ESAB Origo™Feed 304 M13u User manual

Brand: ESAB

Model: Origo™Feed 304 M13u

Category: Welding System

Type: User manual

Origo™

Instruction manual

0461 284 131 US 20181228

Valid for: serial no. 623-xxx-xxxx

Feed304M13u

TABLE OF CONTENTS

0461 284 131 © ESAB AB 2018

USER RESPONSIBILITY ............................................................................ 3

INTRODUCTION.......................................................................................... 4

TECHNICAL DATA ...................................................................................... 5

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 ........................................................................ 14

DIAGRAM ............................................................................................................ 15

ORDERING NUMBERS....................................................................................... 17

WEAR PARTS...................................................................................................... 18

ACCESSORIES ................................................................................................... 21

Rights reserved to alter specifications without notice.

1 USER RESPONSIBILITY

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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.

2 INTRODUCTION

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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.

3 TECHNICAL DATA

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3 TECHNICAL DATA

Feed 304

Power supply 42V, 50-60Hz

Power requirement 336VA

Motor current I

max

8A

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.

4 INSTALLATION

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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.

5 OPERATION

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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.

5 OPERATION

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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.

5 OPERATION

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5.1 Connections and control devices

1. Knob for setting the voltage 6. Switch for 2-stroke/4-stroke

2. Switch for inching/gas purge 7. Knob for setting burnback time

3. Switch for creep start OFF/ON 8. Connection for welding current from power

source (OKC)

4. Knob for setting wire feed speed 9. Connection for control cable from power

source

5. Connection for welding torch 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.

5 OPERATION

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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).

5 OPERATION

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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.

6 MAINTENANCE

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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.

6 MAINTENANCE

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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.

7 ORDERING SPARE PARTS

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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.

DIAGRAM

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DIAGRAM

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ORDERING NUMBERS

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ORDERING NUMBERS

Ordering no. Denomination Type

0459 115 860 Wire feed unit Origo Feed 304, M13u

0459 839 060 Spare parts list Feed 304

WEAR PARTS

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WEAR PARTS

Item Ordering no. Denomination Notes Wire type Wire dimensions

HI1 0455 072 002 Intermediate nozzle 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 Drive gear

Item Ordering no. Denomination Wire

type

Wire dimensions Groove

type

Roller

markings

HI5b 0459 052 001 Feed/pressure rollers Fe, Ss

& cored

Ø 0.6 &0.8mm

(0.023 & 0.030in.)

V 0.6 S2

&0.8S2

0459 052 002 Feed/pressure rollers Fe, Ss

& cored

Ø 0.8 &1.0mm

(0.030 & 0.039in.)

V 0.8 S2

&1.0S2

0459 052 003 Feed/pressure rollers Fe, Ss

& cored

Ø 0.9/1.0 &1.2mm

(0.035/0.039 &

0.045in.)

V 1.0 S2

&1.2S2

0459 052 013 Feed/pressure rollers Fe, Ss

& cored

Ø 1.4 &1.6mm

(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

(0.035/0.039 &

0.045in.)

V-

Knurled

1.0 R2

&1.2R2

0458 825 010 Feed/pressure rollers Cored Ø 1.2 & 1.2mm

(0.045 & 0.045in.)

V-

Knurled

1.2 R2

&1.2R2

0458 825 002 Feed/pressure rollers Cored Ø 1.2 &1.4mm

(0.045 & 0.055in.)

V-

Knurled

1.2 R2

&1.4R2

0458 825 003 Feed/pressure rollers Cored Ø 1.6mm

(0.063in.)

V-

Knurled

1.6 R2

&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.

WEAR PARTS

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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 Wire type Wire dimensions

HI18 0156 602 001 Inlet nozzle 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.

WEAR PARTS

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ESAB Origo™Feed 304 M13u User manual

Brand: ESAB

Model: Origo™Feed 304 M13u

Category: Welding System

Type: User manual

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ESAB Origo™Feed 304 M13u User manual

ESAB Origo™Feed 304 M13u User manual

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