ESAB U8 Aristo Aristo®Pendant U8 User manual

Brand: ESAB

Model: U8 Aristo Aristo®Pendant U8

Type: User manual

0740 800 154 Valid for serial no. 317--xxx--xxxx to 620--xxx--xxxx061017

Aristo

Service manual

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Rights reserved to alter specifications without notice.

READ THIS FIRST 3.................................................................

INTRODUCTION 3...................................................................

DESCRIPTION OF OPERATION 4.....................................................

AP1B Welding data board 4........................................................

AP1B:1 Power supply 4...........................................................

AP1B:2 The display window 4.....................................................

AP1B:3 Communication 6.........................................................

AP1B:4 Sounder 6...............................................................

AP1B Component positions 7....................................................

AP3B Keyboard panel 8...........................................................

F AULT LOG 9.......................................................................

Summary of fault codes 11.........................................................

Fault code descriptions, U8 12......................................................

SERVICE FUNCTIONS 15.............................................................

Show software versions 17.........................................................

Service function in weld data unit 18................................................

Service functions in the power source 20............................................

Service functions in the wire feeder 26..............................................

Coded access to weld data unit 30..................................................

Coded access through the bus 30...................................................

Manual generation of CAN messages 31.............................................

SERVICE INSTRUCTIONS 32..........................................................

What is ESD? 32...................................................................

Service aid 32......................................................................

Replacing the battery 33............................................................

SPARE PARTS 34....................................................................

NOTES 34...........................................................................

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READ THIS FIRST

Maintenance and repair work should be performed by an experienced person, and

electrical work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault--tracing and repair.

This manual contains details of design changes that have been made up to and including

September 2006.

The manual is valid for:

AristoPendant U8 with serial no. 347--xxx--xxxx, 445--xxx--xxxx

Aristot U8 with serial no. 620--xxx--xxxx.

INTRODUCTION

The control box is renamed:

New name Old name

Aristot U8 AristoPendant U8

The design features, construction and method of operation of the control box are

described in this manual. A description of its use, however, is in a separate

instruction manual.

The instructions can be downloaded from the Internet: www.esab.com/login/

Filename: 0459 310 2

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

S Observe precautions for handling electrostatic--

sensitive devices.

S Use proper static--proof bags and boxes.

ESD

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DESCRIPTION OF OPERATION

The control box, contains a welding data board (AP1B), a graphic character display with

background illumination (AP2B) and a keyboard panel (AP3B).

AP1B Welding data board

AP1B:1 Power supply

Circuit board AP1B is supplied with 12V DC from the welding power source.

The supply is unregulated, and connected to contacts B1 and B2. Voltage

regulator VR3 supplies 5 ±0.25V, which supplies all the circuits in the control

box.

The unregulated 12V supply to diode D8 and the +5V supply are monitored by

the reset circuit, IC13.

The 12V supply is monitored via potential divider R6-- R7. Diode D7 and

capacitor C9 prevent brief interference spikes from upsetting operation.

The tolerance for the 12V supply is 9-- 14V.

The supply voltages are monitored in order to be able to save data to RAM

and interrupt or terminate processes in progress in a controlled manner.

The RAM and clock circuits need a maintenance supply when the machine is

turned off, and this is provided by battery BA1.

Reset circuit IC13 incorporates an integral function for automatic changeover

between battery and mains power supply.

The battery voltage is monitored by the processor, which generates alarm code

8 if the voltage drops below 2.4V.

It is also possible to read off the battery voltage via the service functions.

AP1B:2 The display window

The display window incorporates background illumination, which is provided by

parallel -- connected LEDs. The LEDs account for about 75 % of the total power

demand.

Transistor Q1 controls the background illumination. To increase the lifetime of

the illumination it is turned off after 3 minutes, if the control box isn’t in use.

The visual contrast can be adjusted by a trimming potentiometer which is fitted

on the back of the display window control board. It can be reached by

removing a plastic seal on the underside of the unit.

WARNING: Risk of short--circuiting. Use a plastic screwdriver to adjust the

potentiometer.

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Wiring diagram for the U8

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AP1B:3 Communication

CAN bus connection to/from the weld data circuit board AP1B

Communicatio n between the control box and o ther parts of the system is by a

CAN bus, using connectors B3 and B4.

Resistor R3 and R4 are matching resistors for the bus.

AP1B:4 Sounder

A sounder, BZ1, is fitted to the circuit board to indicate certain faults and

pushbutton operations. It can be controlled by a service function.

