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ESAB RobustFeed U82 Instruction Manual
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ESAB RobustFeed U82 Instruction Manual

ESAB RobustFeed U82 Instruction Manual

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RobustFeed U82
Instruction manual
Valid for: Serial number: 111-, 116-, 251,
OP422-xxx-xxxx
0446 748 301   US   20240708

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Summary of Contents for ESAB RobustFeed U82

  • Page 1 RobustFeed U82 Instruction manual Valid for: Serial number: 111-, 116-, 251, OP422-xxx-xxxx 0446 748 301   US   20240708...

  • Page 2: Table Of Contents

    Rotating the external control panel .......................... MAINTENANCE ..............Inspection, cleaning and replacement ........................ TROUBLESHOOTING ....................... ORDERING SPARE PARTS ..................... ASSEMBLY INSTRUCTIONS ..........................WIRING DIAGRAM ......................... ORDERING NUMBERS ............................WEAR PARTS 0446 748 301 - 2 - © ESAB AB 2024...
  • Page 3 TABLE OF CONTENTS ............................. ACCESSORIES 0446 748 301 - 3 - © ESAB AB 2024...

  • Page 4: Safety

    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. 0446 748 301 - 4 - © ESAB AB 2024...

  • Page 5: Fires And Explosions

    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. 0446 748 301 - 5 - © ESAB AB 2024...
  • Page 6 2. Have only qualified people remove covers for maintenance and troubleshooting as necessary 3. Keep hands, hair, loose clothing and tools away from moving parts. 4. Reinstall panels or covers and close doors when service is finished and before starting the unit. 0446 748 301 - 6 - © ESAB AB 2024...

  • Page 7: User Responsibility

    ANSI Z87.1, "Occupational and Educational Personal Eye and Face 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.
  • Page 8 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. Recommended ESAB coolant ordering number: 0465 720 002. For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
  • Page 9 • 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! 0446 748 301 - 9 - © ESAB AB 2024...

  • 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

    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.

  • Page 12: Technical Data

    -40 to +176 °F (-40 to +80 °C) Shielding gas All types intended for GMAW welding Maximum gas pressure 72.5 psi (5 bar, 0.5 Mpa) Coolant ESAB's ready mixed coolant Maximum coolant pressure 72.5 psi (5 bar, 0.5 Mpa) Permissible load at +40°C: 35% duty cycle 630 A...
  • Page 13 Equipment with the IP44 marking is intended for indoor and outdoor use and can withstand rain from all directions. Equipment marked IP23 is intended for indoor and outdoor use. 0446 748 301 - 13 - © ESAB AB 2024...

  • Page 14: 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 748 301 - 14 - © ESAB AB 2024...
  • Page 15 The 44 kg/97 lb approved weight includes the wire feeder and any accessories (the standard feeder weight is 18.5 kg/40.8 lb). For all weights, please see the TECHNICAL DATA chapter. 0446 748 301 - 15 - © ESAB AB 2024...

  • Page 16: Operation

    WARNING! Make sure the side panels are closed during operation. WARNING! To prevent the reel from sliding off the hub, lock the reel in place by tightening the nut. 0446 748 301 - 16 - © ESAB AB 2024...

  • Page 17: Recommended Maximum Current Values For Connection

    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. 0446 748 301 - 17 - © ESAB AB 2024...

  • Page 18: Connections And Control Devices

    18. Connection for U82 pendant (Tweco variant) (only on product variants with SMAW) ELP = ESAB Logic Pump (see the "Cooling liquid connection" section) WARNING! The right and left side doors of the wire feed unit must be closed during welding and/or wire feeding.

  • Page 19: Cooling Liquid Connection

    Some wire feed unit variants with cooling liquid connections included are equipped with a detection system called ESAB Logic Pump (ELP), which checks that the water hoses are connected. When connecting a water-cooled welding torch, the water pump starts automatically. The detection only works with power sources that are equipped with ELP (for instance Aristo 4004i together with Cool 1).
  • Page 20 Locate the welding current cable in the larger of the two holes in the strain relief clamp! • Ensure that the cable ties around the insulating sleeve are tightened properly! 0446 748 301 - 20 - © ESAB AB 2024...

  • Page 21: 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 spool nut. 0446 748 301 - 21 - © ESAB AB 2024...

  • Page 22: 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. 0446 748 301 - 22 - © ESAB AB 2024...

  • Page 23: Changing The Wire Guides

    For information about the correct wire guides depending on wire diameter and type, see the WEAR PARTS appendix. For tips about easy access to essential wear parts, see the "Wear parts storage compartment" section in this manual. 5.11.1 Inlet wire guide 0446 748 301 - 23 - © ESAB AB 2024...

