ESAB ESABFeed Airmatic User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
GB
Valid for serial no. 338--xxx--xxxx0459 454 001 GB 041101
ESABFeed Airmatic
Instruction manual
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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 4...................................................
3.1 Equipment 5................................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Lifting instructions 6.........................................................
6 OPERATION 7.......................................................
6.1 Connections and control devices 7............................................
6.2 Connecting welding hose 8...................................................
6.3 Connecting compressed air 8.................................................
6.4 Wire feed pressure 8........................................................
6.5 Replacing and inserting wire 8................................................
6.6 Changing feed roller 9.......................................................
7 MAINTENANCE 9....................................................
7.1 Inspection and cleaning 9....................................................
8 ORDERING SPARE PARTS 10..........................................
DIAGRAM 11............................................................
ORDERING NUMBER 12.................................................
WEAR COMPONENTS 13.................................................
ACCESSORIES 14.......................................................
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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, declares that Wire feed unit ESABFeed
Airmatic from serial number 338 onwards, conforms to standard EN 60974--5, in accordance with the
requirements of directive (73/23/EEC) and appendix (93/68/EEC) and standard EN 50199 in accord-
ance with the requirements of directive (89/336/EEC) and appendix (93/68/EEC).
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Henry Selenius
Vice President
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2003--10--02
2SAFETY
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:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorized 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
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bm37d1ea
WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS 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 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 y our 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 y our 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!
ESAB can provide you with all necessary welding protection an d accessories.
WARNING!
Read and understand the instruction manual before installing
or operating.
This product is solely intended for arc welding.
3 INTRODUCTION
Wire feed unit ESABFeed Airmatic with control panel M10 is intended for MIG/MAG
welding together with stepped and thyristor--controlled welding power sources.
The wire feed unit is a component in ESAB’s “push--pull” system. The wire feed unit
pushes the wire through the welding hose to the welding gun, after which the
pneumatically--operated motor in the gun piston draws the wire to the contact tip.
This provides even, interference--free wire feed, which is beneficial when welding
with soft auxiliary material such as aluminium and with thin wires.
The welding wire is insulated from the outer casing of the feed unit.
This can be used together with wire on ESAB’s MarathonPact, or on wire bobbin
(standard Ø 300 mm, accessory Ø 440 mm).
GB
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bm37d1ea
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.
ESAB’s accessories for the product can be found on page 14.
3.1 Equipment
ESABFeed Airmatic is supplied with an Allen key, hose clamp, 5 inlet nozzles for the
welding gun and an instruction m anual.
4 TECHNICAL DATA
ESABFeed Airmatic
Power supply 42 V 50--60 Hz
Power requirement 85 VA
Motor current I
max
2A
Wire feed speed Max 15 m/min (set on the welding gun)
Gun connection ESAB
Max. diameter wire bobbin 300 mm (*440 mm)
Wire dimension
Inlet nozzle
Outflow nozzle
0.6--1.6 mm
Hole diameter Ø 2.7 mm
Hole diameter Ø 1.5 mm **
Weight 15 kg
Dimensions (l x b x h) 690 x 275 x 420 mm
Shielding gas
max pressure
All types intended for MIG/MAG welding
5 bar
Air pressure Min 5 bar
Maximum permissible load at
60% duty cycle
400 A
Enclosure class
with wire bobbin *440 mm
IP23
IP2X
* Accessories, see page 14.
** At 1.6 mm wire the outflow nozzle is removed.
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Apparatus marked IP 2X are intended for indoor use.
GB
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bm37d1ea
5 INSTALLATION
The installation must be execu ted by a p rofession al.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’ s responsibility to take adequate precautions.
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 .
5.1 Lifting instructions
Order number for lifting eyelet can be found on page 14.
Note! If another mounting device is used, this should be insulated from the wire feed
unit.
GB
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bm37d1ea
6OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
WARNING!
Assure that the side panels are closed during operation.
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!
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.
When moving the equipment use intended handle. NOTE! Never pull on the gun.
6.1 Connections and control devices
1 Display 6 Connection for welding current from power sour-
ce, (OKC)
2 Knob for setting the voltage 7 Connection for control cable from power unit
3 Switch for remote control OFF / ON 8 Connection for compressed air
4 Connection for remote control unit 9 Connection for shielding gas
5 Connection for welding gun
Note! Display (digital instrument) is an accessory, see page 14.
