ESAB Robust Feed PRO Instruction Manual
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ESAB Robust Feed PRO Instruction Manual

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Robust Feed PRO
Instruction manual
Valid for: serial no. 904-xxx-xxxx
0463 691 001 US 20190710

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Summary of Contents for ESAB Robust Feed PRO

  • Page 1 Robust Feed PRO Instruction manual Valid for: serial no. 904-xxx-xxxx 0463 691 001 US 20190710...

  • Page 2: Table Of Contents

    CONTROL PANEL..................Pro......................6.1.1 External control panel................6.1.2 Internal control panel ................Setting the speed unit of measurement (metric/imperial) ....Explanation of functions................ Overtemperature indicator ..............Measured values ..................Setting the gas flow................0463 691 001 © ESAB AB 2019...
  • Page 3 Inspection, cleaning and replacement ..........Calibration and validation of measured values ........TROUBLESHOOTING ................. ORDERING SPARE PARTS ................ DIAGRAM ......................ORDERING NUMBERS ..................41 WEAR PARTS...................... ACCESSORIES ....................44 Rights reserved to alter specifications without notice. 0463 691 001 © ESAB AB 2019...

  • Page 4: Safety

    Failure to observe Safety Precautions can result in injury or death. 0463 691 001 - 4 - © ESAB AB 2019...
  • Page 5 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. 0463 691 001 - 5 - © ESAB AB 2019...
  • Page 6 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. 0463 691 001 - 6 - © ESAB AB 2019...
  • Page 7 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. 0463 691 001 - 7 - © ESAB AB 2019...

  • Page 8: User Responsibility

    Protection Devices" 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.
  • Page 9 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. 0463 691 001 - 9 - © ESAB AB 2019...
  • Page 10 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. 0463 691 001 - 10 - © ESAB AB 2019...
  • Page 11 1 SAFETY 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. 0463 691 001 - 11 - © ESAB AB 2019...

  • Page 12: Introduction

    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).

  • Page 13: Technical Data

    -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...
  • Page 14 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. 0463 691 001 - 14 - © ESAB AB 2019...

  • Page 15: Installation

    Risk of crushing when lifting the wire feeder. Protect yourself and warn bystanders of the risk. CAUTION! To avoid personal injury and damage to the equipment, lift using the methods and attachment points detailed below. 0463 691 001 - 15 - © ESAB AB 2019...
  • Page 16 The 40 kg/90 lb approved weight includes the wire feeder and any accessories (the standard feeder weight is 17.6 kg/38.7 lb). For all weights, please see the TECHNICAL DATA chapter. 0463 691 001 - 16 - © ESAB AB 2019...

  • Page 17: Operation

    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. 0463 691 001 - 17 - © ESAB AB 2019...

  • Page 18: Recommended Maximum Current Values For Connection Cables Set

    375 A (100% duty cycle) 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. 0463 691 001 - 18 - © ESAB AB 2019...

  • Page 19: Connections And Control Devices

    OFF position and the cooling unit switch must be in position 0. A liquid cooling kit can be ordered as an accessory (see the "ACCESSORIES" appendix). 0463 691 001 - 19 - © ESAB AB 2019...

  • Page 20: Retrofitting An Interconnection Strain Relief Kit

    5 OPERATION Retrofitting an interconnection strain relief kit 0463 691 001 - 20 - © ESAB AB 2019...
  • Page 21 Locate the welding current cable in the larger (2) of the two holes in the strain relief clamp. • Ensure that the cable ties wrapped around the insulating sleeve (9) are securely tightened. 0463 691 001 - 21 - © ESAB AB 2019...

  • Page 22: Heat Kit Switch (Offshore Versions Only)

    Do not overload the bobbin brake. If the brake force is too high, it may overload the motor, resulting in a lower-quality welding result. The bobbin brake force is adjusted using the 6-mm hexagon Allen screw in the middle of the brake hub nut. 0463 691 001 - 22 - © ESAB AB 2019...

  • Page 23: Changing And Loading Wire

    "Wear parts storage compartment" section in this manual. Open the left door of the wire feeder. Unlock the feed rollers to be swapped by rotating the roller quick lock (A) for each roller. 0463 691 001 - 23 - © ESAB AB 2019...

  • Page 24: Changing The Wire Guides

    Remove the inlet wire guide (B). Fit the correct inlet wire guide (according to the WEAR PARTS appendix). Lock the new inlet wire guide into place using the wire guide quick lock (A). 0463 691 001 - 24 - © ESAB AB 2019...

  • Page 25: Middle Wire Guide

    Start by making sure that the wire moves smoothly through the wire guide. Then set the pressure of the wire feeder's pressure rollers. It is important that the pressure is not too high. 0463 691 001 - 25 - © ESAB AB 2019...
  • Page 26 Wire material Fe, Ss Tensioner unit 1 58.3 / 2.5 Tensioner unit 2 3-3.5 Cored Tensioner unit 1 Tensioner unit 2 2.5-3 Tensioner unit 1 Tensioner unit 2 Tensioner unit 1 Tensioner unit 2 0463 691 001 - 26 - © ESAB AB 2019...

