ESAB RobustFeed AVS Instruction Manual Download Page 1

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RobustFeed AVS

Instruction manual

0446 680 001 US 20211216

Valid for: Serial number:

OP139YY-XXXXXX

Summary of Contents for RobustFeed AVS

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

Page 2: ... pressure 20 5 9 Wear parts storage compartment 22 5 10 Attaching the wheel kit 22 5 10 1 Attaching the wheels to the wheel kit frame 22 5 10 2 Wire feed unit in vertical position 23 5 10 3 Wire feed unit in horizontal position 23 5 11 Attaching both the wheel kit and the torch strain relief accessory 24 5 12 Marathon Pac installation 25 6 CONTROL PANEL 28 6 1 External control panel 28 6 2 Interna...

Page 3: ...TABLE OF CONTENTS 0446 680 001 3 ESAB AB 2021 ACCESSORIES 40 ...

Page 4: ...n emits ultraviolet UV and other radiation and can injure the skin and eyes Hot metal can cause burns Training in the proper use of the processes and equipment is essential to prevent accidents Therefore 1 Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching 2 Always wear safety glasses with side shields in any work area even if welding ...

Page 5: ... cable can overheat and create a fire hazard 7 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 ELECTRICAL SHOCK Contact between live electrical parts and earth can cause severe injury or death DO NOT use AC welding current in damp areas if movement is confined or if there is danger of falli...

Page 6: ...oxic gas and other irritant gases 4 If you develop momentary eye nose or throat irritation while operating this is an indication that the ventilation is not adequate Stop work and take the necessary steps to improve ventilation in the work area Do not continue to operate if physical discomfort persists 5 Refer to ANSI ASC Standard Z49 1 for specific ventilation recommendations 6 WARNING This produ...

Page 7: ... 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 WARNING EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installation troubleshooting and maintenance work Do not perform any electrical work unless...

Page 8: ... 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 l...

Page 9: ...lders with pacemakers fitted should consult their doctor 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 a...

Page 10: ... 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 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 ...

Page 11: ...e 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 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 ...

Page 12: ...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 Maximum weight wire spool 44 1 lb 20 0 kg Dimensions l w h RobustFeed AVS 23 4 9 8 16 9 in 595 250 430 mm Operating temperature 4 to 131 F 20 to 55 C Transport and storage temperature 40 to 176 F 40 t...

Page 13: ...urces 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 to the equipme...

Page 14: ...ot be secured The lifting points are rated for a maximum total weight of 90 lb 40 kg when lifted in the two outer upper lifting handles according to the graphic above 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 ...

Page 15: ...he equipment use the handle intended for transportation Never pull the equipment by the welding torch WARNING Make sure the side panels are closed during operation WARNING To prevent the reel from sliding off the brake hub lock the reel in place 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 CAUTION Before thread...

Page 16: ... shielding gas 5 Internal control panel see the CONTROL PANEL chapter 10 Connection for welding current from power source OKC WARNING 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 unless both doors are closed 5 2 Starting procedure 1 For Constant Voltage CV set the desired arc voltage on the power s...

Page 17: ...4 Bobbin brake The bobbin brake force should be increased just enough to prevent wire feed overrun The actual brake force required depends on the wire feed speed and the size and weight of the bobbin spool 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 0 236 in 6 mm h...

Page 18: ... feed rollers by folding the tensioner units B down and thereby releasing the swing arms C 4 Remove the feed rollers and install the correct ones according to the WEAR PARTS appendix 5 Reapply the pressure on the feed rollers by pushing the swing arms C down and secure them using the tensioner units B 6 Lock the rollers by rotating the roller quick locks A 7 Close and lock the left door of the wir...

Page 19: ...de according to the WEAR PARTS appendix 4 Lock the new inlet wire guide into place using the wire guide quick lock A 5 7 2 Middle 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 ...

Page 20: ... each tensioner unit depending on the material and diameter of the wire used 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 Figure A Figure B To check that the feed pressure is set correctly you can feed out the wire against an insulated object e g a piece of wood...

Page 21: ...an insulated object as described above A table showing approximate settings can also be found on the inside of the left door of the wire feeder Wire diameter in mm 023 0 6 030 0 8 070 1 8 5 64 2 0 3 32 2 4 Pressure setting Wire material Fe Ss Tensioner unit 1 2 5 Tensioner unit 2 3 3 5 Cored Tensioner unit 1 2 Tensioner unit 2 2 5 3 1 Tensioner unit 1 2 Tensioner unit 2 ...

