ESAB ROBUSTFEED EDGE Instruction Manual
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ESAB ROBUSTFEED EDGE Instruction Manual

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ROBUSTFEED EDGE
Instruction manual
Valid for: Serial number:
OP138YY-XXXXXX
0463 773 001   GB   20240418

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Summary of Contents for ESAB ROBUSTFEED EDGE

  • Page 1 ROBUSTFEED EDGE Instruction manual Valid for: Serial number: OP138YY-XXXXXX 0463 773 001   GB   20240418...

  • Page 3: Table Of Contents

    6.4.1 Setting up a new JOB in the internal control panel ......................6.4.2 Copy a JOB ..........6.4.3 Setting up a new job in the external control panel ..........................Tools ......................6.5.1 Error logs ..................6.5.2 USB import and export 0463 773 001 - 3 - © ESAB AB 2024...
  • Page 4 User management fault ....................... 9.14 Import/export fault ....................... 9.15 Incompatible units ........................9.16 Timing fault ......................9.17 No coolant flow ....................... 9.18 Gas pressure fault ....................... 9.19 Gas flow fault 0463 773 001 - 4 - © ESAB AB 2024...
  • Page 5 ORDERING SPARE PARTS ..................... CALIBRATION AND VALIDATION ..............12.1 Measurement methods and tolerances ............12.2 Requirements, specifications and standards ......................... ORDERING NUMBERS ..........................WIRING DIAGRAM ............................WEAR PARTS ............................. ACCESSORIES 0463 773 001 - 5 - © ESAB AB 2024...

  • Page 6: Safety

    Sheets (SDSs). 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.
  • Page 7 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 8 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. 0463 773 001 - 8 -...

  • Page 9: Introduction

    The wire feed unit is sealed and contains a four-wheel drive wire feed mechanism 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.

  • Page 10: Technical Data

    -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 Gas flow range for RobustFeed Edge BX 5-35 l/min (11-74 CFH) Gas pressure for RobustFeed Edge CX 3-5 bar (43-73 psi) Coolant...

  • Page 11: Installation

    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. 0463 773 001 - 11 - © ESAB AB 2024...
  • Page 12 The 40 kg / 90 lb. approved weight consists of wire feeder plus accessories (standard feeder weight is 17.5 Kg / 38.6 lb., for all weights see the TECHNICAL DATA chapter). 0463 773 001 - 12 - © ESAB AB 2024...

  • Page 13: Operation

    To prevent the reel from sliding off the brake hub, lock the reel by tightening the brake hub nut! NOTE! Replace the brake hub nut and the brake hub sleeve if they are worn out and don´t lock properly. 0463 773 001 - 13 - © ESAB AB 2024...

  • Page 14: Recommended Maximum Current Values For Connection Cables Set

    The gas cylinder should be equipped with a pressure regulator. Set the pressure regulator in the range of 3-5 bar (43-73 psi). The pressure should not exceed 5 bar (73 psi) and the flow should be adjusted on the internal control panel. 0463 773 001 - 14 - © ESAB AB 2024...

  • Page 15: Connections And Control Devices

    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 without having closed both doors! 0463 773 001 - 15 - © ESAB AB 2024...

  • Page 16: Cooling Liquid Connection

    Cooling liquid connection ELP (ESAB Logic Pump) The cooling unit is equipped with a detection system called ELP (ESAB Logic Pump) which checks that the coolant hoses are connected. When a liquid-cooled torch is connected, cooling starts. When connecting a liquid-cooled welding torch, the main power supply switch of the power source must be in the OFF position.

  • Page 17: Changing And Loading Wire

    1) Open the left door of the wire feeder. 2) Unlock the feed rollers to be exchanged, by rotating the roller quick lock (A) for each roller. 0463 773 001 - 17 - © ESAB AB 2024...

