ESAB Feed 30, Feed 30w Instruction manual

Feed 30
Feed 30w



Origo





Instruction manual

Valid for serial no. 6380349 301 132 070426

ENGLISH

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Connection and control devices 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Function explanation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Wire feed pressure 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Changing / loading wire 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Flux -- cored wires welding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Aluminium wire welding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Inspection and cleaning 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 FAULT TRACING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING OF SPARE PARTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEAR COMPONENTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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document

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ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, declares that Wire feed unit OrigoTMFeed
30w from serial number 638 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 60974--10 in accord­ance with the requirements of directive (89/336/EEC) and appendix (93/68/EEC).

DECLARATION OF CONFORMITY

--------------------------------------------------------------------------------------------------------------------------------------

Laxå 2007--04--23

Kent Eimbrodt
Global Director Equipment and Automation
ESAB AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

1 SAFETY

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 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 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 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 draughts

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

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU­TIONS 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 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.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING!

Read and understand the instruction manual
before installing or operating.

WARNING!

Do not use the power source for thawing frozen pipes.

This product is solely intended for arc welding.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human health!

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2 INTRODUCTION

The OrigoTMFeed 30, Feed 30w wire feed unit is intended for MIG/MAG welding
together with step controlled welding power sources, with solid steel, stainless steel,
aluminium wire and flux--cored wires.

ESAB’s accessories for the product can be found on page 18.

2.1 Equipment

The wire feed unit is supplied with:

S Marathon PAC bracket
S Reel adaptors
S Instruction manual

3 TECHNICAL DATA

OrigoTMFeed 30, Feed 30w

Power supply 42V, 1∼∼∼∼50/60 Hz
Power requirement 420 VA
Welding current @60% duty cycle 500 A

Settings data

Wire feed speed 1,5--25 m/min
Burnback time 0,0--0,7 sec
Spot welding time 0,2--5,0 sec

Welding gun connection EURO
Wire dimension range 0,8--1,6 (Fe,SS);

1,0--1,6 ( Al);
1,0--1,6 (FCW)

Shielding gas All types for MIG/MAG -- max 5 bar
Max diam. / weight of wire bobin 300 mm / 18kg
Dimensions lxwxh 700x255x420
Weight 14,8 kg (Feed 30)

with cooling liquid system 15,0 kg (Feed 30w)

Operating temperature --10 to +40oC
Enclosure class IP 23 (wire bobbin -- IP 2X)
Application classification

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer­tain 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.

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.

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Application class

The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION

The installation must be executed by a professional.

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 .

a. Connect the wire feeder with the welding rectifier. Temporary keep the

current cable disconnected.

b. Connect the wire feeder to gas regulator by means of gas hose.

Attention: Use gas heater only for pure CO2.

c. Connect a welding torch. If it is liquid--cooled, connect its hoses to

appropriate connectors, turning aside an arm of the pump switch (ELP).

Hoses and appropriate connectors are marked in red and blue.
d. Install the bobbin with electrode wire.
e. Input the wire between the rolls and further to the torch connector, at least

for 20cm inside. Type of the rolls should match the side and the type of used

electrode wire. Take in account, that for convenience, marking on the side of

the rolls corresponds the size of the groove on the opposite side.
f. Close the rolls and adjust an optimal radial pressure by means of knobs.

Setting recommendation is placed on the inner side of the cover.
g. Set braking force of the wire bobbin by means the bolt placed inside the

bobbin holder.

Attention! Keep attention during replacement of the bobbin. Don’t use gloves

while installing the bobbin and inputting the wire into the torch.

h. Set mode selector (2) in position (inching). Press the torch switch and let

the wire go through the torch up to its appearance out of the torch.

i. Set mode selector (2) in

position (gas purge). Press the torch switch and

adjust the gas flow.

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j. Connect current cables. Set voltage in the welding rectifier. Switch the

rectifier on. The machine is ready for welding.

The wire feeder is factory -- equipped with insulating feet that allow to put the feeder
on top of power source or directly on the ground.
Feeder can optionally be equipped with accessory wheel set (see page 18).

5 OPERATION

General safety regulations for the handling of 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.

WARNING!

To prevent the reel 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.

When moving the equipment use intended handle. NOTE! Never pull on the gun.

5.1 Connection and control devices

1 Power ON indicator 7 Cooling liquid connectors with pump switch

(Feed 30w)

2 Wire feeder speed knob 8 Torch connector
3 Mode selector (see table below) 9 Control cable terminal
4 Burn--back time knob 10 Gas inlet

5 Spot welding time knob 11 Current terminal (from power source)
6 Creep speed knob 12 Cooling liquid connectors (Feed 30w)

Symbols explanation:

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wire feeding / inching gas purge

2--stroke burn--back

4--stroke creep speed

spot welding / spot
welding time

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5.2 Function explanation

5.2.1 2--stroke mode

Set the 2--stroke mode by means of the knob (3). Set required wire speed by means
of the knob (2). The creep speed option can be set by means of the knob (6). If
creep speed is chosen the wire speed before the actual start of welding is reduced
by two. The creep speed is not recommended for speed setting close to the minimal.
The burn--back time should set by means of the knob (4). This setting should be
chosen experimentally, starting from the lowest values.
Pressing the torch switch opens the gas valve and then switching the power source
on and feeding the wire. Releasing the torch switch stops the wire feeding. After
delay proportional to burn--back time setting the power is switched off. Eventually
the gas is cut off too.

