ESABFeed 30-4 48-4 M12

0740 800 150 Valid for serial no. 238--xxx--xxxx030210

ESABFeed 30-4 M12ESABFeed 48-4 M12

Service manual

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LIST OF CONTENTS Page

READ THIS FIRST 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TECHNICAL DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WIRING DIAGRAM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Component description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ESABFeed 30 M12, ESABFeed 48 M12 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1 Control board wire feed unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:1 Power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:2 Activation, power source 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:3 Crater filling 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:4 Voltage adjustment 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:5 Gas valve 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:6 2--stroke / 4--stroke 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:7 Burn--back time 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:8 Wire feed speed 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:9 Motor driving / braking 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:10 Tachometer input 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:11 Creep start / Normal start, Current relay 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:12 Start / Stop 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:13 Processor, Motor type 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:14 Gas purge 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:15 Inching 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1:16 Remote control input 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13AP1 Component positions 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .What is ESD? 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SAFETY 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lifting instructions 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connections and control devices 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water connection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting the wire feed pressure 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS LIST 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rights reserved to alter specifications without notice.

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READ THIS FIRSTMaintenance and repair work should be performed by an experienced person, andelectrical work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training forhelp in connection with fault--tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuitboard is divided into numbered blocks, which are described individually in more detail inthe description of operation. All component names in the wiring diagram are listed in thecomponent description.

This manual contains details of all design changes that have been made up to andincluding January 2003.

The ESABFeed 30--4 M12 and ESABFeed 48--4 M12 are designed and tested inaccordance with international and European standard IEC/EN 60974--1 and EN 50199.On completion of service or repair work, it is the responsibility of the person(s) etc.performing the work to ensure that the product does not depart from the requirementsof the above standard.

INTRODUCTION

The ESABFeed 30--4 and ESABFeed 48--4 wire feed units withcontrol panel M12 are intended for MIG/MAG--welding together with stepped welding power sources.

They can be used together with wire on ESAB’sMarathonPact, or on wire bobbin (standard Ø 300 mm,accessory Ø 440 mm).

The wire feed unit can be installed either at the power source,suspended above the workplace, on a support arm or on thefloor with or without wheel set.

ESAB’s accessories for the product can be found on page 33.

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TECHNICAL DATAESABFeed 30--4 M12 ESABFeed 48--4 M12

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

Power requirement 336 VA 378 VA

Motor current Imax 8 A 9 A

Settings dataWire feed speedBurnback timeCreep start2/4 stroke

1.9--25.0 m/min0--0.5 sOFF or ON2 stroke or 4 stroke

1.9--25.0 m/min0--0.5 sOFF or ON2 stroke or 4 stroke

Welding gun connection EURO EURO

Max. diameter wire bobbin 300 mm (*440mm) 300 mm (*440mm)

Wire dimension 0.6--1.6 mm 0.6--2.4 mm

Weightbasic versionwith sealed bobbin holder

11.5 kg15 kg

14.5 kg19 kg

Dimensions (l x b x h)basic versionwith sealed bobbin holder

380 x 275 x 400 mm690 x 275 x 420 mm

380 x 275 x 400 mm690 x 275 x 420 mm

Shielding gas

max pressure

All types intended forMIG/MAG welding5 bar

All types intended forMIG/MAG welding5 bar

Coolantmax pressure

50% water / 50% glycol5 bar

50% water / 50% glycol5 bar

Permissible load at60% duty cycle 630 A 630 A

Enclosure classwith wire bobbin *440mm

IP23IP2X

IP23IP2X

* Accessory, see page 33.

Duty cycleThe 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.

Enclosure classThe IP code indicates the enclosure class, i. e. the degree of protection against penetration by solidobjects or water. Equipment marked IP23 is designed for indoor and outdoor use.

Equipment marked IP2X is designed for indoor use.

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WIRING DIAGRAM

WARNING !STATIC ELECTRICITY can damage circuitboards and electronic components.SSSS Observe precautions for handling electrostatic

sensitive devices.

SSSS Use proper static--proof bags and boxes.ESD

Component description

13AP1 Main circuit board with control electronics: see the description on page 8.

13C1 -- 13C3 Capacitor 0.1µF, decoupling.

13CXX Capacitor 4700µF. Must be fitted when an intermediate wire feed unit is inuse in extreme applications (low mains voltage and long cables).

13G1 ESABFeed 30: Tachogenerator, 660 Hz output at a wire speed of 25m/min. The tachogenerator is incorporated in motor 13M1.

ESABFeed 48: Tachogenerator, 800 Hz output at a wire speed of 25m/min. The tachogenerator is incorporated in motor 13M2.

13M1 Motor, rated voltage 42 V. ESABFeed 30.

13M2, 13M3 Motor, rated voltage 12 V. ESABFeed 48.

13RP1 Potentiometer, 10 kΩ, for setting the wire feed speed.

13RP3 Potentiometer, 10 kΩ, for setting the burn--back time.

13S1 Microswitch, monitoring the water connection. The pump in the watercooling unit starts when the switched is closed.

13SA1 Switch, 2/4--stroke changeover. When the switch is closed, 4--strokecontrol mode is selected.

