ESAB RobustFeed AVS Instruction Manual
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ESAB RobustFeed AVS Instruction Manual

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RobustFeed AVS
Instruction manual
Valid for: Serial number:
OP139YY-XXXXXX
0446 680 001   US   20211216

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Summary of Contents for ESAB RobustFeed AVS

  • Page 1 RobustFeed AVS Instruction manual Valid for: Serial number: OP139YY-XXXXXX 0446 680 001   US   20211216...

  • Page 2: Table Of Contents

    Internal control panel ....................Function explanation ....................Operating procedures ....................6.4.1 Weld data table ............6.4.2 RobustFeed AVS with CC Power Sources ............6.4.3 RobustFeed AVS with CV power sources ......................6.4.4 Shutdown ..................Rotating the control panel .......................... MAINTENANCE ..............
  • Page 3 TABLE OF CONTENTS ............................. ACCESSORIES 0446 680 001 - 3 - © ESAB AB 2021...

  • Page 4: Safety

    6 Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains. 0446 680 001 - 4 - © ESAB AB 2021...
  • Page 5 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: 0446 680 001 - 5 - © ESAB AB 2021...
  • Page 6 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. 0446 680 001 - 6 - © ESAB AB 2021...
  • Page 7 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. 0446 680 001 - 7 - © ESAB AB 2021...

  • Page 8: User Responsibility

    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 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.

  • Page 10: California Proposition 65 Warning

    This product is solely intended for arc welding. 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. California proposition 65 warning WARNING! Welding or cutting equipment produces fumes or gases which contain chemicals known in the State of California to cause birth defects and, in some cases, cancer.

  • Page 11: Introduction

    2   INTRODUCTION INTRODUCTION The RobustFeed AVS (Arc Voltage Sensing) is a portable wire feeder. The unit is powered entirely on the arc voltage from a constant current (CC) or constant voltage (CV) welding power source. It operates with reversed polarity (Direct Current Electrode Positive - DCEP) or straight polarity (Direct Current Electrode Negative - DCEN).

  • Page 12: Technical Data

    SS wire 0.6 - 1.6 mm (0.023 - 0.062 in.) Cored wire 0.9 - 2.4 mm (0.035 - 0.093 in.) Weight RobustFeed AVS CSA, W/O flowmeter with Tweco connector 40.1 lb (18.2 kg) RobustFeed AVS CSA, with flowmeter with Tweco connector 40.5 lb (18.4 kg)

  • Page 13: 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. 0446 680 001 - 13 - © ESAB AB 2021...
  • Page 14 The 90 lb / 40 kg approved weight consists of wire feeder plus accessories (standard feeder weight is 40.5 lb / 18.4 kg, for all weights see the TECHNICAL DATA chapter). 0446 680 001 - 14 - © ESAB AB 2021...

  • Page 15: 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. 0446 680 001 - 15 - © ESAB AB 2021...

  • Page 16: Connections And Control Devices

    2) For Constant Current (CC) set the desired weld current on the power source. 3) On the RobustFeed AVS, set the desired wire feed speed with the knob for the wire feed speed and use the values shown by the display as guidance. A feeder in CV mode will deliver the actual wire feed speed / welding current while welding.

  • Page 17: Lighting Inside The Wire Feed Unit

    Replace the brake hub nut and the brake hub sleeve if they are worn out and do not lock properly. 6) Close and lock the left door of the wire feeder 0446 680 001 - 17 - © ESAB AB 2021...

  • Page 18: Changing Feed Rollers

    For information about the correct wire guides depending on wire diameter and type, see the "WEAR PARTS" appendix. (For a tip to easy access to necessary wear parts, see the "Wear parts storage compartment" section in this manual.) 0446 680 001 - 18 - © ESAB AB 2021...

  • Page 19: Inlet Wire Guide

    1) Apply a small amount of pressure to the middle wire guide clip and remove the middle wire guide (A). 2) Push in the correct type of wire guide (according to the WEAR PARTS appendix). The clip automatically locks the wire guide when in the correct position. 0446 680 001 - 19 - © ESAB AB 2021...

  • Page 20: Outlet Wire Guide

    The table below serves as a guideline showing approximate roller pressure settings for standard conditions with correct bobbin brake force. If the torch cables are long, dirty or worn, the pressure 0446 680 001 - 20 - © ESAB AB 2021...
  • Page 21 (mm) Pressure setting Wire material Fe, Ss Tensioner unit 1 Tensioner unit 2 3–3.5 Cored Tensioner unit 1 Tensioner unit 2 2.5–3 1 Tensioner unit 1 2 Tensioner unit 2 0446 680 001 - 21 - © ESAB AB 2021...

