ESAB RobustFeed PRO User manual

Instruction manual
0463 658 101 GB 20230112 Valid for: serial no. 904-, 230-xxx-xxxx
RobustFeedPRO

TABLE OF CONTENTS
0463 658 101 © ESAB AB 2023
1SAFETY ....................................................................................................... 6
1.1 Meaning of symbols ............................................................................... 6
1.2 Safety precautions ................................................................................. 6
2INTRODUCTION.......................................................................................... 9
2.1 Equipment ............................................................................................... 9
3TECHNICAL DATA ...................................................................................... 10
4INSTALLATION............................................................................................ 12
4.1 Lifting instructions ................................................................................. 12
5OPERATION ................................................................................................ 14
5.1 Recommended maximum current values for connection cables set 15
5.2 Connections and control devices ......................................................... 16
5.3 Cooling liquid connection ..................................................................... 16
5.4 Retrofit of interconnection strain relief kit........................................... 17
5.5 Heat kit switch (Offshore variants only)............................................... 19
5.6 Starting procedure ................................................................................. 19
5.7 Lighting inside the wire feed unit ......................................................... 19
5.8 Cooling liquid connection ..................................................................... 19
5.9 Bobbin brake........................................................................................... 19
5.10 Changing and loading wire.................................................................... 20
5.11 Changing feed rollers............................................................................. 20
5.12 Changing the wire guides...................................................................... 21
5.12.1 Inlet wire guide ..................................................................................... 21
5.12.2 Middle wire guide ................................................................................. 22
5.12.3 Outlet wire guide .................................................................................. 22
5.13 Roller pressure ....................................................................................... 22
5.14 Wear parts storage compartment ......................................................... 24
5.15 Attachment of wheel kit ......................................................................... 24
5.15.1 Attachment of the wheels to the wheel kit frame.................................. 24
5.15.2 Wire feed unit in vertical position.......................................................... 25
5.15.3 Wire feed unit in horizontal position ..................................................... 25
5.16 Attachment of both wheel kit and the torch strain relief accessory .26
5.17 Marathon Pac™ installation .................................................................. 28
6CONTROL PANEL....................................................................................... 30
6.1 Pro............................................................................................................ 30
6.1.1 External control panel........................................................................... 30
6.1.2 Internal control panel............................................................................ 31
6.2 Setting the speed unit of measurement (metric/imperial) .................. 31
6.3 Function explanations ........................................................................... 32
6.4 Overtemperature indicator .................................................................... 33
6.5 Measured values .................................................................................... 33
6.6 Setting the gas flow................................................................................ 34

TABLE OF CONTENTS
0463 658 101 © ESAB AB 2023
6.7 Rotating the control panel ..................................................................... 34
7MAINTENANCE........................................................................................... 35
7.1 Inspection, cleaning and replacement ................................................. 35
7.2 Calibration and validation of measured values ................................... 35
8TROUBLESHOOTING ................................................................................. 36
9ORDERING SPARE PARTS ........................................................................ 37
DIAGRAM ............................................................................................................ 38
ORDERING NUMBERS....................................................................................... 40
WEAR PARTS...................................................................................................... 41
ACCESSORIES ................................................................................................... 43
Rights reserved to alter specifications without notice.

1 SAFETY
0463 658 101 -6- © ESAB AB 2023
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
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 can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed 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

1 SAFETY
0463 658 101 -7- © ESAB AB 2023
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
○ 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
WARNING!
Arc welding and cutting can be injurious 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 - Can be dangerous to health
• Welders having pacemakers should consult their physician 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 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 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 earmuffs or other hearing protection.

1 SAFETY
0463 658 101 -8- © ESAB AB 2023
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 fire. Make sure therefore that there are no
inflammable materials nearby
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
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.

