ESAB RobustFeed AVS User manual

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

TABLE OF CONTENTS
0446 680 001 -2- © ESAB AB 2021
1 SAFETY ...................................................................................................................................... 4
1.1 Meaning of symbols .................................................................................................... 4
1.2 Safety precautions ...................................................................................................... 4
1.3 User responsibility ...................................................................................................... 8
1.4 California proposition 65 warning ............................................................................. 10
2 INTRODUCTION ......................................................................................................................... 11
2.1 Equipment.................................................................................................................... 11
3 TECHNICAL DATA ..................................................................................................................... 12
4 INSTALLATION........................................................................................................................... 13
4.1 Lifting instructions ...................................................................................................... 13
5 OPERATION ............................................................................................................................... 15
5.1 Connections and control devices .............................................................................. 16
5.2 Starting procedure ...................................................................................................... 16
5.3 Lighting inside the wire feed unit .............................................................................. 17
5.4 Bobbin brake................................................................................................................ 17
5.5 Changing and loading wire......................................................................................... 17
5.6 Changing feed rollers.................................................................................................. 18
5.7 Changing the wire guides........................................................................................... 18
5.7.1 Inlet wire guide ................................................................................................... 19
5.7.2 Middle wire guide ............................................................................................... 19
5.7.3 Outlet wire guide ................................................................................................ 20
5.8 Roller 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 Internal control panel .................................................................................................. 29
6.3 Function explanation .................................................................................................. 29
6.4 Operating procedures ................................................................................................. 31
6.4.1 Weld data table................................................................................................... 31
6.4.2 RobustFeed AVS with CC Power Sources ......................................................... 32
6.4.3 RobustFeed AVS with CV power sources .......................................................... 32
6.4.4 Shutdown ........................................................................................................... 32
6.5 Rotating the control panel .......................................................................................... 33
7 MAINTENANCE.......................................................................................................................... 34
7.1 Inspection, cleaning and replacement ...................................................................... 34
8 TROUBLESHOOTING ................................................................................................................ 35
9 ORDERING SPARE PARTS ....................................................................................................... 36
WIRING DIAGRAM ................................................................................................................................ 37
ORDERING NUMBERS ......................................................................................................................... 38
WEAR PARTS........................................................................................................................................ 39

TABLE OF CONTENTS
0446 680 001 -3- © ESAB AB 2021
ACCESSORIES ..................................................................................................................................... 40

1  SAFETY
0446 680 001 -4- © ESAB AB 2021
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual and follow
all labels, employer's safety practices and Safety Data Sheets
(SDSs).
1.2 Safety precautions
WARNING!
These Safety Precautions are for your protection. They summarise precautionary information
from the references listed in Additional Safety Information section. Before performing any
installation or operating procedures, be sure to read and follow the safety precautions listed
below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe
Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require hearing
protection. The arc, like the sun, 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
helmets, face shields and goggles are also required.
3 Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to look at the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
4 Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
high-topped shoes, and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.
5 Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of the
clothing.
6 Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.

1  SAFETY
0446 680 001 -5- © ESAB AB 2021
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.
FIRES AND EXPLOSIONS
The heat from flames and arcs can start fires. Hot slag or sparks can also
cause fires and explosions. Therefore:
1 Protect yourself and others from flying sparks and hot metal.
2 Move all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.
3 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
4 Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.
5 Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.
6 Do not use equipment beyond its ratings. For example, an overloaded welding 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 falling. Therefore:
1 Be sure the power source frame (chassis) is connected to the earth system of the
input power.
2 Connect the workpiece to a good electrical earth.
3 Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
4 Use well-maintained equipment. Replace worn or damaged cables.
5 Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
6 Make sure that all parts of your body are insulated from both the work piece and from
the ground.
7 Do not stand directly on metal or the ground while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8 Put on dry, hole-free gloves before turning on the power.
9 Turn off the power, before removing your gloves.
10 Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a earth cable.
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:

1  SAFETY
0446 680 001 -6- © ESAB AB 2021
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.
3 Welders should use the following procedures to minimize exposure to EMF:
1 Route the electrode and work cables together. Secure them with tape
when possible.
2 Never coil the torch or work cable around your body.
3 Do not place your body between the torch and work cables. Route
cables on the same side of your body.
4 Connect the work cable to the workpiece as close as possible to the
area being welded.
5 Keep the welding power source and cables as far away from your body
as possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in confined
spaces. Shielding gases can cause asphyxiation. Therefore:
1 Keep your head out of the fumes. Do not breathe the fumes and gases.
2 Always provide adequate ventilation in the work area by natural or mechanical means.
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.
3 Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic 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 product when used for welding or cutting, produces fumes or gases
that contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A sudden
rupture of cylinder valve or relief device can injure or kill. Therefore:
1 Locate cylinders away from heat, sparks and flames. Never strike an arc on a
cylinder.
2 Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.
3 Always secure cylinders in an upright position, by chain or strap, to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
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.

