GB

Valid for serial no. 620-xxx-xxxx0459 508 101 GB 20120621

Origo™ M08, Origo™ M09

Feed L302Feed L304

Instruction manual

- 2 -

- 3 -TOCe

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 Lifting instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Connections and control devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Explanation of function 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Wire feed pressure 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Replacing and inserting wire 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Changing feed roller Feed L302 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Changing feed roller Feed L304 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Inspection and cleaning 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

ORDER NUMBER 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

ACCESSORIES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

© ESAB AB 2004- 4 -

bm38d1ea

1 SAFETYUsers of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on ornear the equipment observes all the relevant safety precautions. Safety precautions must meet therequirements 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.

GB

© ESAB AB 2004- 5 -

bm38d1ea

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 andcutting. Ask for your employer's safety practices which should be based on manufacturers' hazarddata.

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.

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 wherethe electrical power is provided by the public low-voltage supply system.There may be potential difficulties in ensuring electromagneticcompatibility of class A equipment in those locations, due to conductedas well as radiated disturbances.

CAUTION

Read and understand the instruction manual beforeinstalling or operating.

GB

© ESAB AB 2004- 6 -

bm38d1ea

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and ElectronicEquipment and its implementation in accordance with national law, electrical and/orelectronic equipment that has reached the end of its life must be disposed of at arecycling facility.

As the person responsible for the equipment, it is your responsibility to obtaininformation 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 wirefeed 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 wirebobbin 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 24.

2.1 Equipment

The wire feed units are supplied with an instruction manual and stickers.

3 TECHNICAL DATA

Feed L302 Feed L304

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

Power requirement 150 VA 150 VA

Motor current Imax 3.5 A 3.5 A

Settings data

Wire feed speed

Burnback time

Spot welding time

1.5-22.0 m/min

0-0.7 s

-

1.5-22.0 m/min

0-0.7 s

0.2-5 s

Gun connection EURO EURO

Max. diameter wire bobbin 300 mm 300 mm

Wire dimension

Fe

Ss

Al

Cored wire

0.6-1.2 mm

0.6-1.2 mm

1.0-1.2 mm

0.8-1.2 mm

0.6-1.6 mm

0.6-1.2 mm

1.0-1.6 mm

0.8-1.6 mm

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

GB

© ESAB AB 2004- 7 -

bm38d1ea

Feed L304Feed L302

Coolant

max pressure

-

-

50% water / 50% glycol

5 bar

Maximum permissible load at

60% duty cycle

100% duty cycle

365 A

280 A

365 A

280 A

Enclosure class

basic version

with sealed bobbin holder*

with MarathonPac�

IP2X

IP23

IP23

IP2X

IP23

IP23

* Accessories, see page 24.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solidobjects 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 solidobjects 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 ata 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 maycause radio interference. It is the user's responsibility to take adequate precautions.

WARNING

When welding in an environment with increased electrical danger, only powersources intended for this environment may be used. These power sources aremarked with the symbol

GB

© ESAB AB 2004- 8 -

bm38d1ea

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 feedunit.

5 OPERATION

General safety regulations for handling the equipment can be found onpage 4. Read through before you start using the equipment!

AH

0935

GB

© ESAB AB 2004- 9 -

bm38d1ea

WARNING

Assure that the side panels are closed during operation.

WARNING

To prevent the reel from sliding off the hub: Lock thereel in place by turning the red knob as shown on thewarning 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 isimportant to secure the cable with theload-removing grommet.

Ensure that the cover is properly screwedinto place.

GB

© ESAB AB 2004- 10 -

bm38d1ea

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 powersource, (OKC)

3 Switch for 2-stroke / 4-stroke 6 Connection for shielding gas

7 Connection for control cable from powersource

Feed L304

1 Knob for setting wire feed speed

7 Connection RED for cooling water fromwelding gun

2 Switch for activation of 2/4 stroke, spotwelding, cold wire feed or gas purging

8 Connection BLUE, for cooling water towelding gun

3 Knob for setting spot welding time 9 Connection for welding current from powersource, (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 powersource

6 Connection for welding gun

NOTE! Cooling water connections only available on certain models.

10

GB

© ESAB AB 2004- 11 -

bm38d1ea

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 ispressed 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 wirefeed starts when it is released. The welding process continues until the switch ispressed in again, the wire feed stops and when the switch is released the gas stopsflowing.

Spot welding

Spot welding is used when you want to weld on short, repeated occasions with apre-set time.