13SA2 Switch, Creep start function On/Off. When the switch is open, creep startfunction is operative.

13XP1 23 pole panel plug, for connection to the welding power unit.

13XP2 Panel plug for welding current connection from the power unit.

13XS . . Connectors marked 13XS . . are socket connectors.

13XS13 23 pole panel socket for remote control.

13YV1 Gas valve

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ESABFeed 30 M12, ESABFeed 48 M12

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DESCRIPTION OF OPERATION

13AP1 Control board wire feed unit

13AP1:1 Power supply

The wire feed unit receives 42 V from the control power supply transformer inthe welding power unit via connector 13XP01.

42 V AC is supplied to the welding gun trigger switch, the gas valve and thecontactor. In addition, terminals G01 and G02 supply 42 V to a Miggytrac or aRailtrac unit if this is used together with the wire feed unit.

DC power suppliesDiodes D30 -- D33 rectify the 42 V supply to 60 V. Capacitor C61 smooths thesupply, which is then used to power the wire feeder motor.Transistor Q2 is a pre--regulator that drops the voltage from 60 V to 20 V. Q2 iscurrent--limited to about 200 mA.VR1 and VR2 are voltage regulators, producing 5 V and 15 V respectively. Thecircuit board’s microprocessor monitors the voltages. If the 15 V supply fallsbelow 13 V, the wire feed unit is stopped.

13AP1:2 Activation, power source

The start signal is connected to the power unit via pin F in contact 13XP1.

13AP1:3 Crater filling

This function is not used by the ESABFeed with control panel M12.

13AP1:4 Voltage adjustment

This function is not used by the ESABFeed with control panel M12.

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13AP1:5 Gas valve

The gas valve is connected to connectors F04 and F05. If an intermediate wirefeed unit is being used, its gas valve is connected via pins V and U in theremote control connector (13XS13).

13AP1:6 2--stroke / 4--stroke

2--stroke

When switch 13SA1 is open, 2--stroke control mode is selected. This meansthat closing the welding gun trigger switch starts the wire feed motor, opens thegas valve and closes the power unit contactor.Releasing the switch stops the motor, releases the contactor and closes thegas valve. If crater filling and/or burn--back time are operative, they will beactivated before welding ceases.

4--stroke

When switch 13SA1 is closed, 4--stroke control mode is selected. This meansthat first closure of the trigger switch operates the gas valve, with the wire feedmotor starting, and the power unit contactor operating, when the trigger switchis released.

Closing the trigger switch for the second time stops the motor andde--energises the contactor in the power unit. Releasing the switch closes thegas valve. If crater filling and/or burn--back time are operative, they will beactivated before welding ceases.

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13AP1:7 Burn--back time

The burn--back time is the time from when motor braking starts until themachine contactor opens. It can be adjusted by potentiometer 13RP3 between0 and 0.5 seconds.

13AP1:8 Wire feed speed

Adjustment on the front panel of the feeder unit

Potentiometer 13RP1 controls the wire feed speed over a range from 1.9 to 25metres/minute. For use with automated welding processes, a 0 -- 10 Vreference signal can be connected to terminal A17.

Adjustment using the remote control unit

Wire feed speed reference from the remote control unit

Potentiometer 13RP1 is disengaged when a remote control unit is connectedto input 13XS13. The circuit board microprocessor senses that the remotecontrol unit is connected by means of the voltage drop across diode D35.When the remote control unit is connected, the voltage on connector E11cannot drop below about 0.6 V.

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13AP1:9 Motor driving / braking

The motor is powered by the smoothed +60 V supply. Pulse width modulation,controlled by transistor Q3, is used to vary the motor voltage. The pulsefrequency is 12 kHz, and the maximum conducting time of the pulses is 97% ofthe pulse cycle time. Freewheel diode D11 maintains motor current during thepulse breaks.

ESABFeed 30: At a drive roller speed of 266 r/min, the wire feed speed is25 m/min.

ESABFeed 48: At a drive roller speed of 166 r/min, the wire feed speed is25 m/min.

Pins D and E in the remote control unit connector 13XS13 provide power forthe motor in an intermediate wire feed unit or for a PKE (push/pull) weldinggun. If an intermediate wire feed unit is being used in extreme applications (lowmains voltage and long cables), an additional 4700µF smoothing capacitor13CXX must be connected (ordering number 0193 141 048).

The voltage drop across resistor R92 provides a signal that is proportional tothe motor current. When the current exceeds 15.4 A, IC6:2 turns off the gatepulse to Q3. When the current drops, Q3 conducts again at the next gatepulse.

BrakingWhen the motor starts, capacitor C60 charges up to 15 V, with zener diodeD20 limiting the voltage across it. Braking is activated by the optocoupler IC3.When the transistor in IC3 is turned on by the LED, 15 V from capacitor C60 isconnected to the gate of transistor Q4. Transistor Q4 turns on and shortcircuits the motor through the resistors R85--R87. The resistors limit thebraking current to about 20 A.

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13AP1:10 Tachometer input

The tachometer 13G1 is fitted inside the motor casing. Comparator IC5;2converts the sine wave signal from the tachogenerator to a square wave at thesame frequency.

