ESAB Feed 3004 User manual

Brand: ESAB

Model: Feed 3004

Category: Welding System

Type: User manual

This manual is also suitable for

Valid for serial no. 745-xxx-xxxx, 910-xxx-xxxx0444 408 187 US 20120830

Aristo Origo™

Feed 3004

Feed4804

Instruction manual

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TOCa

Rights reserved to alter specifications without notice.

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

2 SAFETY PRECAUTIONS - English 3...................................

3 PRECAUCION DE SEGURIDAD - Spanish 7............................

4 MESURES DE SECURITE - French 11..................................

5 SAFETY 15...........................................................

6 INTRODUCTION 17...................................................

6.1 Equipment 17................................................................

6.2 Control panel 18.............................................................

7 TECHNICAL DATA 18.................................................

8 INSTALLATION 19....................................................

8.1 Lifting instructions 20.........................................................

9 OPERATION 20.......................................................

9.1 Connections and control devices 23............................................

9.2 Water connection 23..........................................................

9.3 Wire feed pressure 24........................................................

9.4 Replacing and inserting Feed 3004 wire 24......................................

9.5 Replacing and inserting Feed 4804 wire 24......................................

9.6 Changing feed rollers on Feed 3004 25..........................................

9.7 Changing feed rollers on Feed 4804 25..........................................

10 MAINTENANCE 26....................................................

10.1 Inspection and cleaning 26....................................................

11 ORDERING SPARE PARTS 27.........................................

SCHEMATIC DIAGRAM 28................................................

ORDERING NUMBER 30.................................................

WEAR COMPONENTS 32.................................................

ACCESSORIES 36.......................................................

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US warnings

Be sure this information reaches the operator.

You can get extra copies through your supplier.

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.

1 USER RESPONSIBILITY

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

Authorized 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 SAFETY PRECAUTIONS - English

WARNING: These Safety Precautions are for your protection. They summarize precautionary

information from the references listed in Additional Safety Information section. Before performing any

installation or operating procedures, be sure to read and follow the safety precautions listed below as

well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety

Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS

Some welding, cutting and gouging precesses are noisy and require ear

protection. The arc, like the sun, emits ultraviolet (UV) and other radiation

and can injure skin and eyes. Hot metal can cause burns. Training in the

proper use of the processes and equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets face

shields and goggles are also required.

2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck

and ears from sparks and rays of the arc when operating or observing operations. Warn

bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or

hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped

shoes and a welding helmet or cap for protection, to protect against arc rays and hot sparks or

hot metal. A flameproof apron may also be desirable as protection against radiated heat and

sparks.

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4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars

should be kept buttoned and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable nonflammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and

can fly far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS

Heat from flames and arcs can start fires. Hot slag or sparks can also cause

fires and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a

protective nonflammable covering. Combusible materials include wood, clot, sawdust, liquid and

gas fuels, solvents, pants and coatings papper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a

hidden smoldering fire or fires on the floor below. Make certain that such openings are protected

from hot sparks and metal.

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so

that there are no substances on the workpiece which might produce flammable or toxic vapors.

Do not do hot work on closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand

bucket, or portable fire extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat

and create a fire hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot

metal which could cause a later fire. Use fire watchers when necessary.

7. For additional information refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and

Welding Processes”, available from the National Fire Protection Association, Batterymarch Park,

Quincy, MA 02269.

ELECTRICAL SHOCK

Contact with live electrical parts and ground can cause severe injury or

death. DO NOT use AC welding current in damp areas, if movement is

confined, or if there is danger of falling. Therefore:

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power

source.

6. Make sure that all parts of your bady are insulated from work and

from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding

recommendations. Do not mistake the work lead for a ground cable.

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ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding and cutting current

creates EMF around welding cables and welding machines.

Therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere

with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

a. Route the electrode and work cables together. Secure them with tape when possible.

b. Never coil the torch or work cable around your body.

c. Do not place your body between the torch and work cables. Route cables on the same side

of your body.

d. Connect the work cable to the workpiece as close as possible to the area being welded.

e. Keep welding power source and cables as far away from your body as possible.

FUMES AND GASES

Fumes and gases, can cause discomfort or harm, particularly in confined

spaces. Do not breathe fumes and gases. Shielding gases can cause

asphyxiation.

Therfore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not

weld, cut or gouge on materials such as galvanized steel, stainless steel, cooper, zinc, lead

beryllium or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes

from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc can react with

chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.

