ESAB Aristo FeedMech 4804 User manual

Valid for serial no. 410-xxx-xxxx0461 066 101 GB 20140625

Aristo®

FeedMech 4804/

FeedControl

Instruction manual

- 2 -

- 3 -

Rights reserved to alter specifications without notice.

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

2 INTRODUCTION 6...................................................

2.1 Equipment 6................................................................

3 TECHNICAL DATA 6.................................................

4 INSTALLATION 7....................................................

4.1 Terminating resistor 7........................................................

4.2 Example of a robotic welding system 8.........................................

5 OPERATION 9.......................................................

5.1 Connections 10..............................................................

5.2 Gas flow guard (if installed) 12.................................................

5.3 Wire feed pressure 13........................................................

5.4 Replacing and inserting wire 13................................................

5.5 Changing feed rollers 13......................................................

6 MAINTENANCE 14....................................................

6.1 Inspection and cleaning 14....................................................

7 ORDERING SPARE PARTS 14.........................................

DIAGRAM 16............................................................

ORDER NUMBER 18.....................................................

WEAR PARTS 20........................................................

ACCESSORIES 22.......................................................

- 4 -

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 ob

served 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 equip

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding and cutting

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno-one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from drafts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

- 5 -

WARNING

Read and understand the instruction manual before installing or operating.

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

SInstall and earth the unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

SKeep your head out of the fumes.

SUse 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.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

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

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.

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.

- 6 -

CAUTION

Read and understand the instruction manual before

installing or operating.

ESAB can provide you with all necessary welding protection and accessories.

2 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 22.

2.1 Equipment

The wire feed unit is supplied with an instruction manual, and the drive unit with a

sticker with recommended wear parts.

3 TECHNICAL DATA

FeedMech 4804 FeedControl

Power supply 42 V 50-60 Hz 42 V 50-60 Hz

Power requirement 378 VA 378 VA

Motor current Imax 9.0 A 9.0 A

Settings data

Wire feed speed 0.8 - 25.0 m/min

Gun connection EURO

Wire dimension

Cored wire

0.6-2.4 mm

1.0-1.6 mm

0.8-2.4 mm

Operating temperature -10 to + 40°C-10 to + 40°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

Gases for MIG/MAG-welding

5 Bar

Gases for MIG/MAG-welding

5 Bar

Maximum permissible load at

60% intermittens

100% intermittens

500 A

280 A

500 A

280 A

Enclosure class IP2X IP2X

- 7 -

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.

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.

4 INSTALLATION

The installation must be carried out 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

distribution 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

4.1 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 (U82), 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.

- 8 -

4.2 Example of a robotic welding system

AH 0934

- 9 -

5 OPERATION

General safety regulations for handling the equipment can be found on

page 4. Read through before you start using the equipment!

H 0935

WARNING

Rotating parts can cause injury, take great care.

WARNING

Risk of crushing when replacing the wire bobbin!

Do not use safety gloves when inserting the welding wire between the feed rollers.

- 10 -

5.1 Connections

FeedMech 4804

1Switch for gas purging 9Connection to drive unit, 4 poles

2Switch for reversed wire feed 10 Connection to drive unit, 8 poles

3Switch for cold wire feed 11 Connection for coolant from power source

(cooling unit), BLUE

4Connection for coolant to welding gun,

BLUE

12 Connection for coolant to power source

(cooling unit), RED

5Connection for coolant from welding gun,

RED

13 Inlet connection for spatter removal air

6Outlet connection for spatter removal air 14 Connection for shielding gas in

7Connection for signals to/from robot

welding gun

15 Connection for welding current from

electronic unit (OKC)

8Connection for welding gun 16 Rating plate

Other manuals for Aristo FeedMech 4804

This manual suits for next models

Table of contents

Other ESAB Welding System manuals

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

Lincoln Electric

Lincoln Electric HANDYMIG 170I Operator's manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Technical specifications

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

Miller

Miller Big Blue 400D owner's manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual

Lincoln Electric

Lincoln Electric POWER WAVE I400 Operator's manual