ESABFeed 30:At a wire feed speed of 25 m/min, it produces a signal frequency of 660 Hz.

ESABFeed 48:At a wire feed speed of 25 m/min, it produces a signal frequency of 800 Hz.

13AP1:11 Creep start / Normal start, Current relay

Creep Start

The creep start function is activated when switch 13SA2 is open. Creep startmeans that the motor runs at a speed of 1.9 m/minute until the current relay isactivated. When the relay operates, the speed increases to the set speed. Ifthe current relay has not operated within one second after starting, the motorincreases to the set speed.

Current relay

The current relay operates if the welding current exceeds 20 A. If the craterfilling function has been selected, it will work only when the current relay hasoperated.

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13AP1:12 Start / Stop

The trigger switch in the welding gun is supplied at 42 V AC. Closing the switchenergises optocoupler IC10, pulling down the voltage across C46.

When the Miggytrac or the Railtrac is used, the start signal to the feed unit issupplied by the remote input.

13AP1:13 Processor, Motor type

Processor

The processor stores the machine program. It monitors the power supplyvoltages: if the voltages drop to too low a level, wire feed is stopped, asdescribed in section 13AP1:1 above.

The processor also monitors speed. If the wire speed deviates from the setvalue by more than 1.5 m/min for more than five seconds, wire feed will bestopped.

Motor type

The wire feeder mechanisms MEM 30 and MEL 48 need different software forthe motors. To enable the processor IC1, to select the correct software for theESABFeed 30, connection L01 must be linked to L02 and L03 to L04. For theESABFeed 48 there is a link only between L03 and L04.

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13AP1:14 Gas purge

The circuit board has an input for gas purge, this is not used by theESABFeed.

13AP1:15 Inching

The circuit board has an input for inching, this is not used by the ESABFeed.

13AP1:16 Remote control input

The following items can be connected to the remote control input :

S Wire feed speed remote control unit: pins M, J and L in 13XS13.

S Welding voltage remote control unit, if the power unit is ofthyristor--controlled or transistor--controlled type: pins J, K, L, Z and Y in13XS13.

S MEK 25 intermediate wire feeder unit.

S Equipment for mechanized welding: Miggytrac or Railtrac

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13AP1 Component positions

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SERVICE INSTRUCTIONS

What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESD stands forElectrostatic Discharge.

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to people.ESD damage occurs when an ungrounded person or object with a static charge comes intocontact with a component or assembly that is grounded. A rapid discharge can occur,causing damage. This damage can take the form of immediate failure, but it is more likelythat system performance will be affected and the component will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from buildingup on you or on anything at your work station, then there cannot be any static discharges.Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold staticcharge, so you should not bring unnecessary nonconductive items into the work area.It is obviously difficult to avoid all such items, so various means are used to drain off anystatic discharge from persons to prevent the risk of ESD damage. This is done by simpledevices: wrist straps, connected to ground, and conductive shoes.

Work surfaces, carts and containers must be conductive and grounded, use only antistaticpackaging materials. Overall, handling of ESD--sensitive devices should be minimized toprevent damage.

WARNING !STATIC ELECTRICITY can damage circuitboards and electronic components.SSSS Observe precautions for handling electrostatic

sensitive devices.

SSSS Use proper static--proof bags and boxes.ESD

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INSTRUCTIONS

This chapter is an extract from the instructions for the ESABFeed 30 and ESABFeed 48with control panel M12.

SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring thatanyone 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 weldingequipment. The following recommendations should be observed in addition to thestandard regulations that apply to the workplace.

All work must be carried out by trained personnel well--acquainted with the operation ofthe welding equipment. Incorrect operation of the equipment may lead to hazardoussituations which can result in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:S its operationS location of emergency stopsS its functionS relevant safety precautionsS welding

2. The operator must ensure that:S no unauthorised person is stationed within the working area of the equipment when it is

started up.S no--one is unprotected when the arc is struck

3. The workplace must:S be suitable for the purposeS be free from draughts

4. Personal safety equipmentS Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautionsS Make sure the return cable is connected securely.S Work on high voltage equipment may only be carried out by a qualified electrician.S Appropriate fire extinquishing equipment must be clearly marked and close at hand.S Lubrication and maintenance must not be carried out on the equipment during operation.

WARNING!

Read and understand the instruction manualbefore installing or operating.

To prevent the reel sliding off the hub: Lock the reel in place by turningthe red knob as shown on the warning label attached next to the hub.

WARNING!

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WARNING!

Rotating parts can cause injury, take great care.

Lifting instructions

Ordering number for the lifting eye can be found on page 33.

Note! If another mounting device is used, this should be insulated from the wire feed unit.

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OPERATION

Connections and control devices1 Knob for setting burnback time 8 Connection for welding gun

2 Switch for creep start OFF / ON 9 Connection for welding current from powersource, (OKC)

3 Knob for setting wire feed speed. 10 Connection for control cable from powersource

4 Switch for 2--stroke / 4--stroke 11 Connection RED, for cooling water to powersource (cooling unit)

5 Connection for remote control unit 12 Connection BLUE, for cooling water frompower source (cooling unit)

6 Connection BLUE, with ELP* for coolingwater to welding gun

13 Connection for shielding gas

7 Connection RED, for cooling water fromwelding gun

NOTE! Cooling water connections only available on certain models.* ELP = ESAB Logic Pump, see “Water connection” below.