  • Page 18: Changing The Wire Guides

    For information about the correct wire guides depending on wire diameter and type, see the WEAR PARTS appendix. (For a tip about easy access to necessary wear parts, see the "Wear parts storage compartment" section in this manual.) 5.10.1 Inlet wire guide 0463 773 001 - 18 - © ESAB AB 2024...

  • Page 19: 5.10.2 Middle Wire Guide

    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. 5.10.3 Outlet wire guide 1) Remove the lower right feed roller (see the "Changing feed rollers" section). 0463 773 001 - 19 - © ESAB AB 2024...

  • Page 20: Roller Pressure

    (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 Tensioner unit 1 1–1.5 Tensioner unit 2 2–3 0463 773 001 - 20 - © ESAB AB 2024...

  • Page 21: Wear Parts Storage Compartment

    1. Inlet wire guide 4. Feed rollers (×4 pcs) 2. Middle wire guide 5. Contact tips for the welding torch (×4 pcs) 3. Outlet wire guide 0463 773 001 - 21 - © ESAB AB 2024...

  • Page 22: Attachment Of Wheel Kit

    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. 5.13.2 Wire feed unit in vertical position 0463 773 001 - 22 - © ESAB AB 2024...

  • Page 23: 5.13.3 Wire Feed Unit In Horizontal Position

    5.13.3 Wire feed unit in horizontal position NOTE! To be able to attach the wire feeder in horizontal position on the wheel kit, the two bumpers on the wire feeder door must be removed! 0463 773 001 - 23 - © ESAB AB 2024...

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

    Make sure 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 closer to the front end of the wire feeder. 0463 773 001 - 24 - © ESAB AB 2024...

  • Page 25: Marathon Pac™ Installation

    5   OPERATION 5.15 Marathon Pac™ installation 0463 773 001 - 25 - © ESAB AB 2024...
  • Page 26 5   OPERATION 0463 773 001 - 26 - © ESAB AB 2024...

  • Page 27: Control Panel

    10. Scales voltage and arc length 5. Trigger modes – 2T / 4T 11. Display – shows set or measured value (wire feed speed / amperage) 6. Weld mode selection button 0463 773 001 - 27 - © ESAB AB 2024...

  • Page 28: Led Indicators Description

    To achieve a good welding result, the arc voltage is a crucial factor. In MIG/MAG welding, the power source is prepared to sense the arc voltage in the wire feeder. Prerequisite for this functionality is that an ESAB wire feeder and an ESAB interconnection cable is used.

  • Page 29: Push Encoder Knobs

    Push encoder knob for setting wire feed speed / A / ~A (9) This knob increases or decreases the value of wire feed speed, amperage and estimated amperage depending on the selected application. 0463 773 001 - 29 - © ESAB AB 2024...

  • Page 30: Buttons

    A process with synergic voltage and arc dynamics control, in relation to wire feed speed using predetermined synergic line programs providing stable arc performance. The process operates through short circuit, globular and spray droplet transfer mode. 0463 773 001 - 30 - © ESAB AB 2024...
  • Page 31 The respective LED's blink and lit in green once the current JOB is saved and activated. If the JOB contains any previous weld setting parameters, they are replaced with the new weld setting parameters. 0463 773 001 - 31 - © ESAB AB 2024...

  • Page 32: Internal Control Panel

    Gas purge occurs without voltage or wire feed start. Wire inch button (6) Wire inching is used to feed wire without welding voltage being applied. The wire is fed as long as the button is pressed. 0463 773 001 - 32 - © ESAB AB 2024...

