ESAB Feed Airmatic User manual

Brand: ESAB

Model: Feed Airmatic

Category: Welding System

Type: User manual

This manual is also suitable for

ESABFeed Airmatic

ESAB Feed Airmatic is a wire feed unit designed for MIG/MAG welding, utilizing a "push-pull" system for smooth and consistent wire feeding. It's compatible with stepped and thyristor-controlled welding power sources and can be used with either wire on ESAB's MarathonPact or on a standard wire bobbin. The unit offers precise wire feed speed control, accepts various shielding gases, and handles wire dimensions ranging from 0.6 to 1.6 mm. Its compact size and flexible mounting options make it suitable for various welding setups.

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.

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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 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).

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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

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.

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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.

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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!

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.

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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.

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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.

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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.

Edition 041 101

Diagram

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ESABFeed Airmatic

Edition 041 101

Ordering number

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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

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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1 Bobbin cover, plastic Ø 300mm ........... 0458 674 880

1 Bobbin cover, metal Ø 300mm ............. 0459 431 880

Bobbin holder ...........................

Adapter for 5 kg bobbin ....................

0458 704 880

0455 410 001

1 Adapter for 440 mm bobbin ................ 0459 233 880

Lifting eye ...............................

Quick connector MarathonPact ...........

0458 706 880

F102 440 880

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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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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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

ESAB Feed Airmatic User manual

Brand: ESAB

Model: Feed Airmatic

Category: Welding System

Type: User manual

This manual is also suitable for

ESABFeed Airmatic

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ESAB Feed Airmatic User manual

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ESAB Feed Airmatic User manual

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