Water connectionWhen connecting a water--cooled welding gun, the power source’s main power supplyswitch must be in the Off position and the cooling unit switch must be in position “ELP/0”.

The wire feed unit with water connection is equipped with a detection system ELP (ESABLogic Pump), which checks that the water hoses are connected. When connecting awater--cooled welding gun, the water pump starts.

Detection only works with power sources that are equipped with ELP.

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Setting the wire feed pressureStart by making sure that the wire moves smoothly through the wire guide. Then set thepressure of the wire feeder’s pressure rollers. It is important that the pressure is not toogreat.

Fig 1 Fig 2

To check that the feed pressure is set correctly, you can feed out the wire against aninsulated object, e.g. a piece of wood.When you hold the welding gun approx. 5 mm from the piece of wood (fig. 1) the feedrollers should slip. If you hold the welding gun approx. 50 mm from the piece of wood, thewire should be fed out and bend (fig. 2).

MAINTENANCERegular maintenance is important for safe, reliable operation.

Note!All guarantee undertakings from the supplier cease to apply if the customer himselfattempts any work in the product during the guarantee period in order to rectify any faults.

Inspection and cleaningWire feed unitCheck regularly that the wire feed unit is not clogged with dirt.

S Cleaning and replacement of the wire feed unit mechanism’s worn parts should takeplace at regular intervals in order to achieve trouble--free wire feed. Note that ifpre--tensioning is set too hard, this can result in abnormal wear on the pressure roller,feed roller and wire guide.

The brake hubThe hub is adjusted when delivered, if readjustment is required, follow the instructionsbelow. Adjust the brake hub so that wire is slightly slack when wire feed stops.

S Adjusting the braking torque:S Turn the red handle to the locked position.S Insert a screwdriver into the springs in the hub.Turn the springs clockwise to reduce the braking torqueTurn the springs anticlockwise to increase the braking torque. NB: Turn both springsthrough the same amount.

Welding gunS Cleaning 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 regularlyand clean the contact tip.

ESABFeed 30-4 M12, ESABFeed 48-4 M12 Edition 030210

Spare parts list

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Valid for serial no. 238--xxx--xxxx

Ordering numbers for ESABFeed 30-4 M12, ESABFeed 48-4 M12

Water cooling kit Feeder for Marathon Pact Feeder withcapsuled bobbin

ESABFeed30--4 0459 114 882 0459 116 882

ESABFeed30--4 x 0459 114 892 0459 116 892

ESABFeed48--4 0459 114 982 0459 116 982

ESABFeed48--4 x 0459 114 992 0459 116 992

Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of thecover. Kindly indicate type of unit, serial number, denominations and ordering numbers according tothe spare parts list.

Maintenance and repair work should be performed by an experienced person, and electrical work onlyby a trained electrician. Use only recommended spare parts.


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C = component designation in the circuit diagram

Item Qty Ordering no. Denomination Notes C

HA1 1 0459 119 001 Handle

HA2 1 0459 069 002 Side panel

0459 213 001 Label for side panel

HA3 1 Protection frame For further information see page 32.

HA4 1 MMC module Panel M12, For further information see page 32.

HA5 1 0368 544 005 Socket 23 pole

HA6 1 0456 516 001 Cap 23 pole

HA7 1 Cover plug Ø 26

HA8 1 0367 149 001 Quick connection Male

HA9 2 0192 230 105 Cover plug

HA10 1 0456 496 001 Hose red L=0.32, Ø 9/5mm, to be ordered per metre

HA11 1 0365 803 016 Quick connection Female, Red

HA12 1 0365 803 017 Quick connection Female, Blue

HA13 1 0456 496 002 Hose, blue L=0.33, Ø 9/5mm, to be ordered per metre

HA14 1 0456 496 001 Hose red L=0.33, Ø 9/5mm, to be ordered per metre

HA15 7 Hose clamp Ø 11.3/10.8

HA16 1 Water outlet with lock For futher information see page 31. 13S1

HA17 1 0193 054 002 Solenoid valve 13YV1

HA18 1 0456 496 001 Hose, red L=0.27, Ø 9/5mm, to be ordered per metre

HA19 1 0192 526 002 Sealing strip L=1.34

HA20 1 0459 148 001 Protective coverMMC panel

HA21 1 0367 902 001 Locking device

HA22 1 0459 069 001 Side panel

-- 0459 213 001 Label for side panel

HA23 1 0458 777 001 Protection clamp Handle

HA24 1 Wire feed mechanism Type MEL 48, ESABFeed 48--4, see page 28.

HA25 1 Wire feed mechanism Type MEM 30, ESABFeed 30--4, see page 26.


