ESAB RobustFeed PRO Instruction manual

RobustFeedPRO

Instruction manual

0463 691 001 US 20190710

Valid for: serial no. 904-xxx-xxxx

TABLE OF CONTENTS

1

SAFETY ....................................................................................................... 4

1.1 Meaning of symbols ............................................................................... 4

1.2 California Proposition 65 Warning........................................................ 4

1.3 Safety precautions ................................................................................. 4

1.4 User responsibility ................................................................................. 8

2

INTRODUCTION.......................................................................................... 12

2.1 Equipment ............................................................................................... 12

3

TECHNICAL DATA ...................................................................................... 13

4

INSTALLATION............................................................................................ 15

4.1 Lifting instructions ................................................................................. 15

5

OPERATION ................................................................................................ 17

5.1 Recommended maximum current values for connection cables set 18

5.2 Connections and control devices ......................................................... 19

5.3 Cooling liquid connection ..................................................................... 19

5.4 Retrofitting an interconnection strain relief kit ................................... 20

5.5 Heat kit switch (Offshore versions only) .............................................. 22

5.6 Starting procedure ................................................................................. 22

5.7 Lighting inside the wire feed unit ......................................................... 22

5.8 Bobbin brake........................................................................................... 22

5.9 Changing and loading wire.................................................................... 23

5.10 Changing feed rollers............................................................................. 23

5.11 Changing the wire guides...................................................................... 24

5.11.1 Inlet wire guide ..................................................................................... 24

5.11.2 Middle wire guide ................................................................................. 25

5.11.3 Outlet wire guide .................................................................................. 25

5.12 Roller pressure ....................................................................................... 25

5.13 Wear parts storage compartment ......................................................... 27

5.14 Attaching the wheel kit .......................................................................... 27

5.14.1 Attaching the wheels to the wheel kit frame ......................................... 27

5.14.2 Wire feed unit in vertical position.......................................................... 28

5.14.3 Wire feed unit in horizontal position ..................................................... 28

5.15 Attaching both the wheel kit and the torch strain relief accessory... 29

6

CONTROL PANEL....................................................................................... 31

6.1 Pro............................................................................................................ 31

6.1.1 External control panel........................................................................... 31

6.1.2 Internal control panel ............................................................................ 32

6.2 Setting the speed unit of measurement (metric/imperial) .................. 32

6.3 Explanation of functions........................................................................ 33

6.4 Overtemperature indicator .................................................................... 34

6.5 Measured values .................................................................................... 34

6.6 Setting the gas flow................................................................................ 35

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TABLE OF CONTENTS

6.7 Rotating the control panel ..................................................................... 35

7

MAINTENANCE........................................................................................... 36

7.1 Inspection, cleaning and replacement ................................................. 36

7.2 Calibration and validation of measured values ................................... 36

8

TROUBLESHOOTING ................................................................................. 37

9

ORDERING SPARE PARTS........................................................................ 38

DIAGRAM ............................................................................................................ 39

ORDERING NUMBERS ....................................................................................... 41

WEAR PARTS...................................................................................................... 42

ACCESSORIES ................................................................................................... 44

Rights reserved to alter specifications without notice.

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1 SAFETY

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!
Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!
Means potential hazards which could result in personal injury or loss of life.

CAUTION!
Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual
and follow all labels, employer's safety practices and
Safety Data Sheets (SDSs).

1.2 California Proposition 65 Warning

WARNING!

Welding or cutting equipment produces fumes or gases that contain chemicals
known in the State of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Section 25249.5 et seq.)

WARNING!

This product can expose you to chemicals including lead, which are known to the
state of California to cause cancer and birth defects or other reproductive harm.
Wash hands after use.

For more information, go to www.P65Warnings.ca.gov.

1.3 Safety precautions

WARNING!

These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in Additional Safety Information section. Before
performing any installation or operating procedures, be sure to read and follow the
safety precautions listed below as well as all other manuals, material safety data
sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

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PROTECT YOURSELF AND OTHERS

Some welding, cutting and gouging processes are noisy and require
hearing protection. The arc, like the sun, emits ultraviolet (UV) and
other radiation and can injure the skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes and equipment is
essential to prevent accidents. Therefore:

1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.

2. Always wear safety glasses with side shields in any work area, even if welding
helmets, face shields and goggles are also required.

3. Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to look at the arc and not to expose themselves to
the rays of the electric-arc or hot metal.

4. Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
high-topped shoes, and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.

5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of the
clothing.

6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.

7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly for long distances. Bystanders should also wear goggles over safety
glasses.

FIRES AND EXPLOSIONS

The heat from flames and arcs can start fires. Hot slag or sparks can
also cause fires and explosions. Therefore:

1. Protect yourself and others from flying sparks and hot metal.

2. Move all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.

3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.

4. Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.

5. Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.

6. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.

7. After completing work, inspect the work area to make sure there are no hot sparks or
hot metal that could cause a fire later. Use fire watchers when necessary.

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ELECTRICAL SHOCK

Contact between live electrical parts and earth can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:

1. Be sure the power source frame (chassis) is connected to the earth system of the
input power.

2. Connect the workpiece to a good electrical earth.

3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.

6. Make sure that all parts of your body are insulated from both the work piece and from
the ground.

7. Do not stand directly on metal or the ground while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power, before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a earth cable.

ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:

1. Welders with pacemakers fitted should consult their doctor before welding. EMF may
interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

a) Route the electrode and work cables together. Secure them with tape when

possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on

the same side of your body.
d) Connect the work cable to the workpiece as close as possible to the area being

welded.
e) Keep the welding power source and cables as far away from your body as

possible.

FUMES AND GASES

Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therefore:

1. Keep your head out of the fumes. Do not breathe the fumes and gases.

2. Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe in the fumes from these materials.

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1 SAFETY

3. Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other
irritant gases.

4. If you develop momentary eye, nose or throat irritation while operating, this is an
indication that the ventilation is not adequate. Stop work and take the necessary steps
to improve ventilation in the work area. Do not continue to operate if physical
discomfort persists.

5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.

6. WARNING: This product when used for welding or cutting, produces fumes or gases
that contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING

Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:

1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.

2. Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.

3. Always secure cylinders in an upright position, by chain or strap, to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.

4. When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.

MOVING PARTS

Moving parts, such as fans, rotors and belts can cause
injury. Therefore:

1. Keep all doors, panels, guards, and covers closed and securely in place.

2. Stop the engine or drive systems before installing or connecting a unit.

3. Have only qualified people remove covers for maintenance and troubleshooting as
necessary

4. To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.

5. Keep hands, hair, loose clothing and tools away from moving parts.

6. Reinstall panels or covers and close doors when service is finished and before
starting engine.

WARNING!
FALLING EQUIPMENT CAN INJURE

• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any
other accessories.

• Use equipment of adequate capacity to lift and support unit.

• If using lift forks to move unit, be sure forks are long enough to extend beyond
opposite side of unit.

• Keep cables and cords away from moving vehicles when working from an
aerial location.

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WARNING!
EQUIPMENT MAINTENANCE

Faulty or improperly maintained equipment can cause injury or death.
Therefore:

CAUTION!
ADDITIONAL SAFETY INFORMATION

1. Always have qualified personnel perform the installation, troubleshooting and

maintenance work. Do not perform any electrical work unless you are
qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect

the power source from the incoming electrical power.

3. Maintain cables, earthing wire, connections, power cord and power supply in

safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from

heat sources such as furnaces, wet conditions such as water puddles, oil or
grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices for
Arc Welding, Cutting and Gouging.” Form 52-529.

The following publications are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”

2. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”

3. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”

4. AWS SP - “Safe practices” - Reprint, Welding Handbook

5. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of

Containers That Have Held Hazardous Substances”

6. OSHA 29 CFR 1910 - "Safety and health standards"

7. CSA W117.2 - "Code for safety in welding and cutting"

8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other

Hot Work"

9. CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in

Cylinders”

10.ANSI Z87.1, "Occupational and Educational Personal Eye and Face

Protection Devices"

1.4 User responsibility

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 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
could result in injury to the operator and damage to the equipment.

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1. Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:
○ no unauthorized person is within the working area of the equipment when it is

started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

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 extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Wire feeders are intended to be used in GMAW (MIG/MAG) mode only.

If used in any other welding mode, such as SMAW (MMA), the welding cable between
wire feeder and power source must be disconnected, or else the wire feeder becomes
live or energized.

WARNING!

The right and left side doors of the wire feed unit must be closed and locked when
welding and/or wire feeding occurs. Never weld or feed the wire unless both doors are
closed.