2 INTRODUCTION
0463 658 101 -9- © ESAB AB 2023
2 INTRODUCTION
The RobustFeedPROwire feed unit is intended for MIG/MAG-welding together with the
following welding power sources:
• Warrior™ 400i CC/CV
• Warrior™ 500i CC/CV
• Warrior™ 400i MV
• Warrior™ 350i MV
The wire feed unit comes in different variants (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 from ESAB's Marathon Pac™ or from 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
RobustFeedPROis supplied with:
• Instruction manual
• Quick start guide
• Safety instruction
Instruction manuals in other languages can be downloaded from the Internet:
manuals.esab.com

3 TECHNICAL DATA
0463 658 101 - 10 - © ESAB AB 2023
3 TECHNICAL DATA
RobustFeedPRO, Valid from serial no. 904-, 230-xxx-xxxx
Power Supply voltage 42 V AC, 50–60 Hz
Power requirement 181 VA
Rated supply current I14.3 A
Settings data:
Wire feed speed 0.8–25.0 m/min (32–984 in./min)
Creep start OFF or ON
2-/4-stroke 2-stroke or 4-stroke
Wire selection Solid or Cored
Crater fill From 0s (OFF) to 5s
Torch connection EURO, Tweco #4, Tweco #5
Max. diameter wire bobbin 300 mm (12 in.)
Wire dimension:
Fe 0.6–2.0 mm (0.023–5/64 in.)
Ss 0.6–1.6 mm (0.023–1/16 in.)
Al 1.0–1.6 mm (0.040–1/16 in.)
Cored wire 0.9–2.4 mm (0.035–3/32 in.)
Weight:
RobustFeedPRO 16.9 kg (37.1 lb.)
RobustFeedPRO, Water 17.2 kg (37.8 lb.)
RobustFeedPROOffshore 17.3 kg (38.1 lb.)
RobustFeedPROOffshore, Water 17.6 kg (38.7 lb.)
RobustFeedPRO,Tweco 16.9 kg (37.1 lb.)
RobustFeedPROOffshore,Tweco 17.3 kg (38.1 lb.)
Maximum weight wire spool 18.5 kg (40.8 lbs)
Dimensions (l×w×h) RobustFeedPRO 595×250×430mm (23.4×9.8×16.9in.)
Operating temperature -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
Maximum gas pressure 5 bar (0.5 Mpa)
Coolant(for "RobustFeedPRO,Water" and
"RobustFeedPROOffshore,Water")
ESAB's ready mixed coolant
Maximum coolant pressure 5 bar (0.5 Mpa)
Permissible load at +40°C:
50% duty cycle 550 A
60% duty cycle 500 A
100% duty cycle 400 A
Permissible load at +55°C:
50% duty cycle 550 A

3 TECHNICAL DATA
0463 658 101 - 11 - © ESAB AB 2023
RobustFeedPRO, Valid from serial no. 904-, 230-xxx-xxxx
60% duty cycle 500 A
100% duty cycle 400 A
Enclosureclass IP44
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.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP44 is intended for indoor and outdoor use and can withstand splashing
water from all directions.

4 INSTALLATION
0463 658 101 - 12 - © ESAB AB 2023
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 of equipment, lift using methods and attachment
points presented below.

4 INSTALLATION
0463 658 101 - 13 - © ESAB AB 2023
CAUTION!
Do not place heavy objects on or attached to the wire feeder when lifting. The lifting
points are rated for a maximum total weight of 40kg / 90lb. when lifted in the two
outer upper lifting handles according to the graphic above!
The 40kg / 90lb. approved weight consists of wire feeder plus accessories (standard
feeder weight is 17.6kg / 38.7lb., for all weights see the TECHNICAL DATA chapter).

5 OPERATION
0463 658 101 - 14 - © ESAB AB 2023
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 electrode wire or parts in contact with it, or uninsulated
cable or connections.
NOTE!
When moving the equipment, use handle intended for transportation. Never pull the
equipment by the welding torch.
WARNING!
Assure that the side panels are closed during operation.
WARNING!
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.
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.
WARNING!
Rotating parts can cause injury, take great care.

5 OPERATION
0463 658 101 - 15 - © ESAB AB 2023
WARNING!
Secure the equipment, especially if used on an uneven or sloping surface.
5.1 Recommended maximum current values for connection
cables set
At an ambient temperature of +25 °C and normal 10 minutes cycle:
Cable area Duty cycle Voltage loss/10m
100% 60%
70mm2360 400 0.25V/100A
95mm2430 500 0.19V/100A
At an ambient temperature of +40 °C and normal 10 minutes cycle:
Cable area Duty cycle Voltage loss/10m
100% 60%
70mm2310 350 0.27V/100A
95mm2370 430 0.20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.

