

Weight 9.7 kg 4.9 kg

Dimensions (l x b x h) 383 x 161 x 287 mm 330 x 118 x 320 mm

Shielding gas

max pressure

Gases for MIG/MAG-welding

5 Bar

Gases for MIG/MAG-welding

5 Bar

Maximum permissible load at

60% intermittens

100% intermittens

500 A

280 A

500 A

280 A

Enclosure class IP2X IP2X

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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.

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. Apparatus marked IP2X are intended for indoor use.

4 INSTALLATION

The installation must be carried out by a professional.

Note

Mains supply requirements

High power equipment may, due to the primary current drawn from the mains supply, influence the

power quality of the grid. Therefore connection restrictions or requirements regarding the

maximum permissible mains impedance or the required minimum supply capacity at the interface

point to the public grid may apply for some types of equipment (see technical data). In this case it

is the responsibility of the installer or user of the equipment to ensure, by consultation with the

distribution network operator if necessary, that the equipment may be connected.

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 (U8

2

), 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.

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4.2 Example of a robotic welding system

AH 0934

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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!

A

H 0935

WARNING

Rotating parts can cause injury, take great care.

WARNING

Risk of crushing when replacing the wire bobbin!

Do not use safety gloves when inserting the welding wire between the feed rollers.

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5.1 Connections

FeedMech 4804

1 Switch for gas purging 9 Connection to drive unit, 4 poles

2 Switch for reversed wire feed 10 Connection to drive unit, 8 poles

3 Switch for cold wire feed 11 Connection for coolant from power source

(cooling unit), BLUE

4 Connection for coolant to welding gun,

BLUE

12 Connection for coolant to power source

(cooling unit), RED

5 Connection for coolant from welding gun,

RED

13 Inlet connection for spatter removal air

6 Outlet connection for spatter removal air 14 Connection for shielding gas in

7 Connection for signals to/from robot

welding gun

15 Connection for welding current from

electronic unit (OKC)

8 Connection for welding gun 16 Rating plate

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FeedControl

1 White indicating lamp – Power supply ON 9 Rating plate

2 Connection from electronic unit to drive

unit

10 Connection for terminating resistor or

forwarding to next wire feed unit

3 Connection from electronic unit to drive

unit

11 Connection for control cable from power

source

4 Outlet connection for spatter removal air 12 Connection for shielding gas, in

5 Connection for coolant to welding gun,

BLUE

13 Inlet connection for spatter removal air

6 Connection for welding current from drive

unit (OKC)

14 Connection for coolant from power source

(cooling unit), BLUE

7 Connection for coolant from welding gun,

RED

15 Connection for welding current from power

source (OKC)

8 Connection for shielding gas, out 16 Connection for coolant to power source

(cooling unit), RED

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Symbol and function explanations

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.

Reversed wire feed

Used to reverse the wire, for example when replacing the wire bobbin.

Inching

Used when wire is to be fed without switching on the welding voltage.

Inlet spatter removal air

Outlet spatter removal air

Used for spray-cleaning the contact tip on the welding gun.

Shielding gas in

Shielding gas out

5.2 Gas flow guard (if installed)

The gas flow monitor interrupts the ongoing welding process if the gas flow drops

below 3.5 l/min. When this occurs, an error message is displayed via the control unit.

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5.3 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 insulated 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).

5.4 Replacing and inserting wire

S Open the side panel.

S Disconnect the pressure sensor by folding it backwards, the pressure rollers

slide up.

S Straighten out the new wire 10-20 cm. File away burrs and sharp edges from the

end of the wire before inserting it into the wire feed unit.

S Make sure that the wire goes properly into the feed

roller's track and into the outflow nozzle or wire guide.

S Secure the pressure sensor.

S Close the side panel.

5.5 Changing feed rollers

S Push down the pressure device (1) and pull it

towards you and upwards.

S Pull out the bogey (2).

S Remove the socket-head bolts (3) on the

intermediate nozzle and remove it.

S Loosen the bolt holding the outlet nozzle (4)

and push the nozzle back.

S Remove the socket-head bolt (5) in the centre

S Slacken the two socket-head bolts (6) by half a turn.

S Pull out the feed rollers (7).

Reassemble in the reverse order.

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Selecting the correct groove in the

feed rollers

Place no, one or two carrier washers

between the outer washer and the feed

rollers. NB: Replace the entire bogey

when changing the pressure rollers (8).

6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any

work to rectify any faults in the product during the guarantee period.

6.1 Inspection and cleaning

Wire feed unit

Check regularly that the wire feed unit is not clogged with dirt.

S 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 gun

S The welding gun's wear parts 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.

