ESAB Aristo RoboFeed 3004w User manual

Valid for serial no. 620--xxx--xxxx0461 030 101 GB 060523

RoboFeed 3004w

Aristot

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

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 6.........................................

6 OPERATION 7.......................................................

6.1 Connections and control devices 7............................................

6.2 Gas flow guard (if installed) 8.................................................

6.3 Wire feed pressure 9........................................................

6.4 Replacing and inserting wire 9................................................

6.5 Changing feed rollers 9......................................................

7 MAINTENANCE 10....................................................

7.1 Inspection and cleaning 10....................................................

8 ORDERING SPARE PARTS 10..........................................

DIAGRAM 12............................................................

ORDERING NUMBER 15.................................................

WEAR PARTS 16........................................................

ACCESSORIES 18.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, declares that Wire feed unit RoboFeed

3004w from serial number 620 onwards, conforms to standard IEC/EN 60974--5, in accordance with

the requirements of directive (73/23/EEC) and appendix (93/68/EEC) and standard IEC/EN 60974--10

in accordance with the requirements of directive (89/336/EEC) and appendix (93/68/EEC).

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Kent Eimbrodt

Global Director Equipment and Automation

ESAB AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2006--05--22

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 recommen-

dations 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:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorized 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 PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

SInstall and earth the welding 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!

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

WARNING!

Read and understand the instruction manual before installing

or operating.

This product is solely intended for arc welding.

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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3 INTRODUCTION

The RoboFeed 3004w wire feed unit is intended for MIG/MAG welding along with

robotic equipment.

ESAB’s accessories for the product can be found on page 18.

3.1 Equipment

The wire feed unit is supplied with an instruction manual and a sticker with

recommended wear parts.

4 TECHNICAL DATA

RoboFeed 3004w

Power supply 42 V 50--60 Hz

Power requirement 147 VA

Motor current Imax 3.5 A

Settings data

Wire feed speed 0.8--25.0 m/min

Gun connection EURO

Wire dimension

Cored wire

0.6--1.6 mm

0.6--1.2 mm

1.0--1.6 mm

0.8--1.6 mm

Weight 7.3 kg

Dimensions (l x b x h) 362 x 246 x 235 mm

Shielding gas

max pressure

Gases for MIG/MAG welding

5 bar

Coolant

max pressure

50% water / 50% glycol

5 bar

Maximum permissible load at

60% duty cycle

100% duty cycle

500 A

280 A

Enclosure class IP2X

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain 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.

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5 INSTALLATION

The installation must be executed by a professional.

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.

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, which

has an integral terminating resistor. The other end is at

the wire feed unit and must be fitted with the

terminating resistor, as shown on the right.

5.2 Example of a robotic welding system

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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!

Assure that the side panels are closed during operation.

WARNING!

Rotating parts can cause injury, take great care.

6.1 Connections and control devices

1White indicating lamp – Power supply ON 9Connection for welding gun (EURO)

2Switch for gas purging 10 Inlet connection for spatter removal air

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

(cooling unit), BLUE

4Switch for cold wire feed 12 Connection for coolant to power source

(cooling unit), RED

5Connection for signals to/from robot

welding gun 13 Connection for shielding gas

6Outlet connection for spatter removal air 14 Connection for welding current from power

source, (OKC)

7Connection for coolant from welding gun,

RED 15 Connection for terminating resistor or

forwarding to next wire feed unit

8Connection for coolant to welding gun,

BLUE 16 Connection for control cable from power

source

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Symbol and function explanations

Inlet spatter removal air (10)

Shielding gas (13)

Outlet spatter removal air (6)

Used for spray--cleaning the contact tip on the welding gun.

Gas purging (2)

Used to measure the 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.

Reversed wire feed (3)

Used to reverse the wire, for example when replacing the wire bobbin.

Inching (4)

Used when wire is to be fed without switching on the welding voltage.

6.2 Gas flow guard (if installed)

The gas flow monitor interrupts the ongoing welding process if the gas flow drops

below 3.5 l/min. When this occurs, an error message is displayed via the control unit.

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6.3 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.

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).

6.4 Replacing and inserting wire

SOpen the side panel.

SDisconnect the pressure sensor by folding it backwards, the pressure rollers

slide up.

SStraighten out the new wire 10--20 cm. File away burrs and sharp edges from the

end of the wire before inserting it into the wire feed unit.

SMake sure that the wire goes properly into the feed roller’s track and into the

outflow nozzle or wire guide.

SSecure the pressure sensor.

SClose the side panel.

6.5 Changing feed rollers

SOpen the side panel.

SDisconnect the pressure sensor (1) by folding it

backwards, the pressure rollers slide up.

SDisconnect the pressure rollers (2) by turning the

axle (3) 1/4 turn clockwise and pulling out the axle.

The pressure rollers disconnect.

SDisconnect the feed rollers (4) by unscrewing the nuts

(5) and pulling out the rollers.

During installation, repeat the above in the reverse order.

Choice of track in the feed rollers

Turn the feed roller with the dimensioning mark for the required

track towards you.

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7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any

faults.

7.1 Inspection and cleaning

Wire feed unit

Check regularly that the wire feed unit is not clogged with dirt.

SCleaning 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.

Welding gun

SCleaning and replacement of the welding gun’s wear parts should take place at

regular intervals in order to achieve trouble--free wire feed. Blow the wire guide

clean regularly and clean the contact tip.

8 ORDERING SPARE PARTS

RoboFeed 3004w is designed and tested in accordance with the international and Eu-

ropean standards IEC/EN 60974--5 and 60974--10. 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.

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