ESAB FeedControl 3004HW User manual

GB

Valid for serial no. 201-xxx-xxxx0463 280 001 GB 20120808

Aristo

RoboFeed 3004HW

FeedControl 3004HW

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 7.................................................

4 INSTALLATION 8....................................................

4.1 Terminating resistor 8........................................................

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

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

5.1 Connection and control devices 10.............................................

5.2 Replacing and inserting wire 12................................................

5.3 Changing feed rollers 13......................................................

5.4 Wire feed pressure 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

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.

CAUTION

This product is solely intended for arc welding.

CAUTION

Read and understand the instruction manual before

installing or operating.

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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.

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 on page 22.

2.1 Equipment

The wire feed unit is supplied with an instruction manual and a quick connection for

MarathonPact.

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3 TECHNICAL DATA

RoboFeed 3004HW

Motor voltage 60 VDC PWM (Pulse Width Modulation)

Motor current I

max

8 A

Wire feed speed 0.8 - 30.0 m/min

Gun connection EURO

Wire dimension

Steel (Fe)

Stainless steel (Ss)

Aluminum (Al)

Cored wire (FCW)

0.8-1.6 mm

1.0-1.6 mm

0.8-1.6 mm

Shielding gas

max pressure

Gases for MIG/MAG welding

0.5 Mpa (5 bar)

Maximum permissible load at

60% duty cycle

100% duty cycle

500 A

280 A

Weight 5.4 kg

Dimensions (l x b x h) 251 x 182 x 221 mm

Operating temperature -10 till + 40° C

Transport temperature -20 till + 55° C

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 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.

FeedControl 3004HW

Motor voltage 42 V 50-60 Hz

Power requirement 378 VA

Motor current I

max

9.0 A

Weight 4.9 kg

Operating temperature -10 till + 40° C

Transport temperature -20 till + 55° C

Coolant

max pressure

ESAB ready-mixed coolant *)

0.5 Mpa (5 bar)

Dimension (l x b x h) 330 x 118 x 320 mm

Shielding gas

max pressure

Gases for MIG/MAG-welding

0.5 Mpa (5 Bar)

*) Accessories, see page 22

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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 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.

If U8

2

is used together with W8

2,

the terminal resistor in

the W8

2

must be disconnected, see the instruction

manual for the W8

2.

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.

BS-11-006

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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!

WARNING

Assure that the side panels are closed during operation.

WARNING

Rotating parts can cause injury, take great care.

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5.1 Connection and control devices

RoboFeed 3004HW

1 Outlet for connection to the drive unit from

the electronic unit

5 Rating plate

2 Connection for shielding gas, in 6 Push button for inching

3 Connection for the welding cable or the

return cable.

7 Push button for gas purging

4 Connection for welding gun (EURO) 8 Quick connector MarathonPact

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FeedControl

1

White indicating lamp – Power supply ON

9 Rating plate

2 Connection from electronic unit to drive

unit - pulse signal encoder

10 Connection for terminating resistor or

forwarding to next wire feed unit

3 Connection from electronic unit to drive

unit - 42V power

11 Connection for control cable from power

source

4 Connection for spatter removal air, out 12 Connection for shielding gas, in

5 Connection for coolant to welding gun,

BLUE

13 Connection for spatter removal air, in

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

Inlet spatter removal air

Shielding gas

Outlet spatter removal air

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

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.

Inching

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

Shielding gas out

5.2 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 off any 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.

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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5.3 Changing feed rollers

S Open the side panel.

S Disconnect the pressure sensor (1) by

folding it backwards, the pressure rollers

slide up.

S Disconnect the pressure rollers (2) by

turning the axle (3) 1/4 turn clockwise and

pulling out the axle. The pressure rollers

disconnect.

S Disconnect the feed rollers (4) by

unscrewing the nuts (5) and pulling out the

rollers.

During installation, repeat the above in the

reverse order.

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.

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).

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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

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 pro

duct 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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p

Diagram

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RoboFeed 3004HW

Order number

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Ordering no. Denomination Type

0465 040 880 Drive unit Aristo

R

RoboFeed 3004HW

0461 080 881 Feed Box Aristo

R

Feed Control 3004HW

0465 113 880 Cable and Bracket unit Aristo

R

RoboFeed 3004HW

0459 839 070 Spare parts list Aristo

R

Robo Feed 3004HW & Aristo

R

Feed Control

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

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notes

NOTES

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

RoboFeed 3004HW

S0463 280/E20120808/P24

Wear parts

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Item Ordering no. Denomination Wire type Wire dimensions

HJ 1 0455 072 002

0456 615 001

Intermediate nozzle

Fe, Ss & cored

Al

HJ 2 0469 837 880

0469 837 881

Outlet nozzle

Fe, Ss & cored

Al

Ø 2.0 mm steel for 0.6-1.6 mm

Ø 2.0 mm plastic for 0.8-1.6 mm

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 no. Denomination Wire type Wire dimensions Groove

typ

Roller

markings

HJ 5b 0459 052 001 Feed/pressure rollers Fe, Ss & cored Ø 0.6 & 0.8 mm V 0.6 S2 & 0.8 S2

0459 052 002 Feed/pressure rollers Fe, Ss & cored Ø 0.8 & 1,0 mm V

0.8 S2 & 1.0 S2

0459 052 003 Feed/pressure rollers Fe, Ss & cored Ø 0.9/1.0 & 1.2 mm V 1.0 S2 & 1.2 S2

0459 052 013 Feed/pressure rollers Fe, Ss & cored Ø 1.4 & 1.6 mm V 1.4 S2 & 1.6 S2

0458 825 001 Feed/pressure rollers Cored Ø 0.9/1.0 & 1.2 mm V-Knurled 1.0 R2 & 1.2 R2

0458 825 002 Feed/pressure rollers Cored Ø 1.2 & 1.4 mm V-Knurled 1.2 R2 & 1.4 R2

0458 825 003 Feed/pressure rollers Cored Ø 1.6 mm V-Knurled 1.6 R2 & 2.0 R2

0458 824 001 Feed/pressure rollers Al Ø 0.8 & 0.9/1.0 mm U 0.8 A2 & 1.0 A2

0458 824 002 Feed/pressure rollers Al Ø 1.0 & 1.2 mm U 1.0 A2 & 1.2 A2

0458 824 003 Feed/pressure rollers Al Ø 1.2 & 1.6 mm U 1.2 A2 & 1.6 A2

0458 874 002 Feed/pressure rollers Al Ø 1.0 & 1.2 mm U 1.0 A2 & 1.2 A2

Use only 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

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 3mm for 0.6-1.6mm Fe, Ss, Al and cored wire

HJ 14 0458 999 001 Shaft

HJ 15 F102 440 880 Quick connector For Marathon Pac

TM

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 gun for aluminium wire, equipped with appropriate

wear parts.

Rights reserved to alter specifications without notice.

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