  • Page 27: Wear Parts Storage Compartment

    Before attaching the wire feed unit to the wheel kit, fasten the wheels to the frame using the M12 screws, washers and nuts, using a tightening torque of 40 ±4 Nm (354 ±35.4 in. lb). The fixed wheels at the rear end should be positioned parallel to the frame. 0463 691 001 - 27 - © ESAB AB 2019...

  • Page 28: Wire Feed Unit In Vertical Position

    Wire feed unit in horizontal position NOTE! In order to attach the wire feeder to the wheel kit in the horizontal position, the two bumpers on the wire feeder door must be removed. 0463 691 001 - 28 - © ESAB AB 2019...

  • Page 29: Attaching Both The Wheel Kit And The Torch Strain Relief Accessory

    If the torch strain relief accessory is to be used with the wheel kit when it is fitted in the vertical position, the assembly steps below must be completed in the following order: 0463 691 001 - 29 - © ESAB AB 2019...
  • Page 30 Fasten the wheel kit and the torch strain relief to the wire feeder using the two screw joints located closer to the front end of the wire feeder. 0463 691 001 - 30 - © ESAB AB 2019...

  • Page 31: Control Panel

    Knob for setting the voltage (V) Push button for wire inching Knob for setting the wire feed speed Push button for gas purge (m/min or in./min) 0463 691 001 - 31 - © ESAB AB 2019...

  • Page 32: Internal Control Panel

    Save the selected speed unit setting, leave the hidden functions and return to the default panel view by keeping the gas purge button pressed down for three seconds. Function letter Function Unit of measurement 0 = inch/min, 1 = m/min 0463 691 001 - 32 - © ESAB AB 2019...

  • Page 33: Explanation Of Functions

    SCT is a way to stop the welding with some small short circuits to reduce the end crater and oxidation. It also gives the advantage of a good start performance with solid wire. 0463 691 001 - 33 - © ESAB AB 2019...

  • Page 34: Overtemperature Indicator

    The measured value on the display for arc voltage V is the arithmetic average value. Measured current The measured value on the display for welding current A is the arithmetic average value. 0463 691 001 - 34 - © ESAB AB 2019...

  • Page 35: Setting The Gas Flow

    Remove the two screws for the control panel and remove the panel. Rotate the control panel 90° counter-clockwise. Attach the control panel, ensuring that the small tabs are in the correct position. Fasten the screws. 0463 691 001 - 35 - © ESAB AB 2019...

  • Page 36: Maintenance

    Calibration and validation should be performed by a trained service technician with sufficient training in welding and measurement technology. Guiding principles for calibration/validation and the accepted deviation for each displayed parameter can be found in the service manual. 0463 691 001 - 36 - © ESAB AB 2019...

  • Page 37: Troubleshooting

    If the fault persists despite performing these actions, try replacing the torch. • If the fault persists despite replacing the torch, contact an ESAB authorized service technician. The overheating protection Overtemperature error — The wire feeder has reached a trips frequently: More critical temperature level and the ongoing weld is suspended.

  • Page 38: Ordering Spare Parts

    Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back cover of this document. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list.

  • Page 39: Diagram

    DIAGRAM DIAGRAM 0463 691 001 - 39 - © ESAB AB 2019...
  • Page 40 DIAGRAM 0463 691 001 - 40 - © ESAB AB 2019...

  • Page 41: Ordering Numbers

    With Tweco 4 connector 0445 800 885 Robust Feed PRO Offshore, With Tweco 4 connector, incl. gas Tweco flow meter and heater 0463 659 001 Spare parts list Robust Feed PRO 0463 660 001 Service manual Robust Feed PRO 0463 691 001 - 41 - © ESAB AB 2019...

  • Page 42: Wear Parts

    0446 080 882 0.9–1.6 mm (2 mm) 0445 830 881 (Euro) 0445 830 884 (Tweco) Wire diameter 0.070–3/32 in. 0445 822 002 0446 080 883 1.8–2.4 mm (3 mm) 0445 830 882 (Euro) 0463 691 001 - 42 - © ESAB AB 2019...
  • Page 43 0445 850 051 0445 850 052 Inlet wire guide Middle wire guide Outlet wire guide 0445 830 886 (Tweco) 0445 822 001 0446 080 881 (2 mm) 0445 830 885 (Euro) 0463 691 001 - 43 - © ESAB AB 2019...

  • Page 44: Accessories

    0446 120 882 Tweco 4 connector including front plate 0446 120 884 Tweco 5 connector including front plate 0446 123 880 Liquid cooling kit F102 440 880 Quick connector Marathon Pac™ 0463 691 001 - 44 - © ESAB AB 2019...
  • Page 45 95 mm², liquid cooled, 10.0 m 0446 160 993 95 mm², liquid cooled, 15.0 m 0446 160 994 95 mm², liquid cooled, 25.0 m 0446 160 995 95 mm², liquid cooled, 35.0 m 0463 691 001 - 45 - © ESAB AB 2019...
  • Page 46 For contact information visit esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 http://manuals.esab.com...

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