ESAB Fabricator Feed 304, Fabricator Feed 304w Instruction manual

FabricatorFeed304,
FabricatorFeed304w

Instruction manual

0446 451 101  GB  20220303

Valid for: Serial number: from

OP110YY-XXXXXX

TABLE OF CONTENTS

1 SAFETY

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

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 Overview

2.2 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 Overview

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4.2 Lifting Instructions

5 OPERATION

5.1 Overview

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5.2 Connection and control devices

5.3 Water connection

5.4 Starting procedure

5.5 Function explanations

5.6 Wire feed pressure

5.7 Changing and loading wire

5.8 Changing feed rollers

6 MAINTENANCE

6.1 Overview

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6.2 Inspection and cleaning

7 ORDERING SPARE PARTS

WIRING DIAGRAM

ORDERING NUMBERS

ACCESSORIES

WEAR PARTS

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© ESAB AB 2022

1  SAFETY

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!
Means immediate hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life.

WARNING!
Means potential hazards which could result in personal injury or loss of life.

CAUTION!
Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual and follow
all labels, employer´s safety practices and Safety Data Sheets
(SDSs).

1.2 Safety precautions

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 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 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 equipment must be familiar with:

• its operation

• location of emergency stops

• its function

• relevant safety precautions

• welding and cutting or other applicable operation of the equipment

2 The operator must ensure that:

• no unauthorised person is stationed within the working area of the
equipment when it is started up

• no-one is unprotected when the arc is struck or work is started with the
equipment

3 The workplace must:

• be suitable for the purpose

• be free from drafts

4 Personal safety equipment:

• Always wear recommended personal safety equipment, such as safety
glasses, flame-proof clothing, safety gloves

• Do not wear loose-fitting items, such as scarves, bracelets, rings, etc.,
which could become trapped or cause burns

5 General precautions:

• Make sure the return cable is connected securely

• Work on high voltage equipment may only be carried out by a

qualified electrician

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1  SAFETY

• Appropriate fire extinguishing equipment must be clearly marked and
close at hand

• Lubrication and maintenance must not be carried out on the equipment
during operation

WARNING!

Wire feeders are intended to be used with power sources in MIG/MAG mode only.

If used in any other welding mode, such as MMA, the welding cable between wire feeder and
power source must be disconnected, or else the wire feeder becomes live or energized.

If equipped with ESAB cooler

Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize
product safety. In case of such damage, all warranty undertakings from ESAB cease to apply.

For ordering information, see the "ACCESSORIES" chapter in the instruction manual.

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions when
welding and cutting.

ELECTRIC SHOCK - Can kill

• Do not touch live electrical parts or electrodes with bare skin, wet gloves
or wet clothing

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side

of your body. Secure them with tape when possible. Do not
place your body between the torch and work cables. Never coil
the torch or work cable around your body. Keep welding power
source and cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible

to the area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes

• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area

0446 451 101

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing

• Protect bystanders with suitable screens or curtains

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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© ESAB AB 2022

1  SAFETY

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby

• Do not use on closed containers.

HOT SURFACE - Parts can burn

• Do not touch parts bare handed.

• Allow cooling period before working on equipment.

• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.

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.

NOTE!
Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2012/19/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 has an assortment of welding accessories and personal protection equipment for
purchase. For ordering information contact your local ESAB dealer or visit us on our website.

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© ESAB AB 2022

2  INTRODUCTION

2 INTRODUCTION

2.1 Overview

The FabricatorFeed304, FabricatorFeed304w wire feed unit is intended for MIG/MAG-welding
together with welding power sources:

• Fabricator EM 401i

• FabricatorEM 401i with cooling unit

• FabricatorEM 501i with cooling unit

They come in different variants, see chapter "Ordering Numbers".

The wire feed units are sealed and contain four-wheel drive wire feed mechanisms as well as control
electronics.

They can be used together with wire from ESAB's MarathonPac, or from wire bobbin (standard Ø 200
mm, Ø 300 mm and accessory Ø 440 mm).

The wire feed unit can be placed on a trolley, suspended above the workplace with a lifting eye, on a
counter balance or on the floor with or without wheel set.