3. If you develop momentary eye, nose or throat irritation while operating, this is an indication that

ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.

5. WARNING: This product when used for welding or cutting, produces fumes or gases which

contain chemicals known to the State of Californa to cause birth defects and in some cases

cancer (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING

Cylinders, if mishandled, can rupture and violently release gas. Sudden

rupture of cylinder valve or relief device can injure or kill.

Therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in

good condition. Follow manufacturer's operating instructions for mounting regulator to a

compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks,

undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or fixtures

where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is

not connected. Secure and move cylinders by using suitable hand trucks.

4. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, “Precations for Safe Handling of

Comporessed Gases in Cylinders”, which is available from Compressed Gas Association, 1235

Jefferson Davis Highway, Arlington, VA 22202.

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EQUIPMENT MAINTENANCE

Faulty or improperly maintained equipment can cause injury or death. Therefore:

1. Always have qualified personnel perform the installaion, troubleshooting and maintenance work.

Do not perform any electrical work unless you are qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source

from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord and power supply in safe working

order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as

furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and

inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

ADDITIONAL SAFETY INFORMATION

For more information on safe practices for electric arc welding and cutting equipment,

ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,

Cutting and Gouging”, Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene

Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”

2. AWS C5.1 . “Recommended Practices for Plasma Arc Welding”

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting“

4. AWS C5.3 - “Recommended Practices for Air Carbon, Arc Gouging and Cutting”

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”

7. AWS SP - “Safe practices” - Reprint, Welding Handbook

8. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of Containers That

Have Held Hazardous Substances”

MEANING OF SYMBOLS

As used throughout this manual: Means Attention! Be Alert!

Means immediate hazards which, if not avoided, will result in

immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss

of life.

Means hazards which could result in minor personal injury.

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US warnings

INFORMATIONS COMPLEMENTAIRES RELATIVES A LA SECURITE Pour plus

d'informations relatives aux règles de sécurité pour les travaux de gougeage, de

découpage et de soudage à l'arc électrique, demander au fournisseur une copie du

formulaire 52/529.

L'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 – USA, publie les documents

suivants dont la lecture est également recommandée :

1. ANSI/ASC Z49.1 - ”Safety in Welding and Cutting”

2. AWS C5.1 . ”Recommended Practices for Plasma Arc Welding”

3. AWS C5.2 - ”Recommended Practices for Plasma Arc Cutting”

4. AWS C5.3 - ”Recommended Practices for Air Carbon, Arc Gouging and Cutting”

5. AWS C5.5 - ”Recommended Practices for Gas Tungsten Arc Welding”

6. AWS C5.6 - ”Recommended Practices for Gas Metal Arc welding”

7. AWS SP - ”Safe practices” - Réédition, Manuel de soudage

8. ANSI/AWS F4.1 - ”Recommended Safe Practices for Welding and Cutting of Containers That

Have Held Hazardous Substances”

SYMBOLES

Signification des symboles utilisés dans ce manuel : = Attention ! Rester prudent !

= danger immédiat ; risque de blessures graves ou mortelles.

= danger potentiel ; risque de blessures graves ou mortelles.

= danger ; risque de blessures légères.

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5 SAFETY

Users of ESAB welding 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 welding equipment. The following recommen

dations 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 welding

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 welding equipment must be familiar with:

 its operation

 location of emergency stops

 its function

 relevant safety precautions

 welding

2. The operator must ensure that:

 no unauthorized person is stationed within the working area of the equipment when it is

started up.

 no-one is unprotected when the arc is struck

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 ground 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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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. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES

WHICH SHOULD BE BASED ON MANUFACTURERS' HAZARD DATA.

ELECTRIC SHOCK - CAN KILL

S INSTALL AND EARTH (GROUND) THE WELDING 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!

Read and understand the instruction manual

before installing or operating.

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.

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This product is solely intended for arc welding. Any other use may result in personal

injury and / or equipment damage.

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.

6 INTRODUCTION

The wire feed units Feed 3004 / Feed 4804 with control panel U6, MA23 or MA24

are intended for MIG/MAG welding together with 400A, 500A and 600A CAN

welding power sources.

The wire feed units contain four-wheel drive wire feed mechanisms as well as control

electronics.

They can be used together with wire on ESAB's MarathonPac, or on wire bobbin

(standard Ø 12 inch, accessory Ø 17 inch).