GB
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6.2 Connecting welding hose
S Select an inlet nozzle with the correct dimension
for the wire.
S Press the inlet nozzle (a) into the welding hose.
S Open the side panel. Undo the Allen screw (c) in
the connection plate.
S Connect the welding hose ( b) to the wire feed unit
and tighten the Allen screw (c) in the connection
plate.
S Remove the plastic cover from the gun housing.
Undo the locking screw (d) and press the front
end of the hose into the gun. Tighten the locking
screw (d) and reinstall the plastic cover.
6.3 Connecting compressed air
Connect compressed air, at least 5 bar. The air goes to a filter regulator that is
pre--set to 5 bar. The regulator drains itself when the compressed air is switched off.
6.4 Wire feed pressure
The wire feed unit has a driving feed roller (5) and an accompanying pressure roller
(2). The pressure roller is located on a shaft supported on bearings. The pressure on
the wire can be altered with the pressure roller’s spring ( 3), which can be adjusted to
different positions.
6.5 Replacing and inserting wire
The wire guide is made of plastic and is sensitive to sharp objects. File away burrs
and sharp edges from the tip of the wire before the new welding wire is inserted in
the wire guide.
S Open the side panel.
S Disconnect the pressure roller’s spring (3).
S Roll back the remaining wire from the wire guide.
Remove the bobbin.
S Install the new bobbin.
S Straighten out 5--10 cm of wire and file away
burrs from the tip of the wire.
S Check that the dimensions of the following
components are correct: feed roller (5), outflow
nozzle (1), inlet nozzle ( 4), welding gun’s inlet
nozzle and contact tip.
S Insert the wire into the wire feed unit. Make sure that it goes properly
into the feed roller’s track and into the outflow n ozzle. (When welding with 1.6
mm welding wire, the outflow nozzle must b e removed.) Insert the wire
approximately 10 cm into the welding hose.
GB
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bm37d1ea
S Secure the pressure roller’s spring (3).
S Start up the power source, press in the gun trigger switch and allow the wire to
be fed forwards through the welding hose and out through the contact tip.
6.6 Changing feed roller
S Open the side panel.
S Disconnect the pressure roller’s spring (3).
S Disconnect the feed roller ( 5) by twisting it so that the pipe pin is horizontal,
press out the pipe pin and pull out the roller.
During installation, repeat in the reverse order.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
7.1 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.
Cleaning the inlet and outflow nozzles
S Undo the screw in the connection block with an Allen key. Remove the
welding hose.
S Undo the two stop screws holding the inlet and outflow nozzles in place and
remove them.
S Install in reverse order.
Filter regulator
Regularly check that the regulator’s drainage is working. Water
in the compressed air to the gun causes operational
interference.
S When the compressed air is on, there m ay be water in the
container (1).
S When the compressed air is switched off, the valve (2) in
the bottom of the container opens and any water runs out.
GB
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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 that wire is slightly
slack when wire feed stops.
S Adjusting the braking torque:
S Turn the red handle to the locked position.
S Insert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs counterclockwise to increase the braking torque. NB: Turn
both springs through the same amount.
Weldin g gu n
S 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.
8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
ESABFeed Airmatic is designed and tested in accordance with the international and
European standards IEC/EN 60974--5 and EN 50199. 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
Edition 041 101
Diagram
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bm37e11a
ESABFeed Airmatic
Edition 041 101
Ordering number
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bm37o11a
Ordering no. Denomination Type
0459 116 680 Wire feed unit ESABFeed Airmatic
0459 454 990 Spare parts list ESABFeed Airmatic
ESABFeed Airmatic
Edition 041 101
Wear components
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bm37w11a
1.