-- 23 --bm33sha1

C


-- 24 --bm33shb1

C = component designation in the circuit diagram(W) = wear part


HB1 1 0459 071 881 Cover

HB2 1 0459 099 001 Middle plate

HB3 1 0458 662 880 Bottom plate

HB4 1 0156 602 001 Inlet nozzle (W) Ø 2mm plastic, for 0.6--1.2mm Fe. Ss and Al wire

HB5 1 0458 748 001 Insulating bushing

HB6 1 0458 748 002 Insulating washer

HB7 1 Nut M 10

HB8 4 0467 695 001 Rubber foot Ø 20/6.4x3, When ordering: 4 pieces delivered.

HB9 4 Plastic spacer Ø 20/6.4

HB10 1 0368 543 005 Connector (Burndy plug) 12 pole 13XP1

HB11 1 0459 102 001 Rear plate

HB12 1 0160 609 881 Welding current terminal

HB13 1 Contact sleeve Included in item HB12

HB14 1 Spacer ring Included in item HB12

HB15 1 Washer Included in item HB12

HB16 1 Nut Included in item HB12

HB17 1 0458 678 001 Bar flexible

HB18 1 0467 911 881 Capacitor 13C4

HB19 1 Washer Ø 22/10.5x2

HB20 2 Spring washer Ø 20/10.2x1.1

HB21 1 Screw M10x20

HB22 4 0194 019 005 Spacer

HB23 1 0486 205 886 Circuit board 13AP1

HB24 1 0459 108 001 Front plate water

HB25 1 0459 108 003 Front plate air

For more wear parts see page 37.


-- 25 --bm33shb1

ESABFeed 30-4 M12 Edition 030210

-- 26 --bm29shh1


(W) = wear part (V) = V--groove


0459 000 882 Wire feed mechanismType MEM 30

Includes items HH1 -- HH21 and HH23 -- HH41

HH1 1 0455 077 001 Drive unit With tachometer 13M1HH2 1 0332 351 012 Shaft (with pinion) Included in item HH1HH3 1 0191 496 114 Key Included in item HH1HH4 1 0215 701 007 Locking washer Included in item HH1HH5 1 0455 046 003 Gear housingHH6 1 Screw M6x40HH7 2 Washer Ø 12/6.4x1.5HH8 1 0455 048 001 Insulating tubeHH9 1 Nut M6HH10 1 0467 911 880 Capacitor 0.1 ìF 250V with cable lugs 13C5HH11 1 Flat pin 6.3x0.8 M6HH12 4 Screw M6x12HH13 1 0455 045 001 Insulating sleeveHH14 1 0455 044 001 Current connectionHH15 1 Screw M8x25HH16 1 Spring washer Ø 16/8.2x0.9HH17 1 Washer Ø 16/8.4x1.5HH18 1 Nut M6HH19 1 0459 229 880 Cable set Includes sleeves and insulating sleeves.HH20 1 0458 918 880 Front flange with PC--board Current relayHH21 1 0469 837 880 Outlet nozzle (W) Ø 2mm for 0.6--1.6mm Fe, Ss and cored wireHH22 4 0153 043 002 Insulating washerHH23 1 0469 838 001 CoverHH24 3 Screw M6x12HH25 1 0455 052 001 Drive gear (W)HH26 1 Washer Ø 16/5x1HH27 1 Screw M4x12HH28 2 Axle feed roll See item HH102HH29 4 0455 053 880 Gear adapter (W)HH30 4 0459 052 003 Feed/pressure roller (W) (V) For Ø 1.0 & 1.2mm Fe, Ss, Al and cored wireHH31 2 Locking nut See item HH102HH32 3 0458 689 001 Screw for nozzleHH33 1 Pin bolt See item HH101HH34 1 0455 049 001 Inlet nozzle (W) Ø 3mm for 0.6--1.6mm Fe, Ss, Al and cored wireHH35 1 Pressure device See item HH101HH36 1 0455 072 002 Intermediate nozzle (W) For Fe, Ss and cored wireHH37 1 Pressure arm See item HH100HH38 1 Locking washer See item HH100HH39 1 Torsion spring See item HH100HH40 1 Shaft See item HH100HH41 2 0458 999 001 Shaft


SPARE PARTS SETSItem Ordering no. Denomination Notes

HH100 0459 227 880 Pressure arm set Includes items HH37, HH38, HH39 and HH 40

HH101 0459 228 880 Pressure device set Includes items HH33, HH35 and one screw M3x12.

HH102 0458 722 880 Axle and nut Includes items HH28 and HH31.


-- 27 --bm29shh1


-- 28 --bm29shd1


(W) = wear part (V) = V--groove


0458 547 881 Wire feed mechanismType MEL 48

Includes items HD1 -- HD27 and HD29

HD1 1 0156 728 010 Drive unit With tachometer 13M2

-- 1 0193 260 063 Connector 4 pole 13XS4

HD2 1 0156 728 011 Drive unit 13M3

1 0191 548 010 Flat pin

6 Nut M8

HD3 1 0467 911 880 Capacitor 0.1 ìF 250V with cable lugs 13C6

HD4 1 Screw M6X40

HD5 1 Washer Ø 6.4/12x1.5

HD6 1 0455 048 001 Insulating tube

HD7 1 0458 545 001 Connection housingHD8 9 Screw M5X20

HD9 1 Screw M6X16

HD10 1 Nut M6

HD11 1 0458 918 880 Front flange withPC.board

Current relay

HD12 1 0455 044 001 Current connection

HD15 1 0469 837 880 Outlet nozzle (W) Ø 2mm for 0.6--1.6mm Fe, Ss and cored wire

HD16 2 0366 966 880 Feed roller no. 1 (W) (V) For 0.6--1.2mm Fe, Ss and cored wire

