Origo M08, Origo M09. Feed L302 Feed L304. Instruction manual

Transcription

1 GB Origo M08, Origo M09 Feed L302 Feed L304 Instruction manual GB Valid for serial no. 620-xxx-xxxx

2 -2-

3 1 SAFETY INTRODUCTION Equipment TECHNICAL DATA INSTALLATION Lifting instructions OPERATION Connections and control devices Explanation of function Wire feed pressure Replacing and inserting wire Changing feed roller Feed L Changing feed roller Feed L MAINTENANCE Inspection and cleaning ORDERING SPARE PARTS DIAGRAM ORDER NUMBER WEAR PARTS ACCESSORIES Rights reserved to alter specifications without notice. TOCe - 3 -

4 GB 1 SAFETY 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 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 3. The workplace must: be suitable for the purpose be free from drafts 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 extinquishing equipment must be clearly marked and close at hand. Lubrication and maintenance must not be carried out on the equipment during operation. bm38d1ea - 4 -

5 GB 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 workpiece. Ensure your working stance is safe. 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. 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. FIRE HAZARD Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. NOISE - Excessive noise can damage hearing Protect your ears. Use earmuffs or other hearing protection. 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! ESAB can provide you with all necessary welding protection and accessories. WARNING Do not use the power source for thawing frozen pipes. 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. CAUTION Read and understand the instruction manual before installing or operating. bm38d1ea - 5 -

6 GB Dispose of electronic equipment at the recycling facility! In observance of European Directive 2002/96/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. 2 INTRODUCTION The Feed L302 with control panel M08 and Feed L304 with control panel M09 wire feed units are intended for MIG/MAG welding with the Mig L405 power source. They come in different variants, see page 19. The feed units can be used together with wire on ESAB's MarathonPac, or on wire bobbin Ø 300 mm. They can be installed either at the power source, suspended above the workplace, on a support arm or on the floor with or without wheel set. ESAB's accessories for the product can be found on page Equipment The wire feed units are supplied with an instruction manual and stickers. 3 TECHNICAL DATA Feed L302 Power supply 42 V Hz 42 V Hz Power requirement 150 VA 150 VA Motor current I max 3.5 A 3.5 A Settings data Wire feed speed Burnback time Spot welding time m/min s m/min s s Gun connection EURO EURO Max. diameter wire bobbin 300 mm 300 mm Wire dimension Fe Ss Al Cored wire mm mm mm mm mm mm mm mm Feed L304 Weight 12.6 kg 13.2 kg Dimensions (l x b x h) 569 x 259 x 355 mm 569 x 259 x 355 mm Operating temperature -10 to +40 C -10 to +40 C Shielding gas max pressure Gases for MIG/MAG welding 5 bar Gases for MIG/MAG welding 5 bar bm38d1ea - 6 -

7 GB Coolant max pressure Maximum permissible load at 60% duty cycle 100% duty cycle Enclosure class basic version with sealed bobbin holder* with MarathonPac * Accessories, see page A 280 A IP2X IP23 IP23 Feed L302 Feed L304 50% water / 50% glycol 5 bar 365 A 280 A IP2X IP23 IP23 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. 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. Duty cycle The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading. The duty cycle is valid for 40 C. 4 INSTALLATION The installation must be carried out by a professional. CAUTION 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 bm38d1ea - 7 -

8 GB 4.1 Lifting instructions Order number for lifting eyelet can be found on page 24. Note! If another mounting device is used, this should be insulated from the wire feed unit. 5 OPERATION General safety regulations for handling the equipment can be found on page 4. Read through before you start using the equipment! AH 0935 bm38d1ea - 8 -

9 GB WARNING Assure that the side panels are closed during operation. WARNING To prevent the reel from 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. WARNING Rotating parts can cause injury, take great care. WARNING There is a risk of tipping if the wire feed unit is fitted with a counterbalance arm. Secure the equipment, especially if used on an uneven or sloping surface. NOTE: When moving the equipment use intended handle. Never pull on the gun. 5.1 Connections and control devices Connecting control cable When connecting the control cable, it is important to secure the cable with the load-removing grommet. Ensure that the cover is properly screwed into place. bm38d1ea - 9 -