Item Ordering no. Denomination Note
1 0156 602 001 Inlet nozzle Ø 2 mm plastic for 0.6--1.6 mm, Fe, Ss, Al & Cored
2 0458 748 001 Insulating bushing
3 0458 748 002 Insulating washer
4 Nut M10
5 Roll pin Ø2x16mm
6 0258 005 101 Outlet nozzle Ø1.5mm
7 0332 419 001 Inlet nozzle Ø2.0mm
8 0458 229 001
0458 229 002
Feed roller
Feed roller (S)
For Ø 0.6 -- 1.0 mm wire
For Ø 1.0 -- 1.6 mm wire
S= Standard
Edition 041 101
ESABFeed Airmatic
Accessories
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bm37a11a
1 Bobbin cover, plastic Ø 300mm ........... 0458 674 880
1 Bobbin cover, metal Ø 300mm ............. 0459 431 880
1
2
Bobbin holder ...........................
Adapter for 5 kg bobbin ....................
0458 704 880
0455 410 001
1 Adapter for 440 mm bobbin ................ 0459 233 880
1
2
Lifting eye ...............................
Quick connector MarathonPact ...........
0458 706 880
F102 440 880
1
2
3
Turning piece ............................
Guide pin ................................
Quick connector MarathonPact ...........
0458 703 880
0156 654 883
F102 440 880
Edition 041 101
ESABFeed Airmatic
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bm37a11a
1 Wheel kit ................................ 0458 707 880
1 Strain relief for welding gun .............. 0457 341 881
Strain relief bracket for connection set .... 0459 234 880
Digital Volt / Ampere meter
for ESABMig 400t and ESABMig 500t ........
0455 173 882
Remote control unit M1 ..................
MIG/MAG:wire feed speed and voltage
0459 491 895
Remote cable 23 pole -- 8 pole
5m......................................
0459 553 880
Extension cable for remote control 23 pole
8m......................................
16m.....................................
0467 197 880
0467 197 881
Edition 041 101
ESABFeed Airmatic
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bm37a11a
Connection set for 400 A power sources
Connection set 1.7 m ......................
Connection set 5 m ........................
Connection set 10 m .......................
Connection set 15 m .......................
0469 836 900
0469 836 901
0469 836 902
0469 836 903
Welding gun PKB 250 and PKB 400
PKB250 .................................
PKB400 .................................
Welding hose for PKB 250, 5 m .............
Welding hose for PKB 250, 10 m ............
Welding hose for PKB 250, 16 m ............
Welding hose for PKB 400, 5 m .............
Welding hose for PKB 400, 10 m ............
Welding hose for PKB 400, 16 m ............
Curved swanneck for PKB 250 Ø 9 mm, 60˚..
Straight swanneck for PKB 250 Ø 8 mm ......
Curved swanneck for PKB 250 Ø 8 mm, 45˚..
Straight swanneck for PKB 250 Ø 9 mm ......
Curved swanneck for PKB 250 Ø 9 mm, 45˚..
Curved swanneck for PKB 400 Ø 9 mm, 60˚..
Straight swanneck for PKB 400 Ø 8 mm ......
Curved swanneck for PKB 400 Ø 8 mm, 45˚..
0152 700 881
0152 470 881
0468 790 880
0468 790 881
0468 790 882
0468 790 883
0468 790 884
0468 790 885
0469 320 880
0368 002 880
0367 581 880
0368 002 883
0367 581 881
0469 321 880
0368 002 881
0367 582 880
Counter balance device
(includes mast and counter balance)
for 300 mm bobbin ........................
for 440 mm bobbin ........................
0458 705 880
0458 705 882
Edition 041 101
ESABFeed Airmatic
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bm37a11a
Feeder stand . ........................... 0458 522 880
ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.co m
031021
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen-- Valby
Tel:+4536300111
Fax:+4536304003
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel:+33130755500
Fax:+33130755524
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel:+3612044182
Fax:+3612044186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:+3902979681
Fax:+390297289181
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel:+4733121000
Fax:+4733115203
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:+421744882426
Fax:+421744888741
SPAIN
ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:+4631509500
Fax:+4631509222
ESAB International AB
Gothenburg
Tel:+4631509000
Fax:+4631509360
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 3369 4333
Fax: +55 31 3369 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39
SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: +82 551 289 81 11
Fax: +82 551 289 88 63
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA--CIS
ESAB Representative Office
Moscow
Tel:+70959379820
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel:+78123254362
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.co m
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ESAB ESABFeed Airmatic User manual
- Category
- Welding System
- Type
- User manual
- This manual is also suitable for
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