7 ORDERING SPARE PARTS

FeedMech 4804 / FeedControl is designed and tested in accordance with the interna

tional and European standards 60974-1, 60974-5 and 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 last page of

this publication.

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notes

NOTES

.............................................................................................................................................................

Diagram

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FeedControl & FeedMech 4804

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FeedMech 4804/FeedControl

Order number

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Ordering no. Denomination Type Note

0461 070 881

0461 080 880

0459 839 007

Drive unit

Feed box

Spare parts list

Aristo

R

Feed Mech 4804

Aristo

R

Feed Control

12 pole

Technical documentation is available on the Internet at www.esab.com

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FeedMech 4804/FeedControl

Wear parts

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HD = Heavy Duty

Item Ordering no. Denomination Wire type Wire dimensions

HK1 0469 837 880

0469 837 881

0469 837 882

Outlet nozzle

Fe, Ss & cored

Al

Fe, Ss & cored

Ø 2.0 mm steel for 0.6-1.6 mm

Ø 2.0 mm plastic for 1.0-1.6 mm

Ø 3.4 mm steel for 2.0-2.4 mm

Item Ordering no. Denomination Wire type Wire Ø

mm

Groove 1 Groove 2 Groove 3 Groove

typ

Roller /

Bogey

mark

ings

HK2 0366 966 880 Feed Roller Fe, Ss & cored 0.6-1.2 0.6-0.8 0.9-1.0 1.2 V 1

0366 966 881 Feed Roller Fe, Ss & cored 1.4-1.6 1.4-1.6 2.0 2.4 V 2

0366 966 889 Feed Roller Fe, Ss & cored 1.2 .045” / 1.2 .045” / 1.2 .045” / 1.2 V .045 / 7

0366 966 900 Feed Roller Fe, Ss & cored 0.9-1.6 0.9-1.0 1.2 1.4-1.6 V 6

0366 966 882 Feed Roller Cored 1.2-2.0 1.2 1.4-1.6 2.0 V-Knurled 3

0366 966 883 Feed Roller Cored 2.4 2.4 not used not used V-Knurled 4

0366 966 885 Feed Roller Al 1.2 1.2 1.2 1.2 U U2

0366 966 899 Feed Roller Al 1.0-1.6 1.0 1.2 1.6 U U4

Item Ordering no. Denomination Notes

HK3 0156 707 001 Distance washer

HK4 0156 707 002 Adjustment spacer

HK5 Screw M5x20

HK6 Screw M5x16

Item Ordering no. Denomination Wire type Wire dimensions Groove

typ

Roller /

Bogey

markings

HK7 0366 902 880 Bogey (HD) Fe, Ss & cored Ø 0.6 - 1.2 mm V 1

0366 902 900 Bogey (HD) Fe, Ss & cored Ø 0.9 - 1.6 mm V 6

0366 902 881 Bogey (HD) Fe, Ss & cored Ø 1.4 - 2.4 mm V

2

0366 902 894 Bogey (HD) Fe, Ss & cored Ø 1.2 mm V .045 / 7

0366 902 882 Bogey (HD) Cored Ø 1.2 - 2.0 mm V-Knurled 3

0366 902 883 Bogey (HD) Cored Ø 2.4 mm V-Knurled 4

0366 902 899 Bogey (HD) Al Ø 1.0 - 1.6 mm U U4

0366 902 886 Bogey (HD) Al Ø 1.2 mm x 3 U -

Item Ordering no. Denomination Wire type Wire dimensions

HK8 0366 944 001 Washer

HK9 0156 603 001

0156 603 002

0332 322 001

0332 322 002

Intermediate nozzle

Fe, Ss & Al

Cored

Ø 2 mm plastic for 0.6-1.6 mm

Ø 4 mm plastic for 2.0-2.4 mm

Ø 2.4 mm copper for 1.2-2.0 mm

Ø 4 mm copper for 2.4 mm

Item Ordering no. Denomination Note

HK10 0215 702 708 Locking washer

HK11 Nut M10

HK12 0458 748 002 Insulating washer

HK13 0458 748 001 Insulating bushing

Item Ordering no. Denomination Wire type Wire dimensions

HK14 0156 602 001

0156 602 002

0332 318 001

0332 318 002

Inlet nozzle

Inlet nozzle (HD)

Fe, Ss, Al & Cored

Fe, Ss & Cored

Ø 2 mm plastic for 0.6-1.6 mm

Ø 4 mm plastic for 2.0-2.4 mm

Ø 2.4 mm steel for 1.2-2.0 mm

Ø 4 mm steel for 2.4 mm

ESAB FeedMech 4804, FeedControl - Aristo, FeedMech 4804, FeedControl - Aristo® User manual

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