1  SAFETY
0446 680 001 -7- © ESAB AB 2021
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause injury.
Therefore:
1 Keep all doors, panels, guards, and covers closed and securely in place.
2 Stop the engine or drive systems before installing or connecting a unit.
3 Have only qualified people remove covers for maintenance and troubleshooting as
necessary
4 To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
5 Keep hands, hair, loose clothing and tools away from moving parts.
6 Reinstall panels or covers and close doors when service is finished and before
starting engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any
other accessories.
• Use equipment of adequate capacity to lift and support unit.
• 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.
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 you are qualified
to perform such work.
2 Before performing any maintenance work inside a power source, disconnect
the power source from the incoming electrical power.
3 Maintain cables, earthing wire, connections, power cord and power supply in
safe working order. Do not operate any equipment in faulty condition.
4 Do not abuse any equipment or accessories. Keep equipment away from heat
sources such as furnaces, wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
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.

1  SAFETY
0446 680 001 -8- © ESAB AB 2021
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting equipment,
ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging.” Form 52-529.
The following publications are recommended:
• ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
• AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
• AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
• AWS SP - “Safe practices” - Reprint, Welding Handbook
• ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of
Containers That Have Held Hazardous Substances”
• OSHA 29 CFR 1910 - "Safety and health standards"
• CSA W117.2 - "Code for safety in welding and cutting"
• NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other Hot
Work"
• CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in
Cylinders”
• ANSI Z87.1, "Occupational and Educational Personal Eye and Face Protection
Devices"
1.3 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.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment.
Incorrect operation of the equipment may lead to hazardous situations, which could result in injury to
the operator and damage to the equipment.
1 Anyone who uses the equipment must be familiar with:
• its operation
• the location of emergency stops
• its function
• the relevant safety precautions
• welding and cutting or other applicable operation of the equipment
2 The operator must ensure that:
• no unauthorized person is within the working area of the equipment
when it is started up
• no-one is unprotected when the arc is struck or work is started with the
equipment
3 The workplace must:
• be suitable for the purpose
• be free from drafts
4 Personal safety equipment:
• Always wear recommended personal safety equipment, such as safety
glasses, flame-proof clothing, safety gloves
• Do not wear loose-fitting items, such as scarves, bracelets, rings, etc.,
which could become trapped or cause burns
5 General precautions:
• Make sure the return cable is connected securely

1  SAFETY
0446 680 001 -9- © ESAB AB 2021
• Work on high voltage equipment may only be carried out by a
qualified electrician
• Appropriate fire extinguishing equipment must be clearly marked and
close at hand
• Lubrication and maintenance must not be carried out on the equipment
during operation
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.
WARNING!
Arc welding and cutting may cause injury to yourself and others. Take precautions when
welding and cutting.
ELECTRIC SHOCK - Can kill
• Do not touch live electrical parts or electrodes with bare skin, wet gloves,
or wet clothing
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Pose health risks
• Welders 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 and work cables. Never coil
the torch or work cable around your body. Keep the welding
power source and cables as far away from your body as
possible.
○ Connect the work cable to the workpiece as close as possible
to the area being welded.
FUMES AND GASES - Can be dangerous to your health
• Keep your head out of the fumes
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing
• Protect bystanders with suitable screens or curtains
NOISE - Excessive noise can damage hearing
Protect your ears. Use ear defenders or other hearing protection.

1  SAFETY
0446 680 001 - 10 - © ESAB AB 2021
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause a fire. Therefore, make sure that there are no
inflammable materials nearby
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• 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!
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.
1.4 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. (California Health &
Safety Code Section 25249.5 et seq.)
WARNING!
This product can expose you to chemicals including lead, which are known to the state of
California to cause cancer and birth defects or other reproductive harm. Wash hands after use.
For more information, go to www.P65Warnings.ca.gov.

2  INTRODUCTION
0446 680 001 - 11 - © ESAB AB 2021
2 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).
The wire feed unit comes in different versions (see the "ORDERING NUMBERS" appendix).
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).
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 Equipment
The wire feed unit is supplied with:
• An instruction manual in the local language for the wire feed unit
• Drive rolls: 0.9/1.0 mm (0.040 in.) / 1.2 mm (0.045 in.)
• Guide tubes: 0.6–1.6 mm (0.023–1/16 in.)
• Voltage pick up cable with clamp
Instruction manuals in other languages can be downloaded from the Internet: manuals.esab.com

3  TECHNICAL DATA
0446 680 001 - 12 - © ESAB AB 2021
3 TECHNICAL DATA
RobustFeedAVS, Valid from serial no. OP139YY-XXXXXX
Power Supply voltage 15-100 VDC
Maximum weld voltage 45 VDC
Power requirement 194 VA
Rated supply current I14.3 A
Settings data:
Wire feed speed 32–984 in./min (0.8–25.0 m/min)
Torch connection EURO, Tweco 4
Max. diameter wire bobbin 12 in. (300 mm)
Wire dimension:
Fe 0.6 - 2 mm (0.023 - 0.078 in.)
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)
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 to +80°C)
Shielding gas All types intended for MIG/MAG welding
Maximum gas pressure 5 bar (0.5 MPa)
Permissible load at +40°C:
40% duty cycle 500 A / 39 V
60% duty cycle 450 A / 36 V
100% duty cycle 350 A / 31.5 V
Enclosureclass IP44

