ESAB RobustFeed U82 Instruction manual

RobustFeed U82

Instruction manual

0446 747 201  GB  20221228

Valid for: Serial number: 111-, 116-, 117-,

121-, 251-xxx-xxxx

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 Lifting instructions

5 OPERATION

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5.1 Recommended maximum current values for connection

5.2 Connections and control devices

5.3 Cooling liquid connection

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5.4 Retrofit of interconnection strain relief kit

5.5 Heat kit switch (Offshore variants only)

5.6 Starting procedure

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5.7 Lighting inside the wire feed unit

5.8 Bobbin brake

5.9 Changing and loading wire

5.10 Changing feed rollers

5.11 Changing the wire guides

5.11.1 Inlet wire guide

5.11.2 Middle wire guide

5.11.3 Outlet wire guide

5.12 Roller pressure

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5.13 Wear parts storage compartment

5.14 Attachment of the wheel kit

5.14.1 Attachment of the wheels to the wheel kit frame

5.14.2 Wire feed unit in vertical position

5.14.3 Wire feed unit in horizontal position

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5.15 Attachment of both wheel kit and the torch strain relief accessory

5.16 Marathon Pac™ installation

6 CONTROL PANEL

6.1 External blank panel

6.2 Internal control panel

6.3 Setting the gas flow

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6.4 Rotating the external control panel

7 MAINTENANCE

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7.1 Inspection, cleaning and replacement

8 TROUBLESHOOTING

9 ORDERING SPARE PARTS

10 ASSEMBLY INSTRUCTIONS

WIRING DIAGRAM

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ORDERING NUMBERS

WEAR PARTS

ACCESSORIES

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© ESAB AB 2022

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 Safety precautions

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 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 or other applicable operation of the equipment

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 or work is started with the
equipment

3. The workplace must:

• be suitable for the purpose

• be free from drafts

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© ESAB AB 2022

1  SAFETY

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

If equipped with ESAB cooler

Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize
product safety. In case of such damage, all warranty undertakings from ESAB cease to apply.

For ordering information, see the "ACCESSORIES" chapter in the instruction manual.

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions when
welding and cutting.

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 - Can be dangerous to health

• Welders having pacemakers should consult their physician 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 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 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

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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

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© ESAB AB 2022

1  SAFETY

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs 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 fire. Make sure therefore that there are no
inflammable materials nearby

• Do not use on closed containers.

HOT SURFACE - Parts can burn

• Do not touch parts bare handed.

• Allow cooling period before working on equipment.

• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.

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

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

CAUTION!

Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those
locations, due to conducted as well as radiated disturbances.

NOTE!
Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation in
accordance with national law, electrical and/or electronic equipment
that has reached the end of its life must be disposed of at a
recycling facility.

As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection stations.

For further information contact the nearest ESAB dealer.

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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© ESAB AB 2022

2  INTRODUCTION

2 INTRODUCTION

The RobustFeedequipped with a U82control panel is intended for MIG/MAG welding together with
400A, 500A and 600A CAN-based welding power sources.

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

NOTE!

Wire feed unit variants equipped with ESAB Logic Pump (ELP) is intended to be used together
with welding power sources equipped with ELP. For further information about ELP, see the
"Cooling liquid connection" section.

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

It can be used together with standard Ø200 mm and Ø300 mm wire bobbin or with ESAB's Marathon
Pac™ with a wire adapter to feed the wire.

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

The wire feed unit is supplied with:

• Instruction manual - Wire feed unit

• Instruction manual - Control panel

• Quick start guide

• An USB with multi-language Instruction manual for U82and an U82Plus with holding
bracket (not included in U0 variant).

• Drive rolls: 0.9/1.0 mm (0.040 in.) / 1.2 mm (0.045 in.)

• Wire guides: 0.6–1.6 mm (0.023–1/16 in.)

Instruction manuals in other languages can be downloaded from the Internet: manuals.esab.com

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© ESAB AB 2022

3  TECHNICAL DATA

3 TECHNICAL DATA

RobustFeedU8

2

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)

Torch connection EURO, Tweco 4

Max. diameter wire bobbin 300 mm (12 in.)

