Question 1

How to find a manual or spare parts list

Accepted Answer

To find a user manual and or spare parts list for your equipment please go to the following link. http://manuals.esab.com/

Manual search

Search using the product name or the article number specified on the rating plate. The article number is usually the same as the ordering number mentioned in the manual. If the document is valid only for a specific serial number or software version, that will be shown in the search result together with some other information.

Use the filters for language and document type to narrow the search result.

Question 2

Different rotation speed with 484/4804 wire feeders

Accepted Answer

${youtube}Speed difference Feed 484/4804

The two motors are connected in serial and one one of the motors have en encoder output. This results in uneven rotation speed when there is no welding wire linking the 2 motors. The distribution of the speed can be compared with a car differential.

This is normal behaviour, nothing is wrong.

Question 3

Calibration/Validation certificates for new units

Accepted Answer

New products from ESAB are not supplied with certification to EN IEC 60974-14

Q: Different rotation speed with 484/4804 wire feeders

${youtube}<a href="W6YP94KHS6A">Speed difference Feed 484/4804</a> The two motors are connected in serial and one one of the motors have en encoder output. This results in uneven rotation speed when there is no welding wire linking the 2 motors. The distribution of the speed can be compared with a car differential. This is normal behaviour, nothing is wrong.

Q: Quick fault finding - Poor welding condition

Quick fault-finding guide for poor welding quality 11 January 2024 Rob Lee Feed the wire without welding, is it feeding smoothly with no vibraton or jerking? Do you have gas flow? (15-20LPM) Is the contact 􀆟p the correct size for the wire? (0.6, 0.8, 1.0, 1.2mm) Replace the contact 􀆟p. Is the correct size of liner fitted to the torch for the wire size? It the liner the correct length, so there is some mechanical resistance against the 􀆟p when it is screwed in. Try another welding torch? Does the work return cable have a good connec􀆟on at the workpiece and into the welding machine, any signs of overhea􀆟ng or discolouraton of the cable, clamp or cable plug? Is the feed roller set to the correct size for the wire being used? Is the feed roller the correct profile for wire type, “V”, “U”, Knurled? It the welding wire rusty or contaminated? Is the material you are welding clean and shiny new material? Is the adjustment of the pressure roll correct? Is the gas mixture correct for welding wire? Is the welding wire Aluminium, Mild Steel, Flux Cored or Stainless?

All welding products manufactured by ESAB conform to:

EN IEC 60974-1 EN 60974-10 UK S.I 2021/745

The manufacturing standard (60974-1) sets out the required accuracy for the meters used in equipment.

The calibration/validation standard (EN IEC 60974-14) recommends retesting with an interval of 12 months.

If it’s a requirement that you have Calibration/Validation (EN IEC 60974-14) certificates then this can be done by one of our ARC’s (Authorised Service Centre).

An EOL (End Of Line Test) certification from the factory is available for download here, Standard Equipment Certificates

This is a certificate that the machine complies with the 60974-1, this is not a calibration according the 60974-14 This only works for products manufactured in Opole, Poland.

(You need an ART no. and the Serial Number for each unit).

Standard equipment certificates

This EOL certificate shows that the equipment equipment conforms the ESAB specifications of manufacture.

This may be acceptable for your customer as it documents the conformance to the standards.

Question 4

How to order the correct part number by serial number

Accepted Answer

Finding correct part numbers from the ESAB serial numbers and ART numbers

The information below shows how to get the correct part relating to ESAB serial number. The important information is the first three digits from the serial number.

Serial number example

Before Oct 2020 only 1 digit was used to identify year, so we had confusing overlap every 10 years.

Here is an example to help with choosing correct replacement PCB part For serial number 540.xxx.xxxx, from the spare parts list for the Aristo, Origo Feed 3004, 4804. On the cover of the parts list, the serial numbers are listed in chronological order.

The serial number 540.xxx comes after 910.xxx but before 628.xxx

Parts list front page

Part numbers

Correct part number in this case is 0487 187 888

An example from older feed units for serial number 620.xxx.xxxx Referring to the cover of the parts list:

Parts list front page

As serial number 620.xxx.xxxx comes after 451.xxx.xxxx

Parts list numbers

**Bear in mind that any PCB you order may look physically the same, but each

Question 5

Quick fault finding - Poor welding condition

Accepted Answer

Quick fault-finding guide for poor welding quality

11 January 2024 Rob Lee

Feed the wire without welding, is it feeding smoothly with no vibraton or jerking? Do you have gas flow? (15-20LPM) Is the contact 􀆟p the correct size for the wire? (0.6, 0.8, 1.0, 1.2mm) Replace the contact 􀆟p. Is the correct size of liner fitted to the torch for the wire size? It the liner the correct length, so there is some mechanical resistance against the 􀆟p when it is screwed in. Try another welding torch? Does the work return cable have a good connec􀆟on at the workpiece and into the welding machine, any signs of overhea􀆟ng or discolouraton of the cable, clamp or cable plug? Is the feed roller set to the correct size for the wire being used? Is the feed roller the correct profile for wire type, “V”, “U”, Knurled? It the welding wire rusty or contaminated? Is the material you are welding clean and shiny new material? Is the adjustment of the pressure roll correct? Is the gas mixture correct for welding wire? Is the welding wire Aluminium, Mild Steel, Flux Cored or Stainless?

Question 6

How to update a Warrior Edge

Accepted Answer

How to Upgrade

Edge software and WeldMode package is upgraded by using a standard USB memory. Follow the instructions carefully. Note: Edge software must be upgraded before WeldMode package is upgraded.

Power cycle the system by turning it off for 30 sec, then on for 2 min to ensure that the system has started completely.
Save the software file edge.ecf on an empty USB memory.
Insert the USB memory into the service port of the power source.
Wait until the progress indicators have reached 100 % and USb is shown statically in the user interfaces. The system will restart as part of the upgrade. The upgrade takes approximately 40 min. Note: do not restart or interact with the system during this time.
Remove the USB memory. Depending on the previous software version, the system may prompt error 001, 025, 035 which is normal and WeldMode package must be upgraded.
Save the correct WeldMode package file for the power source variant on an empty USB memory.
Insert the USB memory into the service port of the power source.
USb will start flashing in the user interfaces, after approximately 30 sec USb is shown statically in the user interfaces and the USB memory can be removed.
Power cycle the system according to step 1

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