  • Page 33: Menu Selection

    (1, 2 and 3) in the external control panel. 6.4.1 Setting up a new JOB in the internal control panel 1) Press the material button and select the desired material parameters by turning the push encoder knob. 0463 773 001 - 33 - © ESAB AB 2024...
  • Page 34 3) Press the gas button and select the desired gas by turning the push encoder knob. 4) Press the weld mode selection button and select the desired application by turning the push encoder knob. 0463 773 001 - 34 - © ESAB AB 2024...
  • Page 35 5) If the material, dimension or gas option is changed after welding mode selection, synergic line error for the current welding selection may pop-up. 6) Navigate to the Menu button and select JOBs. 0463 773 001 - 35 - © ESAB AB 2024...
  • Page 36 7) Select the desired job position and press the save button on the top left to save and activate. The selected application will appear on the screen. 8) To edit the jobs, select the pre-saved job and navigate to more (on the bottom left). 0463 773 001 - 36 - © ESAB AB 2024...
  • Page 37 6   CONTROL PANEL 9) Select the Edit settings to edit the job parameters. 10)Navigate to Edit limits and enable the Activate limits option to vary the limits. 0463 773 001 - 37 - © ESAB AB 2024...

  • Page 38: Copy A Job

    6   CONTROL PANEL 6.4.2 Copy a JOB 1) Navigate to the Menu button and select JOBs 0463 773 001 - 38 - © ESAB AB 2024...
  • Page 39 3) Select the desired job number and press the save button on the top left to copy or duplicate. NOTE! While saving a job, if the existing job number with presaved data is selected, it will overwrite the new weld parameters. 0463 773 001 - 39 - © ESAB AB 2024...

  • Page 40: Setting Up A New Job In The External Control Panel

    6   CONTROL PANEL 6.4.3 Setting up a new job in the external control panel 1) Select the desired welding application. 0463 773 001 - 40 - © ESAB AB 2024...

  • Page 41: Tools

    The error log shows history and active errors. Press the push button for the corresponding error to view the incident description and time. 6.5.2 USB import and export The import/export can be done in two ways; using tool settings or direct connect to the USB. 0463 773 001 - 41 - © ESAB AB 2024...
  • Page 42 1) Go to Tools and select USB import and export. 2) Insert a USB drive into the power source according to the prompt on the screen. 3) Select Import Jobs Export Jobs. 0463 773 001 - 42 - © ESAB AB 2024...

  • Page 43: Export Jobs

    Direct connect to the USB 1) Insert a USB drive into the power source. 2) Select Import Jobs Export Jobs. 6.5.3 Export Jobs 1) Select Export Jobs. 2) Press Select all. 0463 773 001 - 43 - © ESAB AB 2024...

  • Page 44: Import Jobs

    6   CONTROL PANEL 3) Press Export to export the Jobs to the USB drive. 4) The following prompt is displayed once all jobs are exported. 6.5.4 Import Jobs 1) Select Import Jobs. 0463 773 001 - 44 - © ESAB AB 2024...
  • Page 45 6   CONTROL PANEL 2) Select the Jobs folder which contains the jobs. 3) Select Confirm to overwrite the existing Jobs. 4) The following prompt is displayed once all Jobs are imported. 0463 773 001 - 45 - © ESAB AB 2024...

  • Page 46: Operator Management

    The admin card enables logging in as an administrator and activating operator management. 1. By default, Operator management option is disabled. 2. Use the admin card to enable Operator management. 0463 773 001 - 46 - © ESAB AB 2024...
  • Page 47 6   CONTROL PANEL 3. Administrator can set Login required Access level in operator management. Login required 1. No login: no card is required to lock/unlock the system. 0463 773 001 - 47 - © ESAB AB 2024...
  • Page 48 6   CONTROL PANEL 2. Anonymous login: A user card is needed to lock/unlock the system. NOTE! The user card can access both anonymous login and personal login. 0463 773 001 - 48 - © ESAB AB 2024...
  • Page 49 4. Refer to the step-by-step procedure on the configuration process in the InduSite Helpdesk: manual.indusuite.com/edge-personal-login. Additionally, utilize InduSuite's online chat support (Chat with us) for further information. 0463 773 001 - 49 - © ESAB AB 2024...
  • Page 50 5. When using the user card in Personal login, the username is displayed. Access level Access levels are set by the administrator. 1. Full access - The user can access all system functions except Operator management. 0463 773 001 - 50 - © ESAB AB 2024...
  • Page 51 The icon appears in the inner HMI when the user is logged in with full access. The icon appears in the inner HMI when the user is logged in with limited access. The icon appears in the inner HMI when the system is locked. 0463 773 001 - 51 - © ESAB AB 2024...