The wire feed unit can be installed either on the power source trolley, suspended above

the workplace, on a counter balance device or on the floor with or without wheel set.

ESAB's accessories for the product can be found on page 36.

6.1 Equipment

The wire feed unit is supplied with:

 instruction manual for the wire feed unit

 instruction manual in English for the control panel

Instruction manuals in other languages can be downloaded from the website,

www.esab.com.

 decal with recommended wear parts.

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6.2 Control panel

The wire feed unit is supplied with one of the following control panels:

Empty panel for use with double wire feed units or with

use of control box U8

Knobs for setting the voltage and the wire feed speed /

current. Other parameters are controlled by

pushbuttons, with text in the display panel.

MA23

Knobs for setting the voltage and the wire feed speed /

current. Other settings with push buttons.

MA24

Knobs for setting the voltage / QSet and the wire feed

speed / current. Other settings with push buttons.

See the separate instruction manual for a detailed description of the control panels.

7 TECHNICAL DATA

Feed 3004 Feed 4804

Mains voltage 42 V 50-60 Hz 42 V 50-60 Hz

Power requirement 336 VA 378 VA

Motor current I

max

8 A 9 A

Wire feed speed .030 - 984 inch/min 030 - 984 inch/min

Gun connection EURO EURO

Max. diameter wire bobbin 12 inch (*17 inch) 12 inch (*17 inch)

Wire dimension

Cored wire

.030 - 1/16 inch

.040 & 1/16 inch

.035 - 1/16 inch

.030 - 3/32 inch

.040 & 3/32 inch

.035 - 3/32 inch

Weight 13.1 Ibs 41.9 Ibs

Dimensions (l x w x h) 27.2 x 10.8 x 16.6 inch 27.2 x 10.8 x 16.6 inch

Operating temperature 14 to +104° F 14 to +104° F

Shielding gas

max pressure

All types intended for

MIG/MAG welding

73 PSI

All types intended for

MIG/MAG welding

73 PSI

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Feed 4804Feed 3004

Type of cooling

max pressure

50 % water /

50 % mono-ethylene glycol

73 PSI

50 % water /

50 % mono-ethylene glycol

73 PSI

Maximum permissible load at

60% duty cycle

100% duty cycle

630 A

500 A

630 A

500 A

Enclosure class IP23 IP23

* Accessories, see page 36.

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.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.

8 INSTALLATION

The installation must be done by a professional.

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

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8.1 Lifting instructions

To avoid personal injury and / or equipment damage, lift using method and

attachment points shown here.

Order number for lifting eyelet can be found on page 36.

NOTE! If another mounting device is used, this must be electrically insulated from

the wire feed unit.

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

9 OPERATION

General safety regulations for the handling of the equipment can be found on

page 3. Read through before you start using the equipment!

TO AVOID SHOCK, DO NOT TOUCH ELECTRODE WIRE OR PARTS IN

CONTACT WITH IT, OR UNINSULATED CABLE OR CONNECTIONS.

ASSURE THAT THE SIDE PANELS ARE CLOSED DURING OPERATION.

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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.

ROTATING PARTS CAN CAUSE INJURY, TAKE GREAT CARE.

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.

RISK OF CRUSHING WHEN REPLACING THE WIRE SPOOL!

DO NOT USE SAFETY GLOVES WHEN INSERTING THE WELDING WIRE

BETWEEN THE FEED ROLLERS..

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.

BE SURE TO PROPERLY INSULATE THIS CONNECTION BEFORE APPLYING

POWER TO THE POWER SOURC. 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.

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UNLESS STARTING TO WELD, DO NOT ALLOW THE WELDING WIRE TO TOUCH A

GROUNDED METAL SURFACE. THE WELDING WIRE BECOMES ELECTRICALLY

HOT WHEN THE SEDONDARY CONTACT IS CLOSED. KEEP FINGERS CLEAR OF

THE DRIVE ROLLS; THEY WILL START TURNING WHEN THE TORCH TRIGGER IS

PRESSED.

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 POSSIBILY

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.

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.

FAILURE TO SHUT OFF SHIELD GAS IN A CONFINED SPACE MAY RESULT IN A

BUILD-UP OF FUMES, DISPLACING OXYGEN.

Do not terminate the arc by removing the torch from the weld area. Release the

torch trigger to stop welding before removing the torch.

When moving the equipment use intended handle. Never pull on the gun.