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 0.8–1.6 mm (0.031–1/16 in.)

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

Weight

without U82pendant

with U82pendant

16.3–18.2 kg (35.9–40.1lb. )

17.6–20.1 kg (38.8–44.3 lb.)

Maximum weight wire spool 20.0 kg (44.1 lb.)

Dimensions (l×w×h)

Feeder 595×250×430 mm (23.4×9.8×16.9 in.)

U82pendant 250×222×50mm (9.8×8.7×2in.)

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

1)

ESAB's ready mixed coolant

Maximum coolant pressure 5 bar (0.5 Mpa)

Permissible load at +40°C:

35% duty cycle 630 A

60% duty cycle 500 A

100% duty cycle 400 A

Permissible load at +55°C:

35% duty cycle 600 A

60% duty cycle 450 A

100% duty cycle 350 A

Enclosureclass

1)

For "RobustFeedU82, Offshore, Water", "RobustFeedU82, Offshore, Water, Push Pull"

2)

RobustFeedU82pendant enclosure class is IP23.

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2)

IP44

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© ESAB AB 2022

3  TECHNICAL DATA

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 marked IP44 is intended for indoor and outdoor use and can withstand rain from all
directions.

Equipment marked IP23 is intended for indoor and outdoor use.

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© ESAB AB 2022

4  INSTALLATION

4 INSTALLATION

The installation must be carried out by a professional.

WARNING!

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

.

CAUTION!

This product is intended for industrial use. In a domestic environment this product may cause
radio interference. It is the user's responsibility to take adequate precautions.

4.1 Lifting instructions

CAUTION!

Risk of crushing when lifting the wire feeder. Protect yourself and warn bystanders of the risk.

CAUTION!

To avoid personal injury and damage of equipment, lift using methods and attachment points
presented below.

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© ESAB AB 2022

4  INSTALLATION

CAUTION!

Do not place heavy objects on or attached to the wire feeder when lifting. The lifting points are
rated for a maximum total weight of 44 kg / 97 lb. when lifted in the two outer upper lifting
handles according to the graphic above!

The 44kg / 97lb. approved weight consists of wire feeder plus accessories (standard feeder
weight is 18.5kg / 40.8lb., for all weights see the TECHNICAL DATA chapter).

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© ESAB AB 2022

5  OPERATION

5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY" chapter
of this manual. Read it through before you start using the equipment!

WARNING!

To avoid shock, do not touch electrode wire or parts in contact with it, or uninsulated cable or
connections.

NOTE!

When moving the equipment, use handle intended for transportation. Never pull the equipment
by the welding torch.

WARNING!

Wire feeders are intended to be used with power sources in MIG/MAG and MMA mode. If
used in MIG/MAG, the MMA holder must be disconnected from the wire feeder and the OKC
must be covered. If used in MMA, the MIG/MAG torch must be isolated or kept in the torch
holder if available, or else the torch/holder becomes live or energized.

WARNING!

Assure that the side panels are closed during operation.

WARNING!

To prevent the reel from sliding off the hub, lock the reel by tightening the nut!

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© ESAB AB 2022

5  OPERATION

CAUTION!

Before threading welding wire, make sure the chisel point and burrs have been removed from
the end of the wire to prevent the wire from jamming in the torch liner.

WARNING!

Rotating parts can cause injury, take great care.

WARNING!

Secure the equipment, especially if used on an uneven or sloping surface.

5.1 Recommended maximum current values for

connection

At an ambient temperature of +25°C and normal 10 minutes cycle:

Cable area Duty cycle Voltage loss per 10m

100% 60% 35%

70 mm² 350 A 400 A 480 A 0.28V / 100A

95 mm² 400 A 500A 600A 0.21V / 100A

At an ambient temperature of +40°C and normal 10 minutes cycle:

Cable area Duty cycle Voltage loss per 10m

100% 60% 35%

70 mm² 310 A 350 A 420 A 0.30V / 100A

95 mm² 375 A 430 A 525 A 0.23V / 100A

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.

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© ESAB AB 2022