10 GB Feed L302 1 Knob for setting wire feed speed 4 Connection for welding gun 2 Knob for setting burnback time 5 Connection for welding current from power source, (OKC) 3 Switch for 2-stroke / 4-stroke 6 Connection for shielding gas 7 Connection for control cable from power source Feed L304 1 Knob for setting wire feed speed 2 Switch for activation of 2/4 stroke, spot welding, cold wire feed or gas purging 7 Connection RED for cooling water from welding gun 8 Connection BLUE, for cooling water to welding gun 3 Knob for setting spot welding time 9 Connection for welding current from power source, (OKC) 4 Knob for setting burnback time 10 Connection for shielding gas 5 Switch for creep start OFF / ON 11 Connection for control cable from power source 6 Connection for welding gun NOTE! Cooling water connections only available on certain models. 10 bm38d1ea

11 GB 5.2 Explanation of function Wire feed speed This sets the required feed speed of the filler wire in m/minute. 2 stroke With 2-stroke, the gas flow starts followed by the wire feed when the trigger switch is pressed in. The welding process is concluded when the trigger switch is released, the wire feed stops and the gas stops flowing. 4 stroke With 4 stroke, the gas flow starts when the trigger switch is pressed in and the wire feed starts when it is released. The welding process continues until the switch is pressed in again, the wire feed stops and when the switch is released the gas stops flowing. Spot welding Spot welding is used when you want to weld on short, repeated occasions with a pre-set time. When the trigger switch is pressed in, the gas flow starts for a period of time governed by the printed circuit board. After this the welding process starts for the set time. When the welding process is complete, the gas flow stops. Cold wire feed Cold wire feed is used to feed wire without welding voltage and gas flow. Activation of cold wire feed: press in the trigger switch and the wire feed starts. Gas purging Gas purging is used to measure that 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. Activation of gas purging: press in the trigger switch and gas purging starts. Burnback time Burnback time is a delay between the time when the wire brakes 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. Creep start Creep start means that the wire is fed at 50% lower speed until it comes into electrical contact with the workpiece, at which point the speed increases to the set speed. bm38d1ea

12 GB 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. ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ 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). 5.4 Replacing and inserting wire WARNING Risk of crushing when replacing the wire bobbin! Do not use safety gloves when inserting the welding wire between the feed rollers. Open the side panel. Disconnect the pressure sensor by folding it backwards, the pressure arm is folded up. Straighten out cm of the new wire. File away burrs and sharp edges from the end of the wire before inserting it into the wire feed unit. Make sure that the wire goes properly into the feed roller's track and into the outflow nozzle or wire guide. Fold down the pressure arm and secure it to the pressure sensor. Close the side pannel. bm38d1ea

13 GB 5.5 Changing feed roller Feed L302 Open the side panel. Disconnect the pressure sensor (1) by folding it backwards. Disconnect and remove the Allen screw (2) and the washer. Pull out the feed roller (3). During installation, repeat the above in the reverse order. Choice of track in the feed roller Turn the feed roller with the dimensioning mark for the required track towards you. 5.6 Changing feed roller Feed L304 Open the side panel. Disconnect the pressure sensor (1) by folding it backwards. Disconnect the feed rollers (2) by unscrewing the nuts (3) and pulling out the rollers. During installation, repeat the above in the reverse order. Choice of track in the feed roller Turn the feed roller with the dimensioning mark for the required track towards you. 6 MAINTENANCE Regular maintenance is important for safe, reliable operation. CAUTION All guarantee undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the guarantee period. 6.1 Inspection and cleaning Wire feed unit Check regularly that the wire feed unit is not clogged with dirt. 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. bm38d1ea