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.2 Equipment

The FabricatorFeed304, FabricatorFeed304w wire feed unit is supplied with:

• Instruction manual

• Quick start guide

• Safety instruction

• Four Ø1.0/1.2mm V-groove (assembled)

• Sticker with recommended wear parts

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© ESAB AB 2022

3  TECHNICAL DATA

3 TECHNICAL DATA

FabricatorFeed304, FabricatorFeed304w

Power Supply voltage 42 V DC

Power requirement 252 VA

Rated supply current I

1

6 A

Settings data

1.5–25.0 m/min (4.9–82 ft/min)

Wire feed speed

Torch connection EURO

Max. diameter wire bobbin 300 mm (12 inch), *440 mm (17 inch)

Wire dimension

Fe 0.8–1.6 mm (0.030 – 1/16 inch)

SS 0.8–1.6 mm (0.030 – 1/16 inch)

Cored wire 0.9–1.6 mm (0.035 – 1/16 inch)

Weight

FabricatorFeed304 with bobbin cover 13.9kg (30.6Ibs)

FabricatorFeed304w with bobbin cover 14.2kg (31.3Ibs)

Wire spool weight (ESAB standard)

Ø 200 mm 5 kg (11.0 lbs)

Ø 300 mm 18 kg (39.7 lbs)

Ø 440 mm 30 kg (66.1 lbs)

Dimensions (l × w × h)

(basic)


675×265×418mm (26.6×10.4×16.5inch)

Operating temperature -10° to +40°C (+14° to +104°F)

Transport and storage temperature -20° to +55°C (-4° to +131°F)

Shielding gas

max pressure

Coolant(FabricatorFeed304w)
max pressure

All types intended for MIG/MAG welding
5 bar (0.5 Mpa)

ESAB's ready mixed coolant
5 bar (0.5 Mpa)

Permissible load at

60% duty cycle 500 A

100% duty cycle 400 A

Enclosure class IP23

with the Ø 440 mm (Ø 17 inch) bobbin and/or the
counter balance device

*)

See the "ACCESSORIES" chapter in the instruction manual.

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 104°F (40°C).

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3  TECHNICAL DATA

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 intended for indoor and outdoor use.

Equipment marked IP2X is intended for indoor use.

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© ESAB AB 2022

4  INSTALLATION

4 INSTALLATION

4.1 Overview

The installation must be carried out by a professional.

4.2 Lifting Instructions

CAUTION!

Risk of crushing when lifting the wire feeder. Mounting a large wire bobbin (Ø 440 mm), may
change the centre of gravity of the wire feeder and increase the risk of tipping and crushing.
Protect yourself and warn bystanders of the risk.

CAUTION!

To avoid personal injury and / or equipment damage, lift using method and attachment points
shown here.

Ordering number for the lifting eye can be found in chapter "ACCESSORIES".

NOTE!

If another mounting device is used, this should be insulated from the wire feed unit.

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© ESAB AB 2022

5  OPERATION

5 OPERATION

5.1 Overview

General safety regulations for handling the equipment can be found in the "SAFETY" chapter
of this manual. Read it through before you start using the equipment!

WARNING!

To avoid shock, do not touch electrode wire or parts in contact with it, or uninsulated cable or
connections.

NOTE!

When moving the equipment, use handle intended for transportation. Never pull the equipment
by the welding torch.

WARNING!

Assure that the side panels are closed during operation.

WARNING!

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.

CAUTION!

Before threading welding wire, make sure the chisel point and burrs have been removed from
the end of the wire to prevent the wire from jamming in the torch liner.

WARNING!

Rotating parts can cause injury, take great care.

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© ESAB AB 2022

5  OPERATION

WARNING!

There is a risk of tipping if the wire feed unit is fitted with a counterbalance arm. Make sure to
install the stabilizer kit and secure the equipment, especially if used on an uneven or sloping
surface.

Recommended maximum welding current values for the interconnection set at an ambient
temperature of +25°C and normal 10minutes cycle

Cable size (mm2)

Duty cycle

100% 60% 35%

Voltage drop /

10m

50 290A 320A 370A 0.35V / 100A

70 360A 400A 480A 0.25V / 100A

95 430A 500A 600A 0.19V / 100A

Recommended maximum welding current values for the interconnection set at an ambient
temperature of +40°C and normal 10minutes cycle

Cable size (mm2)

Duty cycle

100% 60% 35%

Voltage drop /

10m

50 250A 280A 320A 0.35V / 100A

70 310A 350A 420A 0.25V / 100A

95 380A 440A 530A 0.19V / 100A

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/104°F, or below.