5 OPERATION
0463 658 101 - 16 - © ESAB AB 2023
5.2 Connections and control devices
1. External control panel (see the
"CONTROL PANEL" chapter)
9. Wire inlet for use with Marathon Pac™
(optional)
2. Connection BLUE for cooling liquid to
the welding torch 1)
10. Interconnection strain relief for cables
from power source
3. Connection RED for cooling liquid from
the welding torch 1)
11. Connection for welding current from
power source (OKC)
4. Connection for Tweco trigger cable
(onlyincombinationwithTwecotorch)
12. Connection RED for cooling liquid to the
power source (the cooling unit) 1)
5. Connection for remote control unit
(optional)
13. Connection BLUE for cooling liquid from
the power source (the cooling unit) 1)
6. Connection for the welding torch
(EuroorTwecotype)
14. Connection for shielding gas
7. Internal control panel (see the
"CONTROL PANEL" chapter)
15. Connection for control cable from power
source
8. Heat kit switch (Offshore variants)
NOTE!
1) Cooling liquid connections only available on certain models.
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 without having
closed both doors!
5.3 Cooling liquid connection
When connecting a liquid-cooled welding torch, the main power supply switch of the power
source must be in the OFF position and the cooling unit switch must be in position 0.
A liquid cooling kit can be ordered as an accessory (see the "ACCESSORIES" appendix).

5 OPERATION
0463 658 101 - 17 - © ESAB AB 2023
5.4 Retrofit of interconnection strain relief kit

5 OPERATION
0463 658 101 - 18 - © ESAB AB 2023
The graphic above shows retrofit of the interconnection strain relief kit (ordering no. 0446 050
880) where the welding current and control cables and, if applicable, also the cooling liquid
and shielding gas hoses are routed through the strain relief device.
There is also the possibility to use a pre-assembled interconnection cable kit, including strain
relief (see the "ACCESSORIES" appendix).
NOTE!
• The interconnection strain relief should be clamped to clean cables.
• Locate the welding current cable in the larger (2) of the two holes in the
strain relief clamp!
• Ensure that the cable ties around the insulating sleeve (9) are tightened
properly!

5 OPERATION
0463 658 101 - 19 - © ESAB AB 2023
5.5 Heat kit switch (Offshore variants only)
Welding OFF
Welding ON
Heat ON and welding OFF
The bobbin area is heated so that the
welding wire is kept dry. Heating of the
bobbin area is of great advantage in
high humidity or when temperature
changes throughout the day.
5.6 Starting procedure
When the wire feed starts, the power source generates welding voltage. If there is no welding
current flow within three seconds, the power source switches the welding voltage off.
The wire feed continues until the welding torch's switch is switched off.
NOTE!
It is important that the power source used together with the feeder is set to GMA
(MIG/MAG) mode when the system is powered on! This is to ensure that calibration is
made between the feeder and the power source before any welding can be done. If
the power source is set to another welding method at power on, the voltage settings
on the feeder panel cannot be guaranteed! If this happens, switch off the power
source, set the mode switch to GMA (MIG/MAG) and restart the power source again!
5.7 Lighting inside the wire feed unit
The wire feed unit is equipped with lights inside the cabinet. The lights are turned on
automatically when the feeder is started, when any of the parameters on the internal control
panel is changed, when wire inching is performed and also after welding. The lights are
automatically turned off after a few minutes.
5.8 Cooling liquid connection
ELP (ESAB Logic Pump)
The cooling unit is equipped wih a detection system called ELP (ESAB Logic Pump) which
checks tha the coolant hoses are connected. When a liquid-coolad 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.
5.9 Bobbin brake
The bobbin brake force should be increased just enough to prevent wire feed overrun. The
actual brake force needed, is dependent of the wire feed speed and the size and weight of
the bobbin spool.
Do not overload the bobbin brake! A too high brake force may overload the motor and reduce
the welding result.

5 OPERATION
0463 658 101 - 20 - © ESAB AB 2023
The bobbin brake force is adjusted using the 6mm hexagon Allen screw in the middle of the
brake hub nut.
5.10 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
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 at the
inside of the feeder unit).
6. Close and lock the left door of the wire feeder.
NOTE!
Replace the brake hub nut and the brake hub sleeve if they are worn out and don´t
lock properly.
5.11 Changing feed rollers
When changing to a different type of wire, the feed rollers should be changed to match the
new type of wire. For information about correct feed roller 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.)
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.