WARNING!

Arc welding and cutting may cause injury to yourself and others. Take precautions
when welding and cutting.

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ELECTRIC SHOCK - Can kill

• Do not touch live electrical parts or electrodes with bare skin, wet gloves,
or wet clothing

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Pose health risks

• Welders with pacemakers fitted should consult their doctor before welding.
EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to
EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep the welding power source and cables
as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to your 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

NOISE - Excessive noise can damage hearing

Protect your ears. Use ear defenders or other hearing protection.

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause a fire. Therefore, make sure that there are no
inflammable materials nearby

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

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ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information, contact your local ESAB dealer or visit us on
our website.

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2 INTRODUCTION

2 INTRODUCTION

The RobustFeedPROwire feed unit is intended for MIG/MAG welding in conjunction with
the following welding power sources:

• Warrior™ 400i CC/CV

• Warrior™ 500i CC/CV

• Warrior™ 400i MV

• Warrior™ 350i MV

The wire feed unit comes in different versions (see the "ORDERING NUMBERS" appendix).

The wire feed units are sealed and contain four-wheel drive wire feed mechanisms as well as
control electronics.

They can be used together with wire on ESAB's Marathon Pac™ or on wire bobbin (standard
Ø 200 mm and Ø 300 mm).

The wire feed unit can be placed on a trolley, suspended above the workplace or on the floor
(standing up or laying down and with or without a wheel set).

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.

2.1 Equipment

RobustFeedPROis supplied with:

• Instruction manual

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3 TECHNICAL DATA

3 TECHNICAL DATA

RobustFeedPRO, valid from serial no. 904-xxx-xxxx

Power Supply voltage 42 V AC, 50–60 Hz

Power requirement 181 VA

Rated supply current I

1

4.3 A

Settings data:

Wire feed speed

0.8–25.0 m/min (32–984 in./min) *

Creep start OFF or ON

2/4-stroke 2-stroke or 4-stroke

Wire selection Solid or Cored

Crater fill From 0s (OFF) to 5s

Torch connection EURO, Tweco #4, Tweco #5

Max. diameter wire bobbin 12 in (300 mm)

Wire dimension:

Fe 0.6–2.0 mm (0.023–5/64 in.)

Ss 0.6-1.6 mm (0.023-1/16 in.)

Al 1.0-1.6 mm (0.040-1/16 in.)

Cored wire 0.9-2.4 mm (0.035-3/32 in.)

Weight:

RobustFeedPRO 37.1 lb (16.9 kg)

RobustFeedPRO, Water 37.8 lb (17.2 kg)

)

RobustFeedPROOffshore 38.1 lb (17.3 kg)

RobustFeedPROOffshore, Water 38.7 lb (17.6 kg)

RobustFeedPRO,Tweco 37.1 lb (16.9 kg)

RobustFeedPROOffshore,Tweco 38.1 lb (17.3 kg)

Maximum weight wire spool 18.5 kg (40.8 lbs)

Dimensions (L×W×H) RobustFeedPRO 26.6×10.4×16.5in (675×265×418mm)

Operating temperature -20° to +55°C (-4 to +131°F)

Transport and storage temperature -40° to +80°C (-40° to +176°F)

Shielding gas All types intended for MIG/MAG welding

Maximum gas pressure 5 bar (0.5 MPa)

Coolant(for "RobustFeedPRO,Water" and

ESAB's ready mixed coolant

"RobustFeedPROOffshore,Water")

Maximum coolant pressure 5 bar (0.5 MPa)

Permissible load at +40°C:

50% duty cycle 550 A

60% duty cycle 500 A

100% duty cycle 400 A

Permissible load at +55°C:

50% duty cycle 550 A

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3 TECHNICAL DATA

RobustFeedPRO, valid from serial no. 904-xxx-xxxx

60% duty cycle 500 A

100% duty cycle 400 A

Enclosureclass IP44

*) Maximum speed is guaranteed across the whole speed range for all wires. For 2.0-mm
solid wires and 2.4-mm cored wires, speed is guaranteed within the speed range of

0.8–8.0m/min (32–315in./min). The RobustFeedPRO will be able to achieve higher
feeding speed above 8.0m/min (315in./min), but with higher tolerances.

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.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.

Equipment with the IP44 marking is intended for indoor and outdoor use and can withstand
rain from all directions.

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