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9.1 Connections and control devices

1 Control panel,

(see separate instruction manual)

6 Connection for welding current from power

source, (OKC)

Connection for remote control unit

Connection for U8

7 Connection for control cable from power

source or cooling unit

3 Connection BLUE, with ELP* for coolant to

the welding gun

8 Connection RED, for coolant to cooling

unit

4 Connection RED, for coolant from welding

gun

9 Connection for shielding gas

5 Connection for welding gun 10 Connection BLUE, for coolant from cooling

unit

NOTE! Display (digital instrument) and coolant connections only available on certain models.

* ELP = ESAB Logic Pump, see point 9.2.

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.

9.2 Water connection

The wire feed unit with water connection is equipped with a detection system ELP

(ESAB Logic Pump) which checks that the water hoses are connected. When

connecting a water-cooled welding gun, the water pump starts.

Detection only works with power sources that are equipped with ELP.

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9.3 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 insolated object, e.g. a piece of wood.

When you hold the gun approx. 0.2” (5 mm) from the piece of wood (fig. 1) the

feed rollers should slip.

If you hold the gun approx. 2” (50 mm) from the piece of wood, the wire should be

fed out and bend (fig. 2).

9.4 Replacing and inserting Feed 3004 wire

 Open the side panel.

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

slide up.

 If necessary, roll back the wire and remove the wire bobbin.

 Straighten out the new wire 4 - 8 inch. File away 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.

9.5 Replacing and inserting Feed 4804 wire

 Open the side panel.

 Press down and pull the pressure device towards you and up.

 Pull out the bogie.

 If necessary, roll back the wire and remove the wire bobbin.

 Straighten out the new wire 4 - 8 inch. File away 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.

 Reinstall the bogie.

 Close the side panel.

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9.6 Changing feed rollers on Feed 3004

 Open the side panel

 Disconnect the pressure sensor (1) by folding it

backwards.

 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 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 towards you.

9.7 Changing feed rollers on Feed 4804

 Open the side panel.

 Press down and pull the pressure device (1) towards

you and up.

 Pull out the bogie (2).

 Undo the socket head cap screws (3) on the holder

for the intermediate nozzle and remove it.

 Undo the screw for the outflow nozzle (4) and

push back the nozzle.

 Completely undo the socket head cap screw (5) in the

centre.

 Undo the two outer socket head cap screws (6) 1/2 a

turn.

 Pull out the feed rollers (7).

During installation, repeat the above in reverse order.

Choice of track in the feed rollers

Place no, one or two driving washers

between the outer washer and the feed

roller. NOTE! When replacing the

pressure rollers (8), the entire bogie is

replaced.

- 26 -

bm50d1aa

10 MAINTENANCE

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 POSISION DOES NOT REMOVE ALL POWER FROM INSIDE

OF THE EQUIPMENT.

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 NOT HAVING SUCH QUALIFICATIONS.

Supplier warranty is void if customer attempts any work on product during the

warranty period.

Regular maintenance is important for safe, reliable operation.

10.1 Inspection and cleaning

IF UNINSULATED CABLE AND PARTS ARE NOT REPLACED, AN ARC CAUSED BY

A BARED CABLE OR PART TOUCHING A GROUNDED SURFACE MAY DAMAGE

UNPROTECTED EYES OR START A FIRE. BODY CONTACT WITH A BARED

CABLE, CONNECTOR, OR UNCOVERED CONDUCTOR CAN SHOCK, POSSIBLY

FATALLY.

Wire feed unit

Check regularly to insure 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 high, this can result in abnormal wear on the

pressure roller, feed roller and wire guide.

- 27 -

bm50d1aa

The brake hub

The hub is adjusted when delivered, if

readjustment is required, follow the instructions

below. Adjust the brake hub so that wire is slightly

slack when 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.

NB: Turn both springs the same amount.

Welding gun

 Cleaning and replacement of the welding gun's wear parts should take place at

regular intervals in order to achieve trouble-free wire feed. Blow the wire guide

clean regularly and clean the contact tip.

11 ORDERING SPARE PARTS

Do not make any repairs to equipment unless you are fully qualified, as described

in the maintenance section.

FEED 3004, Feed 4804 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 pro

duct still conforms to the 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 on

which the parts will be used. The serial number is stamped on the rating plate.

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ESAB Feed 3004 User manual

Brand: ESAB

Model: Feed 3004

Category: Welding System

Type: User manual

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