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AP1B Component positions

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AP3B Keyboard panel

Keyboard panel, circuit diagram and component positions

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FAULT LOG

Acess the fault log through AUXILIARY FUNCTIONS in the main menu. Select ERROR

LOG and press ENTER.

AUXILIARY FUNCTIONS

MEMORY CARD OPERATIONS

PRODUCTION STATISTICS

QUALITY FUNCTIONS

ERROR LOG

CONFIGURATION

SERIAL COMMUNICATION

USER DEFINED SYNERGIC DATA

SOFT WARE UPDATE

QUIT ENTER

All faults that occur when using the welding equipment are documented as error messages

in the fault log: up to 99 error messages can be saved. When 99 messages have been

saved, the oldest message will automatically erased when the next fault occurs.

12 Date Time Unit Error

030213 05:54,29 CBOX 18

Lost contact with power source

030213 05.54,29 CBOX 17

Lost contact with wire feeder

030213 08:54,56 CBOX 22

Overflow in transmit buffer

ERASE

ALL

VIEW

TOTAL

QUIT

Examples of error messages

When the fault log is opened, the most recent fault/error message will be displayed

(selected) in the window. If there are more messages than can be displayed in the window,

this will be indicated by an arrow to the right of the uppermost message. Move the cursor up

to read the other messages.

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To erase error messages

There are two ways to erase error messages, selected by their respective keys.

S ERASE erases the selected error messages.

S ERASE ALL erases all error messages.

Messages cannot be recovered after they have been erased, whether singly or in their

entirety.

Totalling of errors

Press the VIEW TOTAL key to bring up a presentation of the number of error messages

stored in the fault log. This also shows the date and time of the oldest and of the most

recent messages.

ERROR LOG -- TOTAL LISTING

TOT AL ERROR MESSAGES: 37

OLDEST ERROR IN 030105 AT 08:37,36

LATEST ERROR IN 030313 AT 08:54,56

QUIT

An example of a summary display of error messages

Fault detection

Faults are monitored/detected in two ways: by test routines that are run on initiation and by

functions that can detect a fault when it occurs.

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Summary of fault codes

Fault

code

Description Control

box

Power

source

Wire

feed

unit

Remote

control

unit

1 Memory error, EPROM x x x x

2 Memory error, RAM x x x

3 Memory error, external RAM x x

4 +5V power supply x x x

5 Intermediate DC voltage outside limits x

6 High temperature x

7 High primary current x

8 Power supply 1 x x x x

9 Power supply 2 x x x

10 Power supply 3 x

11 Current servo / wire feed speed servo x x

12 Communication error (warning) x x x x

14 Communication error (bus off) x

15 Lost messages x x x x

16 High open circuit voltage x

17 Lost contact with the wire feed unit x

18 Lost contact with the power source x

19 Memory error in data memory x

21 Incompatible setting values x

22 T ransmitter buffer overflow x

23 Receiver buffer overflow x

25 Incompatible data formats x

26 Program operating fault x x x

27 Outofwire x

28 Stack overflow x x x

29 No cooling water flow x

30 Lost contact with the TIG board x

31 No reply from the display unit x

32 No gas flow x x

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Fault code descriptions, U8

The fault codes for the other units of this system are described in the manuals for these

units. This manual describes the fault codes for the control panel.

Fault

code

Description

1 EPROM check sum error -- program memory error

This indicates a fault in the check sum test of the program memory, which is run only when

initiating the unit after power--up.

This fault does not disable any functions.

The program memory is damaged. This is a serious fault, that can have unforeseen effects.

Action: Restart the machine. If the fault persists, load new software via ESAT. If the fault

still persists, replace circuit board AP1B that carries the memory chip.

2 Microprocessor RAM error

The microprocessor is unable to read/write from/to a particular memory address in its

internal memory. This test is preformed only as part of initiation after power--up. This fault

does not disable any functions.

Action: Restart the machine. If the fault persists, replace circuit board AP1B that carries the

microprocessor chip.

3 Error in the external RAM

Read/write test of the processor’s external RAM. This test is performed only on initiation

after power--up.

The microprocessor cannot write/read a particular memory position in the external RAM

memory. No functions are disabled by this fault.

Action: Inspect the solder joints around the RAM memory, IC5, and those around the

microprocessor that are connected to IC5. Correct any dry joints. If the fault persists, replace

circuit board AP1B.

4 5 V power supply too low

The unregulated power supply voltage for the processor is too low: the smoothing

capacitors cannot keep the voltage up enough for the processor to continue to operate. The

processor stops all normal activities, expecting to be shut down.