HD17 4 0156 707 001 Distance washer

HD18 2 0156 707 002 Adjustement spacer

HD19 2 0366 944 001 WasherHD20 2 Screw M5x16

HD21 1 0366 941 880 Bogey no. 1 (W) (V) For 0.6--1.2mm Fe, Ss and cored wire

HD23 1 0366 961 001 Inter nozzle support

HD24 2 0215 702 708 Locking washer

HD25 1 0156 603 001 Intermediate nozzle (W) Ø 1.6 mm plastic for 0.8--1.2mm Fe, Ss and Al wire

HD26 1 0458 546 001 Wire feed plate

HD27 1 0366 962 001 Bogey axle

-- 1 Screw M8X30

-- 1 Washer Ø 26/8.4X5HD28 4 0153 043 002 Insulating washer

HD29 1 0459 229 880 Cable set Includes sleeves and insulating sleeves



-- 29 --bm29shd1


-- 30 --bm29she1

Item Qty Ordering no. Denomination Notes

HE3 1 0458 674 880 Bobbin cover

HE4 1 0146 967 881 Brake hub

HE5 1 0458 676 880 Fixed boom

ESABFeed 30-4 M12, ESABFeed 48-4 M12

Edition 030210-- 31 --bm29shf1


HF1 1 Nut M5

HF2 1 Washer D16/5x1

HF3 1 Spring

HF4 1 Water lock cam

HF5 1 0365 803 015 Quick connector Female, blue Note: only for wire feed units

1 0365 803 009 Quick connector Female, blue Note: only for power source cooling units

HF6 1 Water lock bushing

HF7 1 Water lock outlet

HF8 1 Screw M5x35

HF9 1 Nut M3

HF10 1 0458 589 001 Insulation plate

HF11 1 0458 364 001 Micro switch

HF12 1 0365 803 014 Quick connector Female, red Note: only for wire feed units

1 0365 803 008 Quick connector Female, red Note: only for power source cooling units

HF13 2 Screw M3x20

HF14 2 Nut M3

SPARE PARTS SET


HF50 1 0458 370 900 Water connection spare kit Contains items HF1, HF2, HF3, HF4, HF6, HF7 and HF8

H


-- 32 --bm33shj1

C = component designation in the circuit diagramNO TAG


MMC module

HJ1 1 0459 118 001 Protection frame

HJ2 1 0459 131 002 Label

HJ3 2 0191 870 616 Potentiometer 13RP1, 13RP3

HJ4 1 0321 475 882 Knob

HJ5 3 0321 475 881 Knob

HJ6 2 0194 055 003 Rotary switch 13SA1, 13SA2


Accessories

-- 33 --bm33a11a

1 Bobbin cover 18 kg Ø 300mm . . . . . . . . . . . . . 0458 674 880

12

Bobbin holder . . . . . . . . . . . . . . . . . . . . . . . . . . .Adapter for 5 kg bobbin . . . . . . . . . . . . . . . . . . . .

0458 704 8800455 410 001

1 Adapter for 440 mm bobbin . . . . . . . . . . . . . . . . 0459 233 880

12

Lifting eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick connector MarathonPact . . . . . . . . . . .

0458 706 880F102 440 880

123

Turning piece . . . . . . . . . . . . . . . . . . . . . . . . . . . .Guide pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quick connector MarathonPact . . . . . . . . . . .

0458 703 8800349 302 303F102 440 880


-- 34 --bm33a11a

1 Wheel kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0458 707 880

1 Strain relief for welding gun . . . . . . . . . . . . . . 0457 341 881

Strain relief bracket for connection set . . . . 0459 234 880

Counter balance device . . . . . . . . . . . . . . . . . . .(includes mast and counter balance)

0458 705 880


-- 35 --bm33a11a

Feeder stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0458 522 880

Remote control units, with 5 m cableSetting of current and voltagePAE2 box 23 pole . . . . . . . . . . . . . . . . . . . . . . . .PAE2 bar 23 pole . . . . . . . . . . . . . . . . . . . . . . . .Extension cables23 pole, 8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 pole, 16 m . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 pole, 25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 pole, 35 m . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0466 801 8800466 515 880

0467 197 8800467 197 8810467 197 8820467 197 883

Connection set for 400 A power sourcesConnection set 1.7 m . . . . . . . . . . . . . . . . . . . . . .Connection set 8 m . . . . . . . . . . . . . . . . . . . . . . . .Connection set 16 m . . . . . . . . . . . . . . . . . . . . . . .Connection set 25 m . . . . . . . . . . . . . . . . . . . . . . .Connection set 35 m . . . . . . . . . . . . . . . . . . . . . . .Connection set 1.7 m, water . . . . . . . . . . . . . . . .Connection set 8 m, water . . . . . . . . . . . . . . . . . .Connection set 16 m, water . . . . . . . . . . . . . . . . .Connection set 25 m, water . . . . . . . . . . . . . . . . .Connection set 35 m, water . . . . . . . . . . . . . . . . .

