ESAB FeedMech 4804/FeedControl Instruction manual

GB

FeedMech 4804/
FeedControl

Instruction manual

Valid for serial no. 606--xxx--xxxx0461 066 001 GB 090310

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 5...................................................

3.1 Equipment 5................................................................

4 TECHNICAL DATA 5.................................................

5 INSTALLATION 6....................................................

5.1 Terminating resistor 6........................................................

5.2 Example of a robotic welding system 7.........................................

6 OPERATION 7.......................................................

6.1 Connections 8..............................................................

6.2 Gas flow guard (if installed) 10.................................................

6.3 Wire feed pressure 10........................................................

6.4 Replacing and inserting wire 1 1................................................

6.5 Changing feed rollers 1 1......................................................

7 MAINTENANCE 11....................................................

7.1 Inspection and cleaning 1 1....................................................

8 ORDERING SPARE PARTS 12..........................................

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

ORDERING NUMBER 16.................................................

WEAR PARTS 18........................................................

ACCESSORIES 20.......................................................

Rights reserved to alter specifications without notice.

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1DIRECTIVE

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that unit
FeedMech 4804 / FeedControl from serial number 606 are constructed and tested in compliance with
the standard EN 60974--1/--5 and EN 60974--10 (Class A) in accordance with the requirements of di­rective (2006/95EC) and (2004/108/EEC).

DECLARATION OF CONFORMITY

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Laxå 2008--06--12

Kent Eimbrodt
Global Director
Equipment and Automation

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 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 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

Arc welding and cutting can be injurious to yourself and others. Take precausions 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!

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.

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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CAUTION!

Read and understand the instruction manual before
installing or operating.

ESAB can provide you with all necessary welding protection an d accessories.

3 INTRODUCTION

The wire feed unit consist of a drive unit (FeedMech 4804) and a separate electronic
unit (FeedControl).

The wire feed unit is intended for MIG/MAG welding along with robotic equipment.

NOTE!

The wire feed unit utilizes the robot’s safety system to obtain maximum interference protection.

ESAB’s accessories for the product can be found on page 20.

3.1 Equipment

The wire feed unit is supplied with an instruction manual, and the drive unit with a
sticker with recommended wear parts.

4 TECHNICAL DA TA

FeedMech 4804 FeedControl
Power supply 42 V 50--60 Hz 42 V 50--60 Hz
Power requirement 378 V A 378 V A
Motor current I
Settings data

Wire feed speed

Gun connection EURO
Wire dimension

Fe
Ss
Al
Cored wire

Operating temperature -- 1 0 t o + 4 0 ˚C -- 1 0 t o + 4 0 ˚C
Weight 9.7 kg 4.9 kg
Dimensions (l x b x h) 383 x 161 x 287 mm 330 x 118 x 320 mm
Shielding gas

max pressure

max

9.0 A 9.0 A

0.8 -- 25.0 m/min

0.6--2.4 mm

0.6--2.4 mm

1.0--1.6 mm

0.8--2.4 mm

Gases for MIG/MAG--welding
5Bar

Gases for MIG/MAG--welding
5Bar

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FeedControlFeedMech 4804

Maximum permissible load at

60% intermittens

100% intermittens

Enclosure class IP2X IP2X

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. The duty cycle is valid for 40˚C.

The duty cycle is valid for 40˚C.

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.

500 A
280 A

500 A
280 A

5 INSTALLATION

The installation must be executed by a professional.

Note!

Mains supply requirements

High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case it
is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distrubution network operator if necessary, that the equipment may be connected.

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 Terminating resistor

The ends of the CAN bus must be fitted with terminating
resistors to avoid communication interference.

The terminating resistor is delivered with the power
source.

One end of the CAN bus is at the control panel (U8),
which has an integral terminating resistor.
The other end is at the FeedControl and must be
fitted with the terminating resistor, as shown on the
right.

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5.2 Example of a robotic welding system

6 OPERATION

General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!

WARNING!

Rotating parts can cause injury, take great care.