Page 22: ...e guide 4 Feed rollers 4 pcs 2 Middle wire guide 5 Contact tips for the welding torch 4 pcs 3 Outlet wire guide 5 10 Attaching the wheel kit 5 10 1 Attaching the wheels to the wheel kit frame 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...

Page 23: ...AB 2021 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 ...

Page 24: ... be completed in the following order Attach the torch strain relief to the wire feed unit using the two Torx 5 screws Attach the wheel kit to the wire feeder using the two screw joints near the rear end of the wire feeder 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 scre...

Page 25: ...5 OPERATION 0446 680 001 25 ESAB AB 2021 5 12 Marathon Pac installation ...

Page 26: ...5 OPERATION 0446 680 001 26 ESAB AB 2021 ...

Page 27: ...5 OPERATION 0446 680 001 27 ESAB AB 2021 ...

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

Page 29: ...flow or to flush any air or moisture from the gas hoses before welding starts Gas purging takes place for as long as the button is held depressed and takes place without voltage or wire feed starting Wire inching Wire inching is used when feeding wire without applying a welding voltage The wire is fed as long as the button is depressed 2 stroke With 2 stroke gas pre flow starts when the welding to...

Page 30: ...ding current Circuit breaker 5 A This resettable 5 ampere circuit breaker in series with motor armature protects the control board from damage if the motor stalls Setting the gas flow The gas flow is adjusted using the knob on the internal control panel The present gas flow rate is given on the gas flow meter above the knob NOTE The reading on the flow meter scale will only be correct if the wire ...

Page 31: ...peed inch min m min 150 3 8 200 5 1 250 6 35 300 7 6 350 8 9 400 10 2 450 11 4 500 12 7 600 15 2 045 29 V 150 A 29 V 210 A 30 V 250 A 33 V 290 A 34 V 330 A 052 25 V 155 A 30 V 300 A 1 16 27 V 190 A 30 V 300 A 33 V 365 A 33 V 410 A Metal Core Diameter Wire Feed Speed inch min m min 200 5 1 250 6 35 300 7 6 350 8 9 400 10 2 450 11 4 500 12 7 045 28 V 250 A 29 V 260 A 30 V 270 A 32 V 300 A 32 V 350 A...

Page 32: ...the chosen wire type diameter and arc voltage weld current 4 Use the Weld data table to determine the position of the knob for setting the wire feed speed on the wire feeder 5 Strike an arc and adjust the arc length as needed with the knob for setting the wire feed speed NOTE It is NOT RECOMMENDED to use the CV switch setting when using a CC power source Extreme wire feed speed sensitivity exists ...

Page 33: ...eder in the horizontal position the external control panel may be rotated 90 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 ...

Page 34: ... wire feeding Note that if pretensioning is set too hard this can result in abnormal wear on the pressure roller feed roller and wire guide Cleaning of the liners and other mechanical parts of the wire feed mechanism should be carried out at regular intervals or if the wire feed seems slow Use compressed air for this task Changing nozzles Checking the driving wheel Changing the cog wheel package B...

Page 35: ...e at required settings Check all power cables and connections for evidence of overheating or sparking Gas leakage Check all gas hoses connections flowmeters and regulators for possible sources of breakdown or intermittent failure The trigger lock does not lock ON Check that the trigger lock is ON and then release the trigger after the arc is established The wire feed is slow stiff when moving thro...

Page 36: ... and IEC EN 60974 10 Class A Canadian standard CAN CSA E60974 5 and US standard ANSI IEC 60974 5 It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the mentioned standards Spare parts and wear parts can be ordered through your nearest ESAB dealer see esab com When ordering please state product type serial number...

Page 37: ...APPENDIX 0446 680 001 37 ESAB AB 2021 APPENDIX WIRING DIAGRAM ...

Page 38: ...ameter with Tweco connector 0446 680 Instruction manual CSA The three last digits in the document number of the manual show the version of the manual Therefore they are replaced with 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 ...

Page 39: ...0445 830 883 Tweco 0445 830 881 Euro Cored wire Different wire guides dependent on wire diameter Wire diameter in mm 040 0 9 1 0 045 1 2 052 1 4 1 16 1 6 070 1 8 5 64 2 0 3 32 2 4 Feed roller V K knurled X X 0445 850 030 X 0445 850 031 X X 0445 850 032 X 0445 850 033 X 0445 850 034 X 0445 850 035 X 0445 850 036 Inlet wire guide Middle wire guide Outlet wire guide Wire diameter 0 040 1 16 in 0 9 1 ...

Page 40: ...81 880 Wheel kit 0349 313 450 Trolley 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 ...

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 ...

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