When the trigger switch is pressed in, the gas flow starts for a period of timegoverned by the printed circuit board. After this the welding process starts for the settime. 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 themof any air and moisture before commencing welding. Gas purging is carried out withthe 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 whenthe power source switches off the welding voltage. Too short burnback time resultsin a long wire stickout after completion of welding, with a risk of the wire beingcaught in the weld pool. Too long a burnback time results in a shorter stickout, withincreased 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 intoelectrical contact with the workpiece, at which point the speed increases to the setspeed.

GB

© ESAB AB 2004- 12 -

bm38d1ea

5.3 Wire feed pressure

Start by making sure that the wire moves smoothly through the wire guide. Thenset the pressure of the wire feeder's pressure rollers. It is important that thepressure is not too great.

Fig 1 Fig 2

To check that the feed pressure is set correctly, you can feed out the wire againstan insulated object, e.g. a piece of wood.

When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feedrollers 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).

ÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏ

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 isfolded up.

� Straighten out 10-20 cm of the new wire. File away burrs and sharp edges fromthe 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 theoutflow nozzle or wire guide.

� Fold down the pressure arm and secure it to the pressure sensor.

� Close the side pannel.

GB

© ESAB AB 2004- 13 -

bm38d1ea

5.5 Changing feed roller Feed L302

� Open the side panel.

� Disconnect the pressure sensor (1) by folding itbackwards.

� Disconnect and remove the Allen screw (2) and thewasher.

� Pull out the feed roller (3).

During installation, repeat the above in the reverseorder.

Choice of track in the feed roller

Turn the feed roller with the dimensioning mark for therequired track towards you.

5.6 Changing feed roller Feed L304

� Open the side panel.

� Disconnect the pressure sensor (1) by folding itbackwards.

� Disconnect the feed rollers (2) by unscrewing thenuts (3) and pulling out the rollers.

During installation, repeat the above in the reverseorder.

Choice of track in the feed roller

Turn the feed roller with the dimensioning mark for therequired 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 anywork 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 shouldtake place at regular intervals in order to achieve trouble-free wire feed. Notethat if pre-tensioning is set too hard, this can result in abnormal wear on thepressure roller, feed roller and wire guide.

GB

© ESAB AB 2004- 14 -

bm38d1ea

The brake hub

The hub is adjusted when delivered, ifreadjustment is required, follow the instructionsbelow. Adjust the brake hub so that wire is slightlyslack 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: Turnboth springs the same amount.

Welding gun

� The welding gun's wear parts should be cleaned and replaced at regularintervals in order to achieve trouble-free wire feed. Blow the wire guide cleanregularly and clean the contact tip.

7 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorised ESAB servicetechnician. Use only ESAB original spare and wear parts.

Feed L302 / Feed L304 is designed and tested in accordance with the international andEuropean standards IEC/EN 60974-5 and IEC/EN 60974-10 . It is the obligation of theservice 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 ofthis publication.

GB

- 15 -notes

NOTES

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© ESAB AB 2004

Diagram

- 16 -bm38e11a

Feed L302

© ESAB AB 2004- 17 -

bm38e11a

Feed L304

- 18 -notes

NOTES

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Feed L302, Feed L304

© ESAB AB 2004

Order number

- 19 -bm38o11a

Ordering no. Denomination Type

0459 495 782 Wire feed unit Origo� Feed L302, M08

0459 495 882 Wire feed unit Origo� Feed L304, M09

0459 495 892 Wire feed unit Origo� Feed L304, M09 with watercooling

0459 508 990 Spare parts list

Feed L302

© ESAB AB 2004

Wear parts

- 20 -bm38whm1

Item Ordering no. Denomination Notes

HM1 0455 889 001* Insert tube For Fe, Ss & cored wire

0455 894 001* Insert tube For Al wire

HM2 0455 886 001* Outlet nozzle For Fe, Ss & cored wire

0455 885 001* Outlet nozzle For Al wire

HM3 0455 898 0010215 201 202

ScrewO-ring

(M5x12)

HM4 0455 881 001 Cover plate

HM5 Screw M4x12

HM6 0193 104 002 Washer Ø16/5x1

HM7 0367 556 001 Feed roller For Fe, Ss & cored wire, Ø 0.6 - 0.8 mm, V groove

0367 556 002 Feed roller For Fe, Ss & cored wire, Ø 0.8 - 1.0 mm, V groove

0367 556 003 Feed roller For Fe, SS & cored wire Ø 1.0 - 1.2 mm, V groove

0367 556 004 Feed roller For Al wire, Ø 1.0 - 1.2 mm, U groove

HM8 0466 074 001 Insert tube

HM9 0455 906 001 Spacer sleeve Included in item HM100

HM10 0455 907 001 Pressure roller Flat, Included in item HM100

HM11 Nut M8, Included in item HM100

HM12 0469 835 001 Pressure arm Included in item HM100

HM13 0456 088 001 Shaft Included in item HM100

HM14 0455 896 001 Spring

HM15 Nut M10

HM16 0458 748 002 Insulating washer

HM17 0458 748 001 Insulating bushing

HM18 0156 602 0010332 318 001

Inlet nozzleInlet nozzle

For Fe, Ss, Al & Cored wire, Ø 2 mm plastic for 0.6-1.6 mmFor Fe, Ss & Cored wire, Ø 2.4 mm steel for 1.2-2.0 mm