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© ESAB AB 2022

5  OPERATION

5.2 Connection and control devices

1 Knob for setting the voltage 7 Connection for welding current from power

source (OKC)
2 Knob for setting the wirefeed speed 8 Connection for control cable from power source
3 Switch for wire inching or gas purge 9 Connection for shielding gas
4 Connection RED for cooling water from welding

torch *)

5 Connection BLUE for cooling water to the

welding torch *)

6 Connection for the welding torch

10 Connection BLUE for cooling water from power

source (cooling unit) *)

11 Connection RED for cooling water to power

source (cooling unit) *)

NOTE!

*) Cooling water connections only available on certain models.

5.3 Water connection

When connecting a water-cooled welding torch, the main power supply switch of the power source
must be in the OFF position and the cooling unit switch must be in position 0.

A water connection kit can be orderred as accessory, see chapter "Accessories".

5.4 Starting procedure

When the wire feed starts, the power source generates welding voltage.

If there is no welding current flow within ten seconds, the power source switches the welding voltage
off. The wire feed continues until the welding torch's switch is switched off.

5.5 Function explanations

Wire inching

Wire inching is used when one needs to feed wire without welding voltage being
applied. The wire is fed as long as the button is depressed.

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5  OPERATION

Wire feed speed

This sets the required feed speed of the filler wire in m/minute.

The corresponding current for the respective wire feed speed will be displayed on the
power source.

5.6 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 high.

Figure A Figure B

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 welding torch approximately 5mm from the piece of wood (Figure A), the feed
rollers should slip.

If you hold the welding torch approximately 50 mm from the piece of wood, the wire should be fed out
and bend (Figure B).

5.7 Changing and loading wire

• Open the side panel.

• Disconnect the pressure sensor by folding it backwards, the pressure rollers slide up.

• 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.

• Make sure that the wire goes properly into the feed roller's track and into the outlet

nozzle or wire guide.

• Secure the pressure sensor.

• Close the side panel.

5.8 Changing feed rollers

• Open the side panel.

• Disconnect the pressure sensor (1) by
folding it backwards.

• Disconnect the pressure rollers (2) by
turning the axle (3) 1/4 turn clockwise and
pulling out the axle.

The pressure rollers disconnect

• Disconnect the feed rollers (4) by
unscrewing the nuts (5) and pulling out the
rollers.

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© ESAB AB 2022

5  OPERATION

During installation, repeat the above in the reverse order.

Choice of track in the feed rollers

Turn the feed roller with the dimensioning mark for the required track towards you.

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© ESAB AB 2022

6  MAINTENANCE

6 MAINTENANCE

6.1 Overview

NOTE!

Regular maintenance is important for safe and reliable operation.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer attempts any work
to rectify any faults in the product during the warranty period.

6.2 Inspection and cleaning

Wire feed unit

Check regularly that the wire feed unit is not clogged with dirt.

• 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.

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.

• Adjusting the braking torque:

○ Turn the red handle to the locked

position.

○ Insert a screwdriver into the springs in

the hub.

Turn the springs clockwise to reduce the
braking torque.
Turn the springs counter-clockwise to
increase the braking torque.
Note: Make sure you turn both springs the
same amount.

Welding torch

• Cleaning and replacement of the welding torch'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.

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© ESAB AB 2022

7  ORDERING SPARE PARTS

7 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician.
Use only ESAB original spare and wear parts.

The FabricatorFeed304 and FabricatorFeed304w are designed and tested in accordance with
international and European standards ENIEC60974-5 and ENIEC60974-10. On completion of
service or repair work, it is the responsibility of the person(s) performing the work to ensure that the
product still complies with the requirements of the above standards.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When
ordering, please state product type, serial number, designation and spare part number in accordance
with the spare parts list. This facilitates dispatch and ensures correct delivery.

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© ESAB AB 2022

APPENDIX

APPENDIX

WIRING DIAGRAM

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© ESAB AB 2022

APPENDIX

ORDERING NUMBERS

Ordering Number Denomination Type

0446 401 881 FabricatorFeed304

0446 401 882 FabricatorFeed304w with water cooling

0446 451 * Instruction manual

0463 788 001 Service manual

0463 795 001 Spare parts list

The three last digits in the document number of the manual show the version of the manual. Therefore
they are replaced with * here. Make sure to use a manual with a serial number or software version that
corresponds with the product, see the front page of the manual.

Technical documentation is available on the Internet at: http://manuals.esab.com.

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© ESAB AB 2022

APPENDIX

ACCESSORIES

0458 674 880 Bobbin cover kit, plastic Ø 300 mm

0458 707 880 Wheel kit

0458 707 881 Wheel kit

0459 233 880 Adapter for Ø 440 mm bobbin



Note! IP23 not valid for wire feeder with Ø 17,32
Inch (400 mm) bobbin.

