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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