14 GB 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. Adjusting the braking torque: Turn the red handle to the locked position. Insert a screwdriver into the springs in the hub. Turn the springs clockwise to reduce the braking torque Turn the springs counter-clockwise to increase the braking torque. NB: Turn both springs the same amount. Welding gun The welding gun's wear parts should be cleaned and replaced at regular intervals in order to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the contact tip. 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. Feed L302 / Feed L304 is designed and tested in accordance with the international and European standards IEC/EN and IEC/EN 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. bm38d1ea

15 NOTES notes

16 Diagram Feed L302 bm38e11a

17 Feed L304 bm38e11a

18 NOTES notes

19 Feed L302, Feed L304 Order number Ordering no. Denomination Type Wire feed unit Origo Feed L302, M Wire feed unit Origo Feed L304, M Wire feed unit Origo Feed L304, M09 with water cooling Spare parts list bm38o11a

20 Feed L302 Wear parts Item Ordering no. Denomination Notes HM * Insert tube For Fe, Ss & cored wire * Insert tube For Al wire HM * Outlet nozzle For Fe, Ss & cored wire * Outlet nozzle For Al wire HM Screw O-ring (M5x12) HM Cover plate HM5 Screw M4x12 HM Washer Ø16/5x1 HM Feed roller For Fe, Ss & cored wire, Ø mm, V groove Feed roller For Fe, Ss & cored wire, Ø mm, V groove Feed roller For Fe, SS & cored wire Ø mm, V groove Feed roller For Al wire, Ø mm, U groove HM Insert tube HM Spacer sleeve Included in item HM100 HM Pressure roller Flat, Included in item HM100 HM11 Nut M8, Included in item HM100 HM Pressure arm Included in item HM100 HM Shaft Included in item HM100 HM Spring HM15 Nut M10 HM Insulating washer HM Insulating bushing HM Inlet nozzle Inlet nozzle For Fe, Ss, Al & Cored wire, Ø 2 mm plastic for mm For Fe, Ss & Cored wire, Ø 2.4 mm steel for mm HM Woodruff wedge * Insert tube and outlet nozzle must be used together. Insert tube and outlet nozzle must be used together. PARTS SET Item Ordering no. Denomination Notes HM Pressure arm compl. Includes item HM9, HM10, HM11, HM12 and HM13 Welding with aluminium wire In order to weld with aluminium wire, proper rollers, nozzles and liners for aluminium wire MUST be used, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriate wear parts. bm38whm1-20 -

21 Feed L302 bm38whm1-21 -

22 Feed L304 Item Ordering no. Denomination Notes HD = Heavy Duty HN HN Intermediate nozzle Intermediate nozzle Outlet nozzle Outlet nozzle For Fe, Ss & cored wire For Al Wire For Fe, Ss & cored wire, Ø 2.0 mm steel for mm For Al wire, Ø 2.0 mm plastic for mm HN Woodruff wedge HN Motor gear euro HN5 Washer Ø 16/5x1 HN6 Screw M4x12 HN7 Screw M6x12 HN8 Washer Ø 12/6.4x1.5 HN Cover HN Axle and Nut HN Feed roller For Fe, Ss & cored wire, Ø 0.6 & 0.8 mm, V groove Feed roller For Fe, Ss & cored wire, Ø 0.8 & 1.0 mm, V groove Feed roller For Fe, Ss & cored wire, Ø 1.0 & 1.2 mm, V groove Feed roller For Cored wire, Ø 1.0 & 1.2 mm, V-Knurled groove Feed roller For Cored wire, Ø 1.4 & 1.6 mm, V-Knurled groove Feed roller For Al wire, Ø 0.8 & 0.9 mm, U groove Feed roller For Al wire, Ø 1.0 & 1.2 mm, U groove HN Gear adapter HN Inlet nozzle HN Spacer sleeve HN Pressure roller Flat HN Locking washer HN Axel pressure roll HN18 Nut M10 HN Insulating washer HN Insulating bushing HN Inlet nozzle Inlet nozzle (HD) For Fe, Ss, Al & Cored wire, Ø 2 mm plastic for mm For Fe, Ss & Cored wire, Ø 2.4 mm steel for mm Welding with aluminium wire In order to weld with aluminium wire, proper rollers, nozzles and liners for aluminium wire MUST be used, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriate wear parts. bm38whn1-22 -