0458 706 880 Lifting eye

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© ESAB AB 2022

APPENDIX

0457 341 881 Strain relief for welding torch

F102 440 880 Quick connector MarathonPac™

0459 234 880 Strain relief bracket for connection set

0465 276 881 Water kit

0458 705 880 Counter balance device (includes mast and

counter balance)

Note! IP23 not valid for wire feeder with
counterbalance arm.

Connection set, 70 mm², 19 poles

0459 836 880

0459 836 881

0459 836 882

0459 836 883

0459 836 884

0459 836 885

2 m

5 m

10 m

15 m

25 m

35 m

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© ESAB AB 2022

APPENDIX

Connection set water, 70 mm², 19 poles

0459 836 890

0459 836 891

0459 836 892

0459 836 893

0459 836 894

0459 836 895

2 m

5 m

10 m

15 m

25 m

35 m

Connection set, 95 mm², 19 poles

0459 836 980

0459 836 981

0459 836 982

0459 836 983

0459 836 984

0459 836 985

2 m

5 m

10 m

15 m

25 m

35 m

Connection set water, 95 mm², 19 poles

0459 836 990

0459 836 991

2 m

5 m

0459 836 992

0459 836 993

0459 836 994

0459 836 995

10 m

15 m

25 m

35 m

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© ESAB AB 2022

APPENDIX

WEAR PARTS

Item Ordering

number

HI 1 0455 072 002 Intermediate nozzle Fe, Ss & cored Ø 2.0 mm steel for 0.6-1.6 mm

HI 2 0469 837 880 Outlet nozzle Fe, Ss & cored Ø 2.0 mm steel for 0.6-1.6 mm

HI 3 0191 496 114 Key

HI 4 0215 701 007 Locking washer

HI 5a 0459 440 001 Motor gear euro,

Item Ordering

number

HI 5b 0459 052 001 Feed/pressure rollers Fe, Ss

0459 052 002 Feed/pressure rollers Fe, Ss

0459 052 003 Feed/pressure rollers Fe, Ss

0459 052 013 Feed/pressure rollers Fe, Ss

Denomination Wire type Wire dimensions

drive gear

Denomination Wire

type

& cored

& cored

& cored

& cored

Wire dimen-

sions (mm)

Ø 0.6 & 0.8 V 0.6 S2 &

Ø 0.8 & 1.0 V 0.8 S2 &

Ø 0.9/1.0 & 1.2 V 1.0 S2 &

Ø 1.4 & 1.6 V 1.4 S2 &

Groove

type

Roller

markings

0.8 S2

1.0 S2

1.2 S2

1.6 S2

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

knurled

0458 825 010 Feed/pressure rollers Cored Ø 1.2 & 1.2 V-

knurled

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

knurled

0458 825 003 Feed/pressure rollers Cored Ø 1.6 V-

knurled

Only use pressure and feed rollers marked A2, R2 or S2.

The rollers are marked with wire dimension in mm, some are also marked with inch.

1.0 R2 &

1.2 R2

1.2 R2 &

1.2 R2

1.2 R2 &

1.4 R2

1.6 R2 &

2.0 R2

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APPENDIX

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© ESAB AB 2022

APPENDIX

Item Ordering number Denomination Notes

HI 6 Washer Ø 16/5×1

HI 7 Screw M4×12

HI 8 Screw M6×12

HI 9 Washer Ø 16/8.4×1.5

HI 10 0469 838 001 Cover

HI 11 0458 722 880 Axle and Nut

HI 12 0459 441 880 Gear adapter

HI 13 0455 049 001 Inlet nozzle Ø 3mm for 0.6-1.6mm Fe, Ss and cored wire

0460 007 001 Inlet nozzle Long-life for Fe, Ss and cored wire

HI 14 0458 999 001 Shaft

HI 15 Nut M10

HI 16 0458 748 002 Insulating washer

HI 17 0458 748 001 Insulating

bushing

Item Ordering

Denomination Wire type Wire dimensions

number

HI 18 0156 602 001 Inlet nozzle Ø 16/5×1 Ø 2 mm plastic for 0.6 - 1.6 mm

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APPENDIX

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© ESAB AB 2022

APPENDIX

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© ESAB AB 2022

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone [phone]

http://manuals.esab.com

For contact information visit http://esab.com