0469 836 8800469 836 8810469 836 8820469 836 8830469 836 8840469 836 8850469 836 8860469 836 8870469 836 8880469 836 889

Connection set for 500 A power sourcesConnection set 1.7 m . . . . . . . . . . . . . . . . . . . . . .Connection set 8 m . . . . . . . . . . . . . . . . . . . . . . . .Connection set 16 m . . . . . . . . . . . . . . . . . . . . . . .Connection set 25 m . . . . . . . . . . . . . . . . . . . . . . .Connection set 35 m . . . . . . . . . . . . . . . . . . . . . . .Connection set 1.7 m, water . . . . . . . . . . . . . . . .Connection set 8 m, water . . . . . . . . . . . . . . . . . .Connection set 16 m, water . . . . . . . . . . . . . . . . .Connection set 25 m, water . . . . . . . . . . . . . . . . .Connection set 35 m, water . . . . . . . . . . . . . . . . .

0469 836 8900469 836 8910469 836 8920469 836 8930469 836 8940469 836 8950469 836 8960469 836 8970469 836 8980469 836 899


-- 36 --bm33a11a

MiggytracEquipment for mechanized welding . . . . . . . . . .

More infor--mation at thenearestESAB agency

RailtracEquipment for mechanized welding . . . . . . . . . .

More infor--mation at thenearestESAB agency

Welding gun with EURO connectionSelf cooled

Type Ordering no. Max welding current Wire dimensions

Hose length 3 m Hose length 4,5 m CO2 Mix Ar

PSF 160 0368 100 880 0368 100 881 160A 60% 160A 60% 0.6 -- 0.8

PSF 250 0368 100 882 0368 100 883 250A 60% 225A 60% 0.6 -- 1.0

PSF 305 0458 401 880 0458 401 881 315A 60& 285A 60% 0.6 -- 1.2

PSF 405 0458 401 882 0458 401 883 380A 60% 325A 60% 0.6 -- 1.6

PSF 505 0458 401 884 0458 401 885 475A 60% 410A 60% 0.6 -- 2.4

Water cooled

Type Ordering no. Max welding current Wire dimensions

Hose length 3 m Hose length 4,5 m CO2 Mix Ar

PSF 410W 0458 400 882 0458 400 883 425A 100% 400A 100% 0.6 -- 1.6

PSF 510W 0458 400 884 0458 400 885 500A 100% 440A 100% 0.6 -- 2.4

Feed and pressure rollers for ESABFeed 30--4

Ordering no. Wire dimensions Wire type Groove type Roller markings0459 052 001 Ø 0.6 & 0.8 mm Fe, Ss & cored V 0.6 S2 & 0.8 S20459 052 003 Ø 0.9/1.0 & 1.2 mm Fe, Ss & cored V 1.0 S2 & 1.2 S20459 052 013 Ø 1.4 & 1.6 mm Fe, Ss & cored V 1.4 S2 & 1.6 S20458 825 001 Ø 0.9/1.0 & 1.2 mm Cored V--knurled 1.0 R2 & 1.2 R20458 825 002 Ø 1.2 & 1.4 mm Cored V--knurled 1.2 R2 & 1.4 R20458 825 003 Ø 1.6 & 2.0 mm Cored V--knurled 1.6 R2 & 2.0 R20458 824 001 Ø 0.8 & 0.9/1.0 mm Al U 0.8 A2 & 1.0 A2

0458 824 003 Ø 1.2 & 1.6 mm Al U 1.2 A2 & 1.6 A2Use only pressure and feed rollers marked A2, R2 or S2 for the ESABFeed 30.The rollers are marked with wire dimension in mm, some are also marked with inch.


-- 37 --bm33a11a

Intermediate nozzles for ESABFeed 30--4Ordering no. Wire type

0455 072 002 Fe, Ss & cored

0456 615 001 Al

Outlet nozzles for ESABFeed 30--4 and ESABFeed 48--4Ordering no. Dimensions Wire type Notes

0469 837 880 Ø 2.0 mm steel for 0.6--1.6 mm wire Fe, Ss & cored

0469 837 881 Ø 2.0 mm plastic for 0.8--1.6 mm wire Al

0469 837 882 Ø 3.4 mm steel for 2.0--2.4 mm wire Fe, Ss & cored Only for ESABFeed 48

Inlet nozzles for ESABFeed 30--4 and ESABFeed 48--4

Ordering no. Dimensions Wire type Notes

0156 602 001 Ø 2 mm plastic for 0.6--1.6 mm wire Fe, Ss & Al

0156 602 002 Ø 4 mm plastic for 2.0--2.4 mm wire Fe, Ss & Al Only for ESABFeed 48

