ESAB MED 304 Instruction manual

MED 304

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Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions

Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções

ПдзгЯет чсЮуещт

Instrukjca obs³ugi

Valid from Serial NO 519 XXX--XXXX0469 482 001 980525

SVENSKA 3..............................................

DANSK 11................................................

NORSK 19................................................

SUOMI 27................................................

ENGLISH 35..............................................

DEUTSCH 43.............................................

FRANÇAIS 51.............................................

NEDERLANDS 59.........................................

ESPAÑOL 67..............................................

ITALIANO 75..............................................

PORTUGUÊS 83..........................................

ЕЛЛЗНЙКБ 91.............................................

POLSKI 99.................................................

Rätt ti ll ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.

ДйбфзсеЯфбй фп дйкбЯщмб фспрпрпЯзузт рспдйбгсбцюн ЧщсЯт рспейдпрпЯзуз.

Zastrzegamy sobie prawo do wprowadzenia zmian.

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ENGLISH

1 DIRECTIVE 36........................................................

2SAFETY 36...........................................................

3 INTRODUCTION 37...................................................

3.1 TECHNICAL DESCRIPTION 37................................................

3.2 TECHNICAL DATA 38........................................................

4 INSTALLATION 39....................................................

5 OPERATION 41.......................................................

6 MAINTENANCE 42....................................................

7 ACCESSORIES 42....................................................

8 ORDERING OF SPARE PARTS 42......................................

DIAGRAM 107............................................................

SPARE PARTS LIST 108...................................................

TOCe

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1 DIRECTIVE

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, S--695 81 Laxå, Sweden, declares that Wire feed unit
MED 304 from serial number 519 onwards, conforms to standard EN 60974--1, in
accordance with the requirements of directive (73/23/EEC) and appendix
(93/68/EEC) and standard EN 50199 in accordance with the requirements of direc­tive (89/336/EEC) and appendix (93/68/EEC).

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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

2SAFETY

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 keep fumes and gases 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 ear defenders 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!

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3 INTRODUCTION

MED 304 is a wire feed unit for MIG/MAG welding.

It is a component of the A--10 system.
MED 304 has an electronically controlled electric pusher motor that advances the

wire through the welding hose to the gun.

3.1 TECHNICAL DESCRIPTION

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MED 304 has two motors (1) and two pairs of rollers, each comprising a feed roller
(5) and pressure roller (4). The rollers have toothed rings. The motors drive the feed
rollers, which in turn drive the pressure rollers.
The motors are connected in series and each contributes the same driving force.
Any slip due to differences in the diameters of the rollers will therefore not affect the
uniform feed.

The pressure rollers are incorporated in a bogie that is supported so that the pres­sure exerted by both pairs of rollers is the same.
The bogie is mounted on a lever, which is fitted with a spring--loaded arm (3). T his
unit can be easily removed, for example when changing the wire size.

The pressure exerted on the wire by the rollers is controlled by a knob (2), that acts
on the spring--loaded arm. There is no need to adjust this knob to remove the pres ­sure roller. This means that the pressure is unchanged when the pressure roller is
replaced.
The wire runs in grooves in the rollers, and each wire size has its own groove profile.
The lateral position of the feed roller is adjusted using spacers so that the correct
groove is aligned with the wire.
The pressure roller automatically positions itself correctly.

MED 304 is equipped with inch start, which ensures smoother arc ignition when
welding with large diameter wire. The units also provide 2 stroke or 4 stroke arc con­trol.
To simplify the replacement of large diameter wire the MED 304 has reversible mo­tors. These allow the wire to be reversed out of the welding hose.

The wire feed unit is divided into two sections. One section contains the electrical
equipment, protected by a panel. T he other section is protected by a lockable panel
and contains the wire feed unit and connection socket for the welding hose. Above
the connection socket are switches for selecting 2 stroke or 4 stroke arc control and
for inch start.

Control equipment.

The electronic components are mounted on a circuit card, which is held in place by
two reatiners and screws. T he wiring is connected by spade connectors and multi-­pin connectors.

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3.2 TECHNICAL DATA

Connection

voltage
frequency

Drive motor

rotor voltage, DC
magnetisation

Reel hub

hub diameter
hub length

Feed speed

continuously variable 0--18 m/min

Burn--back time

continuously variable
preset on delivery to

42 V
50/60 Hz

12 V
Permanent magnets

Æ 51.5
100 mm

20--500 ms
100 ms

Dimensions

LxBxH 637x319x465

Continuous A-- weighted noise pressure 58 dB

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4 INSTALLATION

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.

1. Connect the control cable to the power source. The cable has a 23 pin male
plug.

2. The operating voltage is 42 V, 50--60 Hz.

3. Connect the gas hose. T he coupling diameter is 6 mm.

4. A 12 pin socket on the front permits the connection of a remote control.

5. Connect the welding gun. The welding current, control current, shielding gas and
wire are all connected through the connection socket.

6. Check that the feed rollers and nozzles are fitted as shown in the table.

WARNING!