  • Page 52: System Settings

    During ongoing welding with 4-stroke, the welding torch trigger is released. To change a job, press the trigger and release it quickly. 6.6.4 Torch remote configuration The ESAB CX torch remote can be configured by any one of the following functions: 1. JOBs 2. Voltage/Arc length 3. Wire feed speed 4.

  • Page 53: Hot Start Mode In 4-Stroke

    Trigger controlled - The hot start process continues until the trigger is released. 6.6.6 Languages This function enables choosing the language of the display. To choose the desired language, navigate Menu » System settings » Languages 0463 773 001 - 53 - © ESAB AB 2024...

  • Page 54: Unit Of Measurement

    For use of the wire feeder in horizontal position there is a possibility to rotate the external control panel 90°. 1) Remove the two screws for the control panel and remove the panel. 0463 773 001 - 54 - © ESAB AB 2024...
  • Page 55 2) Disconnect the panel harness. 3) Rotate the control panel 90° counter-clockwise. 4) Attach the control panel making sure the small tabs are in the correct position. 5) Fasten the screws. 0463 773 001 - 55 - © ESAB AB 2024...

  • Page 56: Welding

    Hot start V Vmin-Vmax 14.5 V / 0.0 V offset Hot start wire feed speed 50–150 115% Gas pre-flow 0.0–25.0 0.1 s Gas post-flow 0.0–25.0 1.5 s Creep start ON/OFF Crater fill ON/OFF 0463 773 001 - 56 - © ESAB AB 2024...

  • Page 57: Setting Range For Pulse

    Crater fill arc length offset -9.9 – +9.9 0.0 V offset End method SCT/Burnback SCT (Burnback for core wires) Burnback time 0.01 0.00–0.50 0.08 s Job limits ON/OFF Depends on the selected synergic line. 0463 773 001 - 57 - © ESAB AB 2024...

  • Page 58: Setting Range For Speed

    32 in./min Estimated Amperage Dependent on WFS value l/min 5.0–35.0 15 l/min Gas flow 11–74 32 CFH Arc dynamics -9 – +9 Hot start ON/OFF Hot start time 0.0–10 1.2 s 0463 773 001 - 58 - © ESAB AB 2024...

  • Page 59: Function Explanations For Settings

    10 m/min and the hot start wire feed speed is set to 50%, the output will be 5 m/min). The voltage parameter is voltage for MIG/MAG manual, voltage offset for Synergy, and arc length offset for Pulse respectively. 0463 773 001 - 59 - © ESAB AB 2024...
  • Page 60 Too long a burnback time results in a shorter stick out, with increased risk of the arc striking back to the contact tip. 0463 773 001 - 60 - © ESAB AB 2024...

  • Page 61: Mma Welding

    Air is supplied so that the melted material is blown away. When the Gouging application is selected, there is a 5 s delay to protect from unintentional arc strike. 0463 773 001 - 61 - © ESAB AB 2024...

  • Page 62: Function Explanations For Settings

    Voltage A higher voltage produces a wider weld pool, with better penetration into the workpiece. The voltage is set in the measure screen, weld data setting or fast mode menus. 0463 773 001 - 62 - © ESAB AB 2024...

  • Page 63: Tig Welding

    Disconnect all the cables in the interconnection from the power source except for the control cable. The return cable should be connected to positive, and the weld cable should be connected to negative. 0463 773 001 - 63 - © ESAB AB 2024...

  • Page 64: 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. 0463 773 001 - 64 - © ESAB AB 2024...

  • Page 65: Event Codes

    205 - Mains over/under voltage or phase error. Make sure that the supply voltage is stable. Restart the system. Temperature fault This event code is displayed due to one of the following: 0463 773 001 - 65 - © ESAB AB 2024...