Action: Turn off the mains power supply to reset the unit. If the fault persists, check the

power supply to circuit board AP1B.

8 Low battery voltage + 3 V

The voltage must not be less than 2.4 V.

This test is preformed only as part of initiation after power--up.

This fault does not disable any functions.

Action: Replace the battery on circuit board AP1B. If it is not replaced, the entire contents

of the battery--backed memory will be lost.

12 Communication error (warning)

The load on t he system CAN bus is temporarily too high.

Action: Check the equipment to ensure that only one wire feed unit and/or remote control

unit is connected.

14 Communication error (bus off)

The system’s CAN bus has temporarily ceased to work due to excessive load. The current

welding process is stopped.

Action: Check the equipment to ensure that only one wire feed unit and/or remote control

unit is connected. Turn off the mains power supply to reset the unit.

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Fault

code

Description

15 Lost messages in bus communication.

The bus CAN circuit indicates that a message has been lost. No functions are disabled by

this fault.

Action: Check that all units are correct connected to the CAN bus.

17 Lost contact with the wire feed unit

Current activities will be stopped: see Fault Code 18.

This fault can be caused by a break in the connection (i.e. the CAN cable) between the wire

feed unit and the control panel.

Action: Check the CAN cables.

18 Lost contact with the power source

Current activities will be stopped and welding start is prevented.

This fault can be caused by a break in the connection (i.e. the CAN cable) between the

power source and the control panel.

It is possible, with the machine on, to break the connection between units and then to

reconnect them without problems. The control panel “knows” if it has lost contact with any

unit. When it establishes contact again, the power source is updated with all the settings

that applied before the break.

Action: Check the CAN cables.

19 Memory error in data memory

This fault will be detected if the information in the battery--backed memory has become

corrupted.

Action: This fault corrects itself, but stored data in the current memory section will be lost. If

the battery voltage is correct, and if the fault recurs each time the unit is started, there is a

fault in the RAM memory. Replace the welding data board, AP1B.

21 Incompatible setting values stored in RAM

The values selected for welding method, materials, gas and wire size form a forbidden

combination. Detection of this fault will reset the welding data memory. This test is performed

only on initiation after power--up.

No functions are disabled by this fault.

22 T ransmitter buffer overflow

The control panel is unable to transmit information to the other units at a sufficiently high

speed.

Action: A break in the bus line can cause this fault. Check the CAN cabling. T urn off the

mains power supply to reset the unit.

23 Receiver buffer overflow

The control panel is unable to process information from the other units at a sufficiently high

speed. This fault is caused by abnormal loading of the microprocessor in the control panel.

Action: Turn off the mains power supply to reset the unit.

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Fault

code

Description

25 Incompatible welding data formats

When the welding data board is loaded with welding data (not individual welding data, but

block transfers of data), it also receives a version number for the welding data format. If this

version number differs from the version number of the welding data as expected by the

welding data board, this error message will be generated.

The reason for these numbers being different is that the welding data board program may

have been updated between the time when welding data was last downloaded from the

board and when the new data was loaded into it, with the result that the data board program

contains new features that require new parameter setting data.

26 Something has prevented the processor from performing its normal program duties. The

program restarts automatically. The current welding process will be stopped. This fault does

not disable any functions.

This fault should never occur in reality. Contact ESAB if the fault does occur.

28 Stack overflow

The program execution does not work.

This fault code is intended to assist development work: it should never occur in normal use.

If it does occur, contact ESAB and report the fault.

30 Lost contact with the TIG board.

This code is only valid when the CBOX is connected to the AristoMig 320/450 or the Mig

4500i/U4500i.

See fault code 18.

31 No reply from the display unit

The microprocessor has no contact with the display board.

Action: Check the ribbon cable and connectors between the AP1B welding data board and

the AP2B display board.

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SER VICE FUNCTIONS

A number of service functions can be accessed via

the setting unit.

The service functions have several applications over

and above service and fault--tracing. Those that are

of the most importance for service and fault-- tracing

are accessible via text menus, while others are

accessed via code instructions.

Service functions are available only with English text.

Use the

arrow keys to move the cursor up

and down in the display window. In certain menus, it

is also possible to move the cursor sideways via the

’soft keys’ beneath the display window.

The two +/-- keys,

, can be used whenever the

appropriate symbol,

or , is displayed together

with the value to be changed.

ESAB AristoMig .....