HM19 0191 496 114 Woodruff wedge

* Insert tube 0455 889 001 and outlet nozzle 0455 886 001 must be used together. Insert tube 0455 894 001 and outlet nozzle 0455 885 001 must be used together.

PARTS SET

Item Ordering no. Denomination Notes

HM100 0367 529 001 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 beused, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriatewear parts.

Feed L302

© ESAB AB 2004- 21 -

bm38whm1

Feed L304

© ESAB AB 2004- 22 -

bm38whn1

HD = Heavy Duty

Item Ordering no. Denomination Notes

HN1 0455 072 0020456 615 001

Intermediate nozzleIntermediate nozzle

For Fe, Ss & cored wireFor Al Wire

HN2 0469 837 8800469 837 881

Outlet nozzleOutlet nozzle

For Fe, Ss & cored wire, Ø 2.0 mm steel for 0.6-1.6 mmFor Al wire, Ø 2.0 mm plastic for 0.8-1.6 mm

HN3 0191 496 114 Woodruff wedge

HN4 0459 440 001 Motor gear euro

HN5 Washer Ø 16/5x1

HN6 Screw M4x12

HN7 Screw M6x12

HN8 Washer Ø 12/6.4x1.5

HN9 0469 838 001 Cover

HN10 0458 722 880 Axle and Nut

HN11 0369 557 001 Feed roller For Fe, Ss & cored wire, Ø 0.6 & 0.8 mm, V groove

0369 557 002 Feed roller For Fe, Ss & cored wire, Ø 0.8 & 1.0 mm, V groove

0369 557 003 Feed roller For Fe, Ss & cored wire, Ø 1.0 & 1.2 mm, V groove

0369 557 004 Feed roller For Cored wire, Ø 1.0 & 1.2 mm, V-Knurled groove

0369 557 013 Feed roller For Cored wire, Ø 1.4 & 1.6 mm, V-Knurled groove

0369 557 011 Feed roller For Al wire, Ø 0.8 & 0.9 mm, U groove

0369 557 006 Feed roller For Al wire, Ø 1.0 & 1.2 mm, U groove

HN12 0459 441 880 Gear adapter

HN13 0455 049 001 Inlet nozzle

HN14 0455 906 001 Spacer sleeve

HN15 0455 907 001 Pressure roller Flat

HN16 0215 702 708 Locking washer

HN17 0459 518 001 Axel pressure roll

HN18 Nut M10

HN19 0458 748 002 Insulating washer

HN20 0458 748 001 Insulating bushing

HN21 0156 602 0010332 318 001

Inlet nozzleInlet nozzle (HD)

For Fe, Ss, Al & Cored wire, Ø 2 mm plastic for 0.6-1.6 mmFor Fe, Ss & Cored wire, Ø 2.4 mm steel for 1.2-2.0 mm

Welding with aluminium wire

In order to weld with aluminium wire, proper rollers, nozzles and liners for aluminium wire MUST beused, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriatewear parts.

Feed L304

© ESAB AB 2004- 23 -

bm38whn1

© ESAB AB 2004

Feed L302, Feed L304

Accessories

- 24 -bm38a11a

1 Bobbin cover, plastic Ø 300mm . . . . . . . . . . . 0458 674 880

1 Adapter for 5 kg bobbin . . . . . . . . . . . . . . . . . . . . 0455 410 001

1

2

Lifting eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0458 706 880

0146 967 881

1

2

Turning piece . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick connector MarathonPac� . . . . . . . . . . .

0458 703 880

F102 440 880

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

© ESAB AB 2004

Feed L302, Feed L304

- 25 -bm38a11a

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

Water kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0459 564 880

Connection set

Connection set 1.7 m . . . . . . . . . . . . . . . . . . . . . .

Connection set 5 m . . . . . . . . . . . . . . . . . . . . . . . .

Connection set 10 m . . . . . . . . . . . . . . . . . . . . . . .

Connection set 10 m, water . . . . . . . . . . . . . . . . .

0459 532 880

0459 532 881

0459 532 882

0459 532 892

- 26 -notes

NOTES

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AUSTRIAESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

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