  • Page 22: Wear Parts Storage Compartment

    Before attaching the wire feed unit to the wheel kit, fasten the wheels to the frame by means of the M12 screws, washers and nuts, using a tightening torque of 354 ±35.4 in. lb (40 ±4 Nm). The fixed wheels at the rear end should be positioned parallel to the frame. 0446 680 001 - 22 - © ESAB AB 2021...

  • Page 23: 5.10.2 Wire Feed Unit In Vertical Position

    5.10.3 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. 0446 680 001 - 23 - © ESAB AB 2021...

  • Page 24: Attaching Both The Wheel Kit And The Torch Strain Relief Accessory

    Ensure that the two distance washers are inserted between the wheel kit and the wire feeder. 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. 0446 680 001 - 24 - © ESAB AB 2021...

  • Page 25: Marathon Pac™ Installation

    5   OPERATION 5.12 Marathon Pac™ installation 0446 680 001 - 25 - © ESAB AB 2021...
  • Page 26 5   OPERATION 0446 680 001 - 26 - © ESAB AB 2021...
  • Page 27 5   OPERATION 0446 680 001 - 27 - © ESAB AB 2021...

  • Page 28: Control Panel

    6   CONTROL PANEL CONTROL PANEL External control panel 1 Display 2 Knob for setting the wire feed speed 0446 680 001 - 28 - © ESAB AB 2021...

  • Page 29: Internal Control Panel

    2-stroke With 2-stroke, gas pre-flow starts when the welding torch trigger switch is pressed. The welding process then starts. Releasing the trigger switch stops welding entirely and starts gas post-flow. 0446 680 001 - 29 - © ESAB AB 2021...
  • Page 30 Increasing the arc voltage causes an increase in the wire feed speed. When the CV/CC switch inside the RobustFeed AVS, is set to "CV", the "Preset" wire feed speed will be shown on the display. The wire speed will not vary with changes in the arc voltage.

  • Page 31: Operating Procedures

    26 V 27 V 28 V 30 V 260 A 280 A 300 A 320 A 340 A 1/16” 26 V 27 V 30 V 290 A 340 A 400 A 0446 680 001 - 31 - © ESAB AB 2021...

  • Page 32: Robustfeed Avs With Cc Power Sources

    6   CONTROL PANEL 6.4.2 RobustFeed AVS with CC Power Sources 1) Select the weld current/arc voltage needed for the wire type and diameter to be welded, see section "Weld data table" in this chapter. 2) Set the power supply current with the knob for setting the current on the front panel of the power source.

  • Page 33: Rotating The Control Panel

    1) Remove the two screws for the control panel and remove the panel. 2) Rotate the control panel 90° counter-clockwise. 3) Attach the control panel, ensuring that the small tabs are in the correct position. 4) Fasten the screws. 0446 680 001 - 33 - © ESAB AB 2021...

  • Page 34: Maintenance

    The wear parts of the welding torch should be cleaned and replaced at regular intervals in order to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the contact tip. 0446 680 001 - 34 - © ESAB AB 2021...

  • Page 35: Troubleshooting

    The wire feed is slow/stiff Clean the liners and other mechanical parts of the wire feeding when moving through the mechanism with pressurized air. wire feed mechanism. 0446 680 001 - 35 - © ESAB AB 2021...

  • Page 36: Ordering Spare Parts

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

  • Page 37: Wiring Diagram

    APPENDIX APPENDIX WIRING DIAGRAM 0446 680 001 - 37 - © ESAB AB 2021...

  • Page 38: Ordering Numbers

    APPENDIX ORDERING NUMBERS Ordering number Denomination Notes 0446 700 882 RobustFeed AVS W/O Rotameter with Tweco connector 0446 700 883 RobustFeed AVS with Rotameter with Tweco connector 0446 680 * Instruction manual The three last digits in the document number of the manual show the version of the manual. Therefore they are replaced with * here.

  • Page 39: 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) 0446 680 001 - 39 - © ESAB AB 2021...
  • Page 40 (compatible with RobustFeed and Warrior™ Feed 304) 0349 313 100 RF retrofit kit (for use with existing Warrior™ trolley with ordering no. 0465 510 880) F102 440 880 Quick connector Marathon Pac™ 0446 082 880 Torch strain relief 0446 680 001 - 40 - © ESAB AB 2021...
  • Page 41 APPENDIX 0446 680 001 - 41 - © ESAB AB 2021...
  • Page 42 For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 http://manuals.esab.com...

Table of Contents