ESAB Aristo RoboFeed 3004HW User manual

Valid for serial no. 201-xxx-xxxx0463 280 001 GB 20120808

Aristo

RoboFeed 3004HW

FeedControl 3004HW

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

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

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

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

3 TECHNICAL DATA 7.................................................

4 INSTALLATION 8....................................................

4.1 Terminating resistor 8........................................................

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

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

5.1 Connection and control devices 10.............................................

5.2 Replacing and inserting wire 12................................................

5.3 Changing feed rollers 13......................................................

5.4 Wire feed pressure 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.......................................................

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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.

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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

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

This product is solely intended for arc welding.

CAUTION

Read and understand the instruction manual before

installing or operating.

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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.

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

2 INTRODUCTION

The RoboFeed 3004HW and FeedControl 3004HW wire feed unit is intended for

MIG/MAG welding with robotic equipment.

The wire feed unit consists of a drive unit (RoboFeed 3004HW) and a separate

electronic unit (FeedControl 3004HW).

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 a quick connection for

MarathonPact.

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3 TECHNICAL DATA

RoboFeed 3004HW

Motor voltage 60 VDC PWM (Pulse Width Modulation)

Motor current Imax 8 A

Wire feed speed 0.8 - 30.0 m/min

Gun connection EURO

Wire dimension

Steel (Fe)

Stainless steel (Ss)

Aluminum (Al)

Cored wire (FCW)

0.8-1.6 mm

1.0-1.6 mm

0.8-1.6 mm

Shielding gas

max pressure

Gases for MIG/MAG welding

0.5 Mpa (5 bar)

Maximum permissible load at

60% duty cycle

100% duty cycle

500 A

280 A

Weight 5.4 kg

Dimensions (l x b x h) 251 x 182 x 221 mm

Operating temperature -10 till + 40°C

Transport temperature -20 till + 55°C

Enclosure class IP2X

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.

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.

FeedControl 3004HW

Motor voltage 42 V 50-60 Hz

Power requirement 378 VA

Motor current Imax 9.0 A

Weight 4.9 kg

Operating temperature -10 till + 40°C

Transport temperature -20 till + 55°C

Coolant

max pressure

ESAB ready-mixed coolant *)

0.5 Mpa (5 bar)

Dimension (l x b x h) 330 x 118 x 320 mm

Shielding gas

max pressure

Gases for MIG/MAG-welding

0.5 Mpa (5 Bar)

*) Accessories, see page 22

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4 INSTALLATION

The installation must be carried out by a professional.

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.

If U82is used together with W82, the terminal resistor in

the W82must be disconnected, see the instruction

manual for the W82.

4.2 Example of a robotic welding system

Note! A mounting kit and a cable kit are required for mounting to a robot, please

contact your local ESAB dealer for more information.

BS-11-006

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5 OPERATION

General safety regulations for handling the equipment can be found on

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

WARNING

Assure that the side panels are closed during operation.

WARNING

Rotating parts can cause injury, take great care.

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5.1 Connection and control devices

RoboFeed 3004HW

1Outlet for connection to the drive unit from

the electronic unit

5Rating plate

2Connection for shielding gas, in 6Push button for inching

3Connection for the welding cable or the

return cable.

7Push button for gas purging

4Connection for welding gun (EURO) 8Quick connector MarathonPact

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