ESAB RoboFeed 3004HW User manual

Category
Welding System
Type
User manual

This manual is also suitable for

ESAB RoboFeed 3004HW wire feed unit is designed for MIG/MAG welding with robotic equipment. It offers precise wire feeding with a speed range of 0.8 to 30.0 m/min. The unit handles various wire types, including steel, stainless steel, aluminum, and flux-cored wire. It features a EURO gun connection and can withstand a maximum load of 500 A at 60% duty cycle. With its compact design and IP2X enclosure class, it's suitable for indoor use.

ESAB RoboFeed 3004HW wire feed unit is designed for MIG/MAG welding with robotic equipment. It offers precise wire feeding with a speed range of 0.8 to 30.0 m/min. The unit handles various wire types, including steel, stainless steel, aluminum, and flux-cored wire. It features a EURO gun connection and can withstand a maximum load of 500 A at 60% duty cycle. With its compact design and IP2X enclosure class, it's suitable for indoor use.

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.......................................................
© ESAB AB 2012
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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.
GB
© ESAB AB 2012
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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.
GB
© ESAB AB 2012
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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.
GB
© ESAB AB 2012
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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
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
GB
© ESAB AB 2012
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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
GB
© ESAB AB 2012
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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.
GB
© ESAB AB 2012
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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
GB
© ESAB AB 2012
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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
GB
© ESAB AB 2012
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bm54d1ea
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.
GB
© ESAB AB 2012
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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).
GB
© ESAB AB 2012
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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.
GB
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p
© ESAB AB 2012
Diagram
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© ESAB AB 2012
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RoboFeed 3004HW
© ESAB AB 2012
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
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RoboFeed 3004HW
S0463 280/E20120808/P24
© ESAB AB 2012
Wear parts
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Item Ordering no. Denomination Wire type Wire dimensions
HJ 1 0455 072 002
0456 615 001
Intermediate nozzle
Intermediate nozzle
Fe, Ss & cored
Al
HJ 2 0469 837 880
0469 837 881
Outlet nozzle
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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ESAB RoboFeed 3004HW User manual

Category
Welding System
Type
User manual
This manual is also suitable for

ESAB RoboFeed 3004HW wire feed unit is designed for MIG/MAG welding with robotic equipment. It offers precise wire feeding with a speed range of 0.8 to 30.0 m/min. The unit handles various wire types, including steel, stainless steel, aluminum, and flux-cored wire. It features a EURO gun connection and can withstand a maximum load of 500 A at 60% duty cycle. With its compact design and IP2X enclosure class, it's suitable for indoor use.

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