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6.1 Connections

FeedMech 4804

1 Switch for gas purging 9 Connection to drive unit, 4 poles
2 Switch for reversed wire feed 10 Connection to drive unit, 8 poles
3 Switch for cold wire feed 11 Connection for coolant from power source

(cooling unit), BLUE

4 Connection for coolant to welding gun,

BLUE

5 Connection for coolant from welding gun,

RED

6 Outlet connection for spatter removal air 14 Connection for shielding gas in
7 Connection for signals to/from robot

welding gun

8 Connection for welding gun 16 Rating plate

12 Connection for coolant to power source

(cooling unit), RED

13 Inlet connection for spatter removal air

15 Connection for welding current from

electronic unit (OKC)

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FeedControl

1 White indicating lamp – Power supply ON 9 Rating plate
2 Connection from electronic unit to drive

unit

3 Connection from electronic unit to drive

unit

4 Outlet connection for spatter removal air 12 Connection for shielding gas, in
5 Connection for coolant to welding gun,

BLUE

6 Connection for welding current from drive

unit (OKC)

7 Connection for coolant from welding gun,

RED

8 Connection for shielding gas, out 16 Connection for coolant to power source

10 Connection for terminating resistor or

forwarding to next wire feed unit

11 Connection for control cable from power

source

13 Inlet connection for spatter removal air

14 Connection for coolant from power source

(cooling unit), BLUE

15 Connection for welding current from power

source (O KC)

(cooling unit), RED

Symbol and function explanations

Gas purging

Used to measure the gas flow or to flush the gas hoses to clean them of any air and
moisture before commencing welding. Gas purging is carried out with the voltage
and wire feed switched off.

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Reversed wire feed

Used to reverse the wire, for example when replacing the wire bobbin.

Inching

Used when wire is to be fed without switching on the welding voltage.

Inlet spatter removal air

Outlet spatter removal air

Used for spray--cleaning the contact tip on the welding gun.

Shielding gas in

Shielding gas out

6.2 Gas flow guard (if installed)

The gas flow monitor interrupts the ongoing welding process if the gas flow drops
below 3.5 l/min. When this occurs, an error message is displayed via the control unit.

6.3 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 insulated 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).

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6.4 Replacing and inserting 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.

6.5 Changing feed rollers

S Push down the pressure device ( 1) and pull it

towards you and upwards.

S Pull out the bogey (2).
S Remove the socket--head bolts (3) on the

intermediate nozzle and remove it.

S Loosen the bolt holding the outlet nozzle (4)

and push the nozzle back.

S Remove the socket--head bolt (5) in the centre
S Slacken the two socket--head bolts (6) by half a turn.
S Pull out the feed rollers (7).

Reassemble in the reverse order.

Selecting the correct groove in the
feed rollers

Place no, one or two carrier washers
between the outer washer and the feed
rollers. NB: Replace the entire bogey

when changing the pressure rollers (8).

7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

CAUTION!

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.

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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.

8 ORDERING SPARE P ARTS

FeedMech4804 / FeedControl is designed and tested in accordance with the internatio­nal and European standards IEC/EN 60974--1, 60974--5 and 60974--10. 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

FeedControl & FeedMech 4804

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FeedMech 4804/Feed Con t rol

Ordering number

Ordering no. Denomination Type Note

0461 070 880
0461 070 881
0461 080 880
0459 839 007

The spare parts list is available on the Internet at www.esab.com

Drive unit
Drive unit
Feed box
Spare parts list

Aristot Feed Mech 4804
Aristot Feed Mech 4804
Aristot Feed Control

23 pole
12 pole

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Wear parts

Ordering no. Denomination Wire type Wire dimensions

Item

HD = Heavy Duty

HK1 0469 837 880

0469 837 881
0469 837 882

Item Ordering no. Denomination Wire type Wire ØmmGroove 1 Groove 2 Groove 3 Groove

