ESAB FeedMech 4804 User manual

Category
Welding System
Type
User manual

ESAB FeedMech 4804, FeedControl - Aristo® is a wire feed unit designed for MIG/MAG welding in combination with robotic equipment. It offers precise wire feeding with adjustable speed from 0.8 to 25.0 m/min, accommodating various wire diameters and types, including Fe, Ss, Al, and cored wires. The unit features a user-friendly interface for easy operation and monitoring. Its compact design and IP2X enclosure rating make it suitable for indoor use.

ESAB FeedMech 4804, FeedControl - Aristo® is a wire feed unit designed for MIG/MAG welding in combination with robotic equipment. It offers precise wire feeding with adjustable speed from 0.8 to 25.0 m/min, accommodating various wire diameters and types, including Fe, Ss, Al, and cored wires. The unit features a user-friendly interface for easy operation and monitoring. Its compact design and IP2X enclosure rating make it suitable for indoor use.

GB
Valid for serial no. 410-xxx-xxxx0461 066 101 GB 20140625
Aristo
®
FeedMech 4804/
FeedControl
Instruction manual
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- 3 -
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.......................................................
© ESAB AB 2014
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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 2014
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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.
GB
© ESAB AB 2014
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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
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
GB
© ESAB AB 2014
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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.
GB
© ESAB AB 2014
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4.2 Example of a robotic welding system
AH 0934
GB
© ESAB AB 2014
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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.
GB
© ESAB AB 2014
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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
GB
© ESAB AB 2014
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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
GB
© ESAB AB 2014
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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.
GB
© ESAB AB 2014
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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.
GB
© ESAB AB 2014
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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.
GB
© ESAB AB 2014
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NOTES
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© ESAB AB 2014
Diagram
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FeedControl & FeedMech 4804
© ESAB AB 2014
- 17 -
© ESAB AB 2014
FeedMech 4804/FeedControl
Order number
- 18 -
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
© ESAB AB 2014
- 19 -
© ESAB AB 2014
FeedMech 4804/FeedControl
Wear parts
- 20 -
HD = Heavy Duty
Item Ordering no. Denomination Wire type Wire dimensions
HK1 0469 837 880
0469 837 881
0469 837 882
Outlet nozzle
Outlet nozzle
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
Intermediate nozzle
Intermediate nozzle
Intermediate nozzle
Fe, Ss & Al
Fe, Ss & Al
Cored
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
Inlet nozzle (HD)
Inlet nozzle (HD)
Fe, Ss, Al & Cored
Fe, Ss, Al & Cored
Fe, Ss & 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 AB 2014
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ESAB FeedMech 4804 User manual

Category
Welding System
Type
User manual

ESAB FeedMech 4804, FeedControl - Aristo® is a wire feed unit designed for MIG/MAG welding in combination with robotic equipment. It offers precise wire feeding with adjustable speed from 0.8 to 25.0 m/min, accommodating various wire diameters and types, including Fe, Ss, Al, and cored wires. The unit features a user-friendly interface for easy operation and monitoring. Its compact design and IP2X enclosure rating make it suitable for indoor use.

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