23 Feed L304 bm38whn1-23 -

24 Feed L302, Feed L304 Accessories 1 Bobbin cover, plastic Ø 300mm Adapter for 5 kg bobbin Lifting eye... Brake hub Turning piece... Quick connector MarathonPac F Wheel kit bm38a11a

25 Feed L302, Feed L304 1 Strain relief for welding gun Strain relief bracket for connection set Counter balance device... (includes mast and counter balance) Water kit Connection set Connection set 1.7 m... Connection set 5 m... Connection set 10 m... Connection set 10 m, water bm38a11a

26 NOTES notes

27 NOTES notes

28 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges.m.b.H Vienna-Liesing Tel: Fax: BELGIUM S.A. ESAB N.V. Brussels Tel: Fax: BULGARIA ESAB Kft Representative Office Sofia Tel/Fax: THE CZECH REPUBLIC ESAB VAMBERK s.r.o. Vamberk Tel: Fax: DENMARK Aktieselskabet ESAB Herlev Tel: Fax: FINLAND ESAB Oy Helsinki Tel: Fax: FRANCE ESAB France S.A. Cergy Pontoise Tel: Fax: GERMANY ESAB GmbH Solingen Tel: Fax: GREAT BRITAIN ESAB Group (UK) Ltd Waltham Cross Tel: Fax: ESAB Automation Ltd Andover Tel: Fax: HUNGARY ESAB Kft Budapest Tel: Fax: ITALY ESAB Saldatura S.p.A. Bareggio (Mi) Tel: Fax: THE NETHERLANDS ESAB Nederland B.V. Amersfoort Tel: Fax: NORWAY AS ESAB Larvik Tel: Fax: POLAND ESAB Sp.zo.o. Katowice Tel: Fax: PORTUGAL ESAB Lda Lisbon Tel: Fax: ROMANIA ESAB Romania Trading SRL Bucharest Tel: Fax: RUSSIA LLC ESAB Moscow Tel: +7 (495) Fax: +7 (495) SLOVAKIA ESAB Slovakia s.r.o. Bratislava Tel: Fax: SPAIN ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: Fax: SWEDEN ESAB Sverige AB Gothenburg Tel: Fax: ESAB international AB Gothenburg Tel: Fax: SWITZERLAND ESAB AG Dietikon Tel: Fax: UKRAINE ESAB Ukraine LLC Kiev Tel: +38 (044) Fax: +38 (044) North and South America ARGENTINA CONARCO Buenos Aires Tel: Fax: BRAZIL ESAB S.A. Contagem-MG Tel: Fax: CANADA ESAB Group Canada Inc. Missisauga, Ontario Tel: Fax: MEXICO ESAB Mexico S.A. Monterrey Tel: Fax: USA ESAB Welding & Cutting Products Florence, SC Tel: Fax: Asia/Pacific AUSTRALIA ESAB South Pacific Archerfield BC QLD 4108 Tel: Fax: CHINA Shanghai ESAB A/P Shanghai Tel: Fax: INDIA ESAB India Ltd Calcutta Tel: Fax: INDONESIA P.T. ESABindo Pratama Jakarta Tel: Fax: JAPAN ESAB Japan Tokyo Tel: Fax: MALAYSIA ESAB (Malaysia) Snd Bhd USJ Tel: Fax: SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel: Fax: SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel: Fax: UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel: Fax: Africa EGYPT ESAB Egypt Dokki-Cairo Tel: Fax: SOUTH AFRICA ESAB Africa Welding & Cutting Ltd Durbanvill Cape Town Tel: +27 (0) Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page ESAB AB