4  INSTALLATION
0446 680 001 - 13 - © ESAB AB 2021
4 INSTALLATION
The installation must be carried out by a professional.
WARNING!
When welding in an environment with increased electrical danger, only power sources
intended for this environment may be used. These power sources 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 equipment, lift using the methods and attachment
points detailed below.

4  INSTALLATION
0446 680 001 - 14 - © ESAB AB 2021
CAUTION!
Do not place heavy objects on the wire feeder when lifting. Objects should not 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).

5  OPERATION
0446 680 001 - 15 - © ESAB AB 2021
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY" chapter
of this manual. Read it through before you start using the equipment!
WARNING!
To avoid shock, do not touch the electrode wire or parts in contact with it, or uninsulated cable
or connections.
NOTE!
When moving the 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 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.

5  OPERATION
0446 680 001 - 16 - © ESAB AB 2021
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
Secure the equipment, especially if used on an uneven or sloping surface.
5.1 Connections and control devices
1 External control panel (see the "CONTROL
PANEL" chapter)
6 Connection for workpiece
2 Connection for the Tweco trigger cable (only in
combination with Tweco torch)
7 Connection for feeder (3)
3 Connection for Work lead / Voltage pick-up 8 Wire inlet for use with Marathon Pac™
(optional)
4 Connection for the welding torch (Euro or
Tweco type)
9 Connection for 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 source.
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. A feeder in CC mode will deliver a wire feed

5  OPERATION
0446 680 001 - 17 - © ESAB AB 2021
speed that varies with changes in arc voltage. When not welding, the display will show what the
wire feed speed will be at the displayed voltage.
For more information see section "Control panel".
5.3 Lighting inside the wire feed unit
Lights are fitted inside the cabinet of the wire feed unit. The light located by the wire bobbin turns on
automatically when welding starts or when the left side door is opened. The light is automatically
turned off 4 minutes after welding has stopped or the side door has been closed. The light located by
the feeder mechanism turns on automatically when the left side door is opened and turns off when the
door is closed again. The lights automatically switch on when the feeder is started, when any of the
parameters on the internal control panel are changed, when wire inching is performed and after
welding tasks. The lights automatically switch off after a few minutes.
5.4 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) hexagon Allen screw in the middle of
the brake hub nut.
5.5 Changing and loading wire
1) Open the left door of the wire feeder.
2) Untighten and remove the brake hub nut and remove the old wire spool.
3) Insert a new wire spool into the feeder unit and straighten out the new welding wire 3.94–7.87 in.
(10–20 cm). File away burrs and sharp edges from the end of the wire before inserting it into the
feeder mechanism.
4) Lock the wire spool onto the brake hub by tightening the brake hub nut.
5) Thread the wire through the feeder mechanism (according to the illustration on the inside of the
feeder unit).
NOTE!
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

5  OPERATION
0446 680 001 - 18 - © ESAB AB 2021
5.6 Changing feed rollers
When changing to a different type of wire, the feed rollers should also be changed to match the new
type of wire. For more information about correct feed rollers 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.
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.
3) Relieve the pressure on the 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 wire feeder.
5.7 Changing the wire guides
When changing to a different type of wire, the wire guides may need to be changed to match the new
type of wire. 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.)

5  OPERATION
0446 680 001 - 19 - © ESAB AB 2021
5.7.1 Inlet wire guide
1) Unlock the inlet wire guide quick lock (A) by folding it out.
2) Remove the inlet wire guide (B).
3) Fit the correct inlet wire guide (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.

5  OPERATION
0446 680 001 - 20 - © ESAB AB 2021
5.7.3 Outlet wire guide
1) Remove the lower right feed roller (see the "Changing feed rollers" section).
2) Remove the middle wire guide (see the "Middle wire guide" section).
3) Unlock the outlet wire guide quick lock(A) by folding it out.
4) Remove the outlet wire guide(B).
5) Install the correct outlet wire guide (according to the WEAR PARTS appendix).
6) Lock the new outlet wire guide into place using the wire guide quick lock(A).
7) Reattach the second pair of feed rollers and reapply the roller pressure (see the "Changing feed
rollers" section).
5.8 Roller pressure
The roller pressure should be adjusted separately on 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.
When you hold the welding torch approximately 0.197 in. (5 mm) from the piece of wood (figure A) the
feed rollers should slip.
If you hold the welding torch approximately 0.969 in. (50 mm) from the piece of wood, the wire should
feed out and bend (figure B).
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