Rotating parts can cause injury, take great care.

MED 304 can b e in stalled in a variety of ways to suit requirements:
Power source

Swivel unit is attached to casing of wire feed unit. This is equipped with an insulated
stud that fits the hole in the top o f the welding rectifier.
Fit the insulated bushing onto the guide journal on top of the power source. Locate
the wire feed unit on the guide journal. This allows the wire feed unit to be swung
round and allows the welder freedom of movement while working.

Setofwheels

A set of wheels allows the wire feed unit to be set up independently of the power
source. This allows a greater range of movement and increases the working radius.

Support device

The wire feed unit can be suspended from the handle to give a larger working radius.

Gas--wire kit

An accessory that permits wire feed without power on (inching) and gas purging
without wire feed.

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Wire and fittin g s for MED 304.

Wire Nozzle diam. mm / material Feed roller

Æ mm type. Inlet

nozzle

0.8

Fe/Ss 2.0/plastic

1.0

1.2

1.4

1.6

2.0

2.4

0,9

1.2

1.4

1.6

2.0

2.4

Flux-­cored

2.0/plastic

2.0/plastic

4.0/plastic

4.0/plastic

4.0/plastic

4.0/plastic

2.4/steel

2.4/steel

2.4/steel

2.4/steel

2.4/steel

4.0/steel

1.0 Al 2.0/plastic

2.0/plastic

4.0/plastic

4.0/plastic

4.0/plastic

4.0/plastic

Adapter
nozzle

2.0/plastic

2.0/plastic

2.0/plastic

4.0/plastic

4.0/plastic

4.0/plastic

4.0/plastic

2.4/copper

2.4/copper

2.4/copper

2.4/copper

2.4/copper

4.0/copper

2.0/plastic

2.0/plastic

4.0/plastic

4.0/plastic

4.0/plastic

4.0/plastic

Outlet
nozzle

2.0/steel

2.0/steel

2.0/steel

2.0/steel

2.0/steel

3.5/steel

3.5/steel

2.0/steel

2.0/steel

2.0/steel

2.0/steel

3.5/steel

3.5/steel

2.0/steel

2.0/steel

2.0/steel

2.0/steel

3.5/steel

3.5/steel

No. Groove

1
1
1
2
2
2
2

1
3
3
3
3
4

1
1
2
2
2
2

1
2
3
1
1
2
2

2
1
1
2
3
1

2
3
1
1
2
2

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5OPERATION

Check that the wire feed unit is fitted with the correct nozzles and feed rollers for the
selected size and type of wire, refer to the table under Installation.
Connect the return cable to the work piece.

The wire feed unit consists of the following main components:

S Potentiometer (1)

For setting chosen wire feed speed. Range 0--18 m/min.

S Space for meters (2)
S Space for optional equipment (3)
S Gun conn ectio n (4)
S Coupling for water cooling (5)
S Socket (6)

For connecting remote control unit.

S Switch (7)

For selecting remote control.

S Potentiometer (8)

Used to adjust welding voltage with thyristor--controlled or inverter power sour­ces.

S Switch (9)

For selecting initial wire feed speed. There are two settings: inch start or normal
start. With inch start the wire is fed out at low speed until the arc ignites and the
welding current flows. The speed is then increased automatically to the preset
value.

S Switch (10)

Controls function of gun switch.
2 stroke:Wire feed starts when you press the trigger and stops when you relea­se it.
4 stroke:Press the trigger to start welding, then release it. Welding continues
until you press the trigger again.

S Switch (11)

Reverses wire feed.

S Space for gas--wire kit

(12)

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6 MAINTENANCE

Regular maintenance is important for smooth and reliable operation.

S Clean the wire conduit regularly using compressed air and clean the gas nozzle.
S Clean and replace the wear components of the wire feed mechanism regularly to

ensure problem--free wire feed.
Note that excessive pressure on the wire can lead to rapid wear of the pressure
rollers, feed rollers and wire conduit.

IMPORTANT!

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.

7 ACCESSORIES

The following remote control devices can be connected to the wire feed unit:

S PHB 1

With planetary gear for precision control of wire feed speed.

S PHB 2

A rugged unit with two potentiometers for coarse and fine adjustment of wire
feed speed.

S PAB 6

Programmer. PAB 6 is designed for the remote control of voltage and current. To
permit remote control of voltage the power source must be a thyristor or inverter
model. The programmer is connected to the remote socket on MED 304.

3 different sets of welding parameters can be programmed using PAB 6. A
switch on the unit allows you to switch between programs. By fitting an extra
switch to the welding gun you can switch between 2 of the 3 preset welding
programmes using the gun.

S PAE4

Programmer. PAE 4 allows 5 sets of welding parameters (current/voltage) to be
pre--programmed. A switch on the front allows you to switch between programs.
There is also a knob for adjusting the arc length.

8 ORDERING OF SPARE PARTS

When ordering spare parts please state the machine designation, serial number and
the name and number of the spare parts. This will simplify dispatch and en s ure cor­rect delivery.

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