  • Page 66: Battery Warning

    311 - Wire saturation warning/error. • 311 - Wire motor start/work current error. Check the correct liners/contact tip/torch used for types of welding wires. Check the torque tension in the break hub. 0463 773 001 - 66 - © ESAB AB 2024...

  • Page 67: Communication Fault

    This event code is displayed due to one of the following: • 017 - Mandatory node missing. • 017 - Critical node lost. Check the cable connections between the subsystem (wire feeder and power source). 0463 773 001 - 67 - © ESAB AB 2024...

  • Page 68: Internal Memory Fault

    025 - Power converter control module power capacity unknown. Contact service technician. Make sure that the software version should be similar for each connected nodes. Connect the correct wire feed unit and restart. 0463 773 001 - 68 - © ESAB AB 2024...

  • Page 69: Timing Fault

    632 - Gas saturation warning/error. • 632 - No gas out error. Perform the inspections listed in X31 (Gas pressure fault) 1 to 5. Check that the torch gas hose is not strangulated. 0463 773 001 - 69 - © ESAB AB 2024...

  • Page 70: Usb Fault

    035 - Message allocation error. • 035 - Driver message allocation error. • 035 - Event queue overflow. • 035 - Failed to start microservices. Restart the system. Contact service technician. 0463 773 001 - 70 - © ESAB AB 2024...

  • Page 71: Troubleshooting

    Clean the liners and other mechanical parts of the wire feed mechanism. mechanism, using pressurized air. Clean and adjust the roller pressure as per the table on the decal on the left side door. 0463 773 001 - 71 - © ESAB AB 2024...

  • Page 72: 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 73: Calibration And Validation

    (TRMS, RMS or rectified arithmetic mean), significantly larger deviations are to be expected! The ESAB Warrior Edge 500 welding power source presents the measured value in rectified arithmetic mean and should therefore not show any significant differences compared to other ESAB welding equipment, due to the measurement method.

  • Page 74: Ordering Numbers

    * here. Make sure to use a manual with a serial number or software version that corresponds with the product, see the front page of the manual. Technical documentation is available on the Internet at: www.esab.com 0463 773 001 - 74 - © ESAB AB 2024...

  • Page 75: Wiring Diagram

    APPENDIX WIRING DIAGRAM 0463 773 001 - 75 - © ESAB AB 2024...

  • Page 76: Wear Parts

    0446 080 882 0.040–1/16 in. (2 mm) 0445 830 883 (Tweco) 0445 830 882 (Euro) Wire diameter 1.8–2.4 mm 0445 822 002 0446 080 883 0.070–3/32 in. (3 mm) 0445 830 884 (Tweco) 0463 773 001 - 76 - © ESAB AB 2024...
  • Page 77 0445 850 051 0445 850 052 Inlet wire guide Middle wire guide Outlet wire guide 0445 830 885 (Euro) 0445 822 001 0446 080 881 (2 mm) 0445 830 886 (Tweco) 0463 773 001 - 77 - © ESAB AB 2024...

  • Page 78: Accessories

    Guide pin extension kit For the feeder assembled with the wheel kit 0446 120 882 Tweco 4 connector including front plate F102 440 880 Quick connector Marathon Pac™ 0446 082 880 Torch strain relief 0463 773 001 - 78 - © ESAB AB 2024...
  • Page 79 0446 310 985 25 m (82 ft) 0446 310 986 35 m (115 ft) 0446 310 987 50 m (164 ft) Interconnection cable with pre-assembled strain relief, Liquid cooled, 95 mm 0463 773 001 - 79 - © ESAB AB 2024...
  • Page 80 10 m (33 ft) 0446 310 993 15 m (49 ft) 0446 310 994 20 m (66 ft) 0446 310 995 25 m (82 ft) 0446 310 996 35 m (115 ft) 0463 773 001 - 80 - © ESAB AB 2024...
  • Page 81 APPENDIX 0463 773 001 - 81 - © ESAB AB 2024...
  • Page 82 For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 manuals.esab.com...

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