HK2 0366 966 880 Feed Roller Fe, Ss & cored 0.6-- 1.2 0.6--0.8 0.9--1.0 1.2 V 1

0366 966 881 Feed Roller Fe, Ss & cored 1.4-- 1.6 1.4--1.6 2.0 2.4 V 2
0366 966 889 Feed Roller Fe, Ss & cored 1.2 .045” / 1.2 .045” / 1.2 .045” / 1.2 V .045 / 7
0366 966 900 Feed Roller Fe, Ss & cored 0.9-- 1.6 0.9--1.0 1.2 1.4--1.6 V 6
0366 966 882 Feed Roller Cored 1.2--2.0 1.2 1.4--1.6 2.0 V-- Knurled 3
0366 966 883 Feed Roller Cored 2.4 2.4 not used not used V--Knurled 4
0366 966 885 Feed Roller Al 1.2 1.2 1.2 1.2 U U2
0366 966 899 Feed Roller Al 1.0--1.6 1.0 1.2 1.6 U U4

Item Ordering no. Denomination Notes

HK3 0156 707 001 Distance washer

HK4 0156 707 002 Adjustment spacer

HK5 Screw M5x20

HK6 Screw M5x16

Item Ordering no. Denomination Wire type Wire dimensions Groove

HK7 0366 902 880 Bogey (HD) Fe, Ss & cored Ø0.6--1.2mm V 1

0366 902 900 Bogey (HD) Fe, Ss & cored Ø0.9--1.6mm V 6
0366 902 881 Bogey (HD) Fe, Ss & cored Ø1.4--2.4mm V 3
0366 902 894 Bogey (HD) Fe, Ss & cored Ø1.2mm V .045 / 7
0366 902 882 Bogey (HD) Cored Ø1.2--2.0mm V-- Knurled 3
0366 902 883 Bogey (HD) Cored Ø2.4mm V--Knurled 4
0366 902 899 Bogey (HD) Al Ø1.0--1.6mm U U4
0366 902 886 Bogey (HD) Al Ø1.2mmx3 U --

Item Ordering no. Denomination Wire type Wire dimensions

HK8 0366 944 001 Washer

HK9 0156 603 001

0156 603 002
0332 322 001
0332 322 002

Outlet nozzle
Outlet nozzle
Outlet nozzle

Intermediate nozzle
Intermediate nozzle
Intermediate nozzle
Intermediate nozzle

Fe, Ss & cored
Al
Fe, Ss & cored

Fe, Ss & Al
Fe, Ss & Al
Cored
Cored

Ø 2.0 mm steel for 0.6-- 1.6 mm
Ø 2.0 mm plastic for 1.0--1.6 mm
Ø 3.4 mm steel for 2.0-- 2.4 mm

Ø 2 mm plastic for 0.6--1.6 mm
Ø 4 mm plastic for 2.0--2.4 mm
Ø 2.4 mm copper for 1.2--2.0 mm
Ø 4 mm copper for 2.4 mm

typ

typ

Roller /

Bogey

mark-

ings

Roller /

Bogey

markings

Item Ordering no. Denomination Note

HK10 0215 702 708 Locking washer

HK11 Nut M10

HK12 0458 748 002 Insulating washer

HK13 0458 748 001 Insulating bushing

Item Ordering no. Denomination Wire type Wire dimensions

HK14 0156 602 001

0156 602 002
0332 318 001
0332 318 002

Inlet nozzle
Inlet nozzle
Inlet nozzle (HD)
Inlet nozzle (HD)

Fe, Ss, Al & Cored
Fe, Ss, Al & Cored
Fe, Ss & Cored
Fe, Ss & Cored

Ø 2 mm plastic for 0.6--1.6 mm
Ø 4 mm plastic for 2.0--2.4 mm
Ø 2.4 mm steel for 1.2-- 2.0 mm
Ø 4 mm steel for 2.4 mm

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Accessories

Quick connector MarathonPact ............ F102 440 880

Adapterplate for mounting on the robot arm ..... 0461 038 880

1 Check valve ..............................

2 Gas flow meter ..........................

0461 110 880
0460 005 881

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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
USJ
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

081016