ESAB Feed Airmatic Digital Box Instruction manual

Feed Airmatic Digital Box

Instruction manual

0463 429 001 GB 20160128 Valid for: serial no. 541-xxx-xxxx

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

1.1 Meaning of symbols.............................................................................................4

1.2 Safety precautions ............................................................................................... 4

2 INTRODUCTION................................................................................................... 7

2.1 General.................................................................................................................. 7

2.2 Equipment............................................................................................................. 7

3 TECHNICAL DATA ............................................................................................... 8

4 INSTALLATION..................................................................................................... 9

4.1 General.................................................................................................................. 9

4.2 Fitting the unit on top of the power source ....................................................... 9

4.2.1 Power sources Mig3001i and Mig4001i ......................................................... 10

4.2.2 Power sources Mig4004i and Mig5004i ......................................................... 10

5 OPERATION ....................................................................................................... 11

5.1 Connections and control devices..................................................................... 11

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

7 ORDERING SPARE PARTS............................................................................... 13

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

ORDERING NUMBERS .............................................................................................15

ACCESSORIES .........................................................................................................16

Rights reserved to alter specifications without notice.

0463 429 001 © ESAB AB 2016

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 Material Safety Data Sheets (MSDSs).

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

0463 429 001

- 4 -

1 SAFETY

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

○ 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!

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data.

ELECTRIC SHOCK - Can kill

• Install and earth the unit in accordance with applicable standards

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

• Insulate yourself from earth and the work piece

• Ensure your working stance 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

0463 429 001

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.

- 5 -

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. To prevent accidental starting of equipment during service, disconnect negative (-) battery cable from battery.

• 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

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

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 can provide you with all necessary welding protection and accessories.

0463 429 001

- 6 -

2 INTRODUCTION

2.1 General

The Feed Airmatic Digital Box is a component in ESAB's "push-pull" system and is intended for use in MIG/MAG welding together with apower source, anAirmatic wire feeder and aPKB welding torch. The Feed Airmatic Digital Box works as an analogue to digital converter between the analogue Airmatic wire feeder and ESAB CANbus power sources for MIG/MAG welding.

The wire feed unit pushes the wire through the welding hose to the welding torch, after which the pneumatically-operated motor in the torch piston draws the wire to the contact tip. This provides an even, interference-free wire feed, which is beneficial when welding with soft auxiliary material such as aluminium and with thin wires. Feed Airmatic Digital Box is available in two different versions, one with remote control outlet and one without remote control outlet.

For description of operation of the U6control panel, see the U6instruction manual.

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

2.2 Equipment

The wire feed unit is supplied with:

• An instruction manual for Feed Airmatic Digital Box

• An instruction manual for the U6control panel

0463 429 001

- 7 -

3 TECHNICAL DATA

Technical data Feed Airmatic Digital Box

Supply voltage 42VAC

Dimensions l × w × h 320×220×197mm

Weight 3,9kg

Enclosure class IP2X

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid objects or water.

Equipment marked IP2X is intended for indoor use.

0463 429 001

- 8 -

4 INSTALLATION

4.1 General

The installation must be carried out by a professional.

WARNING!

When welding in an environment with increased electrical danger, only power sources intended for this environment may be used. These power sources are

marked with the symbol .

4.2 Fitting the unit on top of the power source

WARNING!

A power source equipped with a Feed Airmatic Digital Box, must be fitted on a trolley.

0463 429 001

- 9 -

4 INSTALLATION

4.2.1 Power sources Mig3001i and Mig4001i

4.2.2 Power sources Mig4004i and Mig5004i

0463 429 001

- 10 -

5 OPERATION

5.1 Connections and control devices

1. Display 5. MENU button

2. Knob for setting of voltage 6. Connection for control cable from power

source

3. Knob for setting of wire feed speed and

current

4. Soft pushbuttons (function keys) 8. Connection for control cable to wire feeder

7. Switch for remote control OFF/ON

0463 429 001

- 11 -

6 MAINTENANCE

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.

0463 429 001

- 12 -

7 ORDERING SPARE PARTS

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

The Feed Airmatic Digital Box is designed and tested in accordance with international and european standards IEC/EN60974-1 and IEC/EN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 standard.

Spare parts may be ordered through your nearest ESAB dealer, see the back cover of this document. 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.

0463 429 001

- 13 -

DIAGRAM

0463 429 001

- 14 -

ORDERING NUMBERS

Ordering number Denomination Type Notes

0464 554 880 Feed Airmatic Digital Box

0464 554 881 Feed Airmatic Digital Box Remote With remote setting option

0463 430 001 Spare parts list

Technical documentation is available on the Internet at: www.esab.com

0463 429 001

- 15 -

ACCESSORIES

0464 558 880 Cable set Amphenol 10pole, 1.0m

0464 555 880 Mig3001i/4001i assembly kit

0464 555 881 Mig4004i/5004i assembly kit

0460 565 880 Trolley

0461 310 880 Trolley adapter kit

for fitting of power sources Mig4004i and Mig5004i to trolley 0460565880

0152 700 881 PKB 250 welding torch

straight swan neck

0463 429 001

- 16 -

ACCESSORIES

0152 470 881 PKB 400 welding torch

straight swan neck

0152 470 882 PKB 400 welding torch

curved swan neck45°

0463 429 001

- 17 -

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. Heist-op-den-Berg Tel: +32 15 25 79 30 Fax: +32 15 25 79 44

BULGARIA

ESAB Kft Representative Office Sofia Tel: +359 2 974 42 88 Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

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

FRANCE

ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

HUNGARY

ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL Bucharest Tel: +40 316 900 600 Fax: +40 316 900 601

RUSSIA

LLC ESAB Moscow Tel: +7 (495) 663 20 08 Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22

ESAB International AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC Kiev Tel: +38 (044) 501 23 24 Fax: +38 (044) 575 21 88

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 2191 4333 Fax: +55 31 2191 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 57 48

Asia/Pacific

AUSTRALIA

ESAB South Pacific Archerfield BC QLD 4108 Tel: +61 1300 372 228 Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 Fax: +86 21 6566 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 0188 Fax: +62 21 461 2929

JAPAN

ESAB Japan Tokyo Tel: +81 45 670 7073 Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924

Distributors

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

www.esab.com

ESAB Feed Airmatic Digital Box Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 General

2.2 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 General

4.2 Fitting the unit on top of the power source

5 OPERATION

5.1 Connections and control devices

6 MAINTENANCE

7 ORDERING SPARE PARTS

DIAGRAM

ORDERING NUMBERS

ACCESSORIES