5.2.2 4--stroke mode

Set the 4--stroke mode by means of the knob (3). Other settings as for 2--stroke
mode.
This mode could be described as follows:

1. switch pressed -- gas starts to flow,

2. switch released -- power source is switched and wire is fed, the actual start of
welding,

3. switched pressed again -- stop of welding, gas remains flowing,

4. switch released -- cut off the gas.

5.2.3 Burnback time

Burnback time is a delay between the time when the wire starts to brake until the
time when the power source switches off the welding voltage. Too short burnback
time results in a long wire stickout after completion of welding, with a risk of the wire
being caught in the weld pool. Too long a burnback time results in a shorter stickout,
with increased risk of the arc striking back to the contact tip.

5.2.4 Creep start

Creep start means that the wire is fed at reduced speed within 1 sec after welding
torch trigger is pressed, and then the speed increases to the set speed.

5.2.5 Inching and gas purge modes

Set the required mode by means of the knob (3). Inching or gas purge is started by
means of the torch switch.

5.2.6 Wire feed speed

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

5.2.7 Spot welding

Set the spot welding mode by means of the knob (3). Set the required time of the
spot welding by means of the knob (5). Other settings as for previously described
modes. The control sequence is similar to 2--stroke mode sequence. The difference
is that the welding is stopped automatically after particular time. The torch switch
must be pressed up to the end of welding. Releasing the torch switch enables the
next spot welding cycle.

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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 insolated 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 Changing / loading 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 Flux -- cored wires welding

A set of special feeding rolls (2 pcs.) for 1,0; 1,2 mm or 1,6 mm wire diameter should
be used for flux--cored wires.

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5.6 Aluminium wire welding

In case of aluminium wires welding, appropriate equipment is to be used.

1. Replace the set of 4 feeding rolls with aluminium intended ones for appropriate
wire diameter.

2. Replace steel nozzle in the torch connector with plastic nozzle for aluminium
wire.

3. Apply the torch armed for aluminium wire of particular wire diameter.

4. Release the roll closer to the torch connector and input the wire guide as close to
roll as possible. Tighten the torch and close the roll.

Attention! Exclusively inert gases can be used for aluminium welding thus
appropriate pressure reductor/regulator should be applied.

6 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.

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.

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 anticlockwise to increase the braking torque. NB: Turn both

springs through the same amount.

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Welding gun

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.

7 FAULT TRACING

Try these recommended checks and inspections before sending for an authorised service technican.

Type of fault

No arc S Check that the mains power supply switch is turned on.

S Check that the welding current supply and return cables are

correctly connected.

S Check the main power supply fuses

Welding current is interrupted
during welding

Poor welding performance S Check that the welding current supply and return cables are

S Check whether the thermal overload trip has operated

(indicated by the orange lamp on the power source).

S Check the main power supply fuses.

correctly connected.

S Check that the correct current value is set.
S Check that the correct welding wires are being used.
S Check the main power supply fuses.

Actions

8 ORDERING OF SPARE PARTS

OrigoTMFeed 30, Feed 30w is designed and tested in accordance with the international
and European standard IEC/EN 60974--5. 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.

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Diagram

OrigoTMFeed 30w

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Origo

T

M

Feed 30, Feed 30w

Valid for serial no. 638--XXX--XXXX

Ordering numbers

0349 304 839 OrigoTMFeed 30w 42V 1∼∼∼∼50/60Hz
0349 304 840 OrigoTMFeed 30 42V 1∼∼∼∼50/60Hz

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Origo

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Feed 30, Feed 30w

Wear components

(W. F. Mechanism 0349 484 083)

Item Denomination Ordering no. Notes

0349 484 335
0349 484 339

A Feed / pressure roller

B Gear adapter 0349 484 355

C Drive gear 0349 484 356

D Pressure roller 0349 484 346 Fe, Ss, cored wire, Al

E Inlet nozzle 0349 308 000 Fe, Ss, cored wire, Al

F Intermediate nozzle 0349 484 344 Fe, Ss, cored wire, Al

G Outlet nozzle

H Liner 0349 496 716 Fe, Ss, cored wire, Al

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

0349 484 342
0349 484 341
0349 484 338
0349 484 340

0349 304 793
0349 305 089

Ø 0.8--1.0mm Fe, Ss, cored wire, V--groove.
Ø 1.2--1.6mm Fe, Ss, cored wire, V--groove.
Ø 1.0--1.2mm cored wire, V--groove, knurled.
Ø 1.2--1.6mm cored wire, V--groove, knurled.
Ø 1.0--1.2mm Al, U--groove.
Ø 1.2--1.6mm Al, U--groove.

Ø 2.0 steel for Fe, Ss, cored wire
Ø 2.0 plastic for Al

Welding with aluminium wires.

In order to weld with aluminium wires, proper rollers, nozzles and liners for
aluminium wires MUST be used. It is recommended to use 3m long welding gun for
aluminium wires, equipped with appropriate wear parts.

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Origo

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Feed 30, Feed 30w

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Origo

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Feed 30, Feed 30w

Accessories

Traction kit Ø 100 (wheels set) . . . . . . . . . . . 0349 493 925

Traction kit Ø 120 (wheels set) . . . . . . . . . . . 0349 493 903

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Herlev
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB international AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax:[phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax:[phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel:[phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

LLC ESAB
St Petersburg
Tel: [phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]

www.esab.com

070514