0332 318 001 Ø 2.4 mm steel for 1.2--2.0 mm wire Cored

0332 318 002 Ø 4 mm steel for 2.4 mm wire Cored Only for ESABFeed 48

Intermediate nozzles for ESABFeed 48--4

Ordering no. Dimensions Wire type

0156 603 001 Ø 2 mm plastic for 0.6 -- 1.6 mm wire Fe, Ss & Al

0156 603 002 Ø 4 mm plastic for 2.0 -- 2.4 mm wire Fe, Ss & Al

0332 322 001 Ø 2.4 mm copper for 1.2 -- 2.0 mm wire Cored

0332 322 002 Ø 4 mm copper for 2.4 mm wire Cored


-- 38 --bm33a11a

Feed rollers for ESABFeed 48--4Ordering

no.Wire

dimensionsWire type Groove

typeRollermarking

Groove1

Groove2

Groove3

0366 966 880 Ø 0.6--1.2 mm Fe, Ss, Al, C V 1 0.6--0.8 0.9--1.0 1.2

0366 966 881 Ø 1.4--2.4 mm Fe, Ss, Al, C V 2 1.4--1.6 2.0 2.4

0366 966 882 Ø 1.2--2.0 mm C V--K 3 1.2 1.4--1.6 2.0

0366 966 883 Ø 2.4--3.2 mm C V--K 4 2.4 not used --

0366 966 884 Ø 1.0 mm x 3 Al U -- 1.0 1.0 1.0

0366 966 885 Ø 1.2 mm x 3 Al U -- 1.2 1.2 1.2

0366 966 886 Ø 1.6 mm x 3 Al U -- 1.6 1.6 1.6

0366 966 887 Ø .030” x 3 Fe, Ss, C V .030 .030” .030” .030”

0366 966 888 Ø .035” x 3 Fe, Ss, C V .035 .035” .035” .035”

0366 966 889 Ø .045” x 3 Fe, Ss, C V .045 .045” .045” .045”

0366 966 890 Ø 1/16” x 3 Fe, Ss, C V 1/16 1/16” 1/16” 1/16”

0366 966 891 Ø 5/64” x 3 Fe, Ss, C V 5/64 5/64” 5/64” 5/64”

0366 966 892 Ø 3/32” x 2 Fe, Ss, C V 3/32 3/32” 3/32” --

0366 966 893 Ø .045” x 3 C V--K .045 .045” .045” .045”

0366 966 894 Ø 1/16” x 3 C V--K 1/16 1/16” 1/16” 1/16”

0366 966 895 Ø 5/64” x 3 C V--K 5/64 5/64” 5/64” 5/64”

0366 966 896 Ø 3/32” x 2 C V--K 3/32 3/32” 3/32” --

0366 966 897 Ø 1/8” x 1 C V--K 1/8 1/8” -- --

0366 966 898 Ø 0.6--1.6 mm Fe, Ss, C V 5 0.6--0.8 0.9--1.0 1.2--1.6

C = cored wire K = knurled groove


-- 39 --bm33a11a

Bogies for ESABFeed 48--4

Ordering no. Ballbearings

Wiredimensions

Wire type Groovetype

Bogeymarking

0366 902 880 X Ø 0.6 -- 1.2 mm Fe, Ss, Al & cored V 1

0366 941 880 Ø 0.6 -- 1.2 mm Fe, Ss, Al & cored V 1

0366 941 881 Ø 1.4 -- 2.4 mm Fe, Ss, Al & cored V 2

0366 902 881 X Ø 1.4 -- 2.4 mm Fe, Ss, Al & cored V 2

0366 941 882 Ø 1.2 -- 2.0 mm Cored V--knurled 3

0366 902 882 X Ø 1.2 -- 2.0 mm Cored V--knurled 3

0366 902 883 X Ø 2.4 -- 3.2 mm Cored V--knurled 4

0366 902 885 X Ø 1.0 mm x 3 Al U --

0366 902 886 X Ø 1.2 mm x 3 Al U --

0366 902 887 X Ø 1.6 mm x 3 Al U --

0366 941 883 Ø .030” x 3 Fe, Ss & cored V .030

0366 941 884 Ø .035” x 3 Fe, Ss & cored V .035

0366 941 885 Ø .045” x 3 Fe, Ss & cored V .045

0366 941 886 Ø 1/16” x 3 Fe, Ss & cored V 1/16

0366 902 888 X Ø 5/64” x 3 Fe, Ss & cored V 5/64

0366 902 889 X Ø 3/32” x 3 Fe, Ss & cored V 3/32

0366 941 887 Ø .045” x 3 Cored V--knurled .045

0366 941 888 Ø 1/16” x 3 Cored V--knurled 1/16

0366 902 890 X Ø 5/64” x 3 Cored V--knurled 5/64



0366 941 889 Ø 0.6 -- 1.6 mm Fe, Ss & cored V 5

0366 902 893 X Ø 0.6 -- 1.6 mm Fe, Ss & cored V 5

-- 40 --notes

NOTES

-- 41 --notes

ESAB ABSE--695 81 LAXÅSWEDENPhone +46 584 81 000Fax +46 584 123 08

www.esab.com

030210

ESAB subsidiaries and representative offices

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ESABFeed 30-4 48-4 M12

Documents

Transcript of ESABFeed 30-4 48-4 M12