  • Page 24: 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. 5.11.3 Outlet wire guide 0446 748 301 - 24 - © ESAB AB 2024...

  • Page 25: Roller Pressure

    When you hold the welding torch approx. (5 mm) from the piece of wood (figure A) the feed rollers should slip. If you hold the welding torch approx. (50 mm) from the piece of wood, the wire should feed out and bend (figure B). 0446 748 301 - 25 - © ESAB AB 2024...
  • Page 26 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 1. Tensioner unit 1 2. Tensioner unit 2 0446 748 301 - 26 - © ESAB AB 2024...

  • 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. 0446 748 301 - 27 - © ESAB AB 2024...

  • Page 28: Wire Feed Unit In Vertical Position

    5.14.3 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 748 301 - 28 - © ESAB AB 2024...

  • Page 29: 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 748 301 - 29 - © ESAB AB 2024...
  • Page 30 5   OPERATION 0446 748 301 - 30 - © ESAB AB 2024...

  • Page 31: Marathon Pac™ Installation

    5   OPERATION 5.16 Marathon Pac™ installation 0446 748 301 - 31 - © ESAB AB 2024...
  • Page 32 5   OPERATION 0446 748 301 - 32 - © ESAB AB 2024...
  • Page 33 5   OPERATION 0446 748 301 - 33 - © ESAB AB 2024...

  • Page 34: Control Panel

    The feeder with an external blank panel can be used with U8 control panel. For installation of U8 on RobustFeed U8 , see the "ASSEMBLY INSTRUCTIONS" chapter of this manual. 0446 748 301 - 34 - © ESAB AB 2024...

  • Page 35: Internal Control Panel

    NOTE! The reading on the flow meter scale will only be correct if the wire feeder is in upright position. 0446 748 301 - 35 - © ESAB AB 2024...

  • Page 36: Rotating The External 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 748 301 - 36 - © ESAB AB 2024...

  • Page 37: Maintenance

    The wear parts of the welding torch should be cleaned and replaced at regular intervals in order to achieve trouble-free wire feed. Regularly blow the wire guide clean and clean the contact tip. 0446 748 301 - 37 - © ESAB AB 2024...

  • Page 38: Troubleshooting

    • Check and adjust the roller pressure as per the table on the decal on the left side door. 0446 748 301 - 38 - © ESAB AB 2024...

  • Page 39: 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 40: Assembly Instructions

    10   ASSEMBLY INSTRUCTIONS ASSEMBLY INSTRUCTIONS 0446 748 301 - 40 - © ESAB AB 2024...

  • Page 41: Wiring Diagram

    APPENDIX APPENDIX WIRING DIAGRAM RobustFeed U8 0446 748 301 - 41 - © ESAB AB 2024...
  • Page 42 APPENDIX RobustFeed U8 Tweco Push-Pull 0446 748 301 - 42 - © ESAB AB 2024...

  • Page 43: Ordering Numbers

    MMA outlet, Water, ELP, push-pull, Offshore, Water, Tweco connector Miggytrac/Railtrac, 12 pole digital remote connector for U8  Plus, 12 pole digital remote connector for remote interface Technical documentation is available on the Internet at: www.esab.com 0446 748 301 - 43 - © ESAB AB 2024...

  • Page 44: 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 748 301 - 44 - © ESAB AB 2024...
  • Page 45 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) 0446 748 301 - 45 - © ESAB AB 2024...
  • Page 46 Liquid cooling kit 0446 082 880 Torch strain relief F102 440 880 Quick connector Marathon Pac™ 0465 508 880 Guide pin extension kit For the feeder assembled with the wheel kit 0446 748 301 - 46 - © ESAB AB 2024...
  • Page 47 • TIG: and MMA current deviation 0459 554 880 Remote cable CAN 4 pole – 12 pole, 16.5 ft (5 m) 0459 554 980 Remote cable CAN 4 pole – 12 pole, 16.5 ft (5 m) HD 0446 748 301 - 47 - © ESAB AB 2024...
  • Page 48 0459 528 961 5 m (16 ft.) 0459 528 962 10 m (33 ft.) 0460 528 963 15 m (49 ft) 0460 528 964 25 m (82 ft) 0460 528 965 35 m (115 ft) 0446 748 301 - 48 - © ESAB AB 2024...
  • Page 49 15 m (49 ft) 0459 528 974 25 m (82 ft) 0459 528 975 35 m (115 ft) 0446 050 881 Interconnection strain relief kit *(for update of cables without strain relief) 0446 748 301 - 49 - © ESAB AB 2024...
  • Page 50 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...