PROCESS: MIG / MAG

METHOD: DIP / SPRAY

WIRE TYPE: Fe

SHIELDING GAS: CO2

WIRE DIMENSION: 1.2 mm

AUXILIARY FUNCTIONS

SET MEASURE MEMORY FAST

MODE

ENTER

The main menu for the AristoMig

To access the service functions, press the three ’soft keys’ in the centre simultaneously

(MEASURE, MEMORY and FAST MODE).

Use the

key at any time to return directly to the main menu, regardless of the level

of the sub-- menu being displayed.

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SERVICE FUNCTIONS FOR AristoMig ....

SHOW SOFTWARE VERSIONS

SERVICE FUNCTION IN WELD DATA UNIT

SERVICE FUNCTION IN POWER SOURCE

SERVICE FUNCTION IN WIRE FEEDER

CODED ACCESS TO WELD DATA UNIT

CODED ACCESS THROUGH BUS

MANUAL GENERATION OF CAN MESSAGES

QUIT ENTER

The main menu for service functions in the AristoMig

Select one of seven alternatives by moving the selected area with the arrow keys. Press

ENTER to reach the selected function, and QUIT to return to the previous display.

In general, the service functions can be reached at any time, including when welding is in

progress. However, there are naturally some limitations, depending on the type of service

function.

The following pages describe the respective service functions:

Service function Page

SHOW SOFTWARE VERSIONS 17

SERVICE FUNCTION IN WELD DATA UNIT 18

SERVICE FUNCTION IN POWER SOURCE 20

SERVICE FUNCTION IN WIRE FEEDER 26

CODED ACCESS TO WELD DATA UNIT 30

CODED ACCESS THROUGH BUS 30

MANUAL GENERATION OF CAN MESSAGES 31

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Show software versions

SHOW SOFTWARE VERSIONS

POWER SOURCE MACHINE ID. 7

WIRE FEEDER MACHINE ID. 8

SOFT WARE VERSIONS:

POWER SOURCE UNIT 0.00A

WIRE FEEDER UNIT 0.00A

WELD DATA UNIT 1.10C

SYNERGIC DATE 030121

QUIT ENTER

The display shows the current program versions and type identifications of the power source and wire

feeder unit

POWER SOURCE MACHINE ID shows the type of power unit that is connected. The codes

indicate the following types:

7 = LUD 320

7=AristoMig320

8 = LUD 320U

8=AristoMigU320

9=AristoMig450

10 = LUD 450U

10 = AristoMig U450

11 = AristoMig 400

11 = AristoMig U400

16 = AristoPower 460 17 = AristoMig 500

17 = AristoMig U500

WIRE FEEDER MACHINE ID shows the type of wire feed unit that is connected. The codes

indicate the following types:

1 = MEK 4C 2 = MEK 44C 1 = MEK 20C 7 = MLC 30C

8 = AristoFeed 30 9 = AristoFeed 48

SYNERGIC DATE: is the latest revision date of the synergy data.

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Service function in weld data unit

SERVICE FUNCTION IN WELD DATA UNIT

GENERAL RESET

RESET ERROR LOG

SET DATE & TIME

RUN TEST FUNCTIONS

BATTERY VOLTAGE 3.24 Volts

QUIT ENTER

The service functions menu in the setting unit

GENERAL RESET

Implementing a GENERAL RESET has the effect of clearing all the welding data memory

files (1 -- 99) and resetting the working date to default values. In addition, it resets various

internal parameters to ensure that the machine is returned to a well--defined starting state.

Note, however, that ERROR LOG is not reset.

Use GENERAL RESET when you have updated the program data memory, or if battery

voltage has been lost and a new battery has been fitted.

Press ENTER to carry out the reset. This will bring up a display asking if you are sure that

you want to reset. Press YES if this is correct and you really do want to carry out a reset.

A message appears on the display to confirm that the reset has been performed.

You can also perform a general reset as follows:

S Turn off the machine.

S Press and hold the middle soft key while turning on the machine. Keep the key

depressed for about three seconds. See also . below.

S The clock will be reset to 1st June 1997. It will do this only when a reset has been

performed using the soft key, and not when a GENERAL RESET has been performed.

RESET ERROR LOG

This function resets only the error log.

Perform the reset in the same way as for GENERAL RESET.

SET DATE & TIME

Select this function and then press ENTER to set the clock on the setting unit.

BATTERY VOLTAGE X.XX Volts

The battery voltage is constantly measured, and must not fall below 2.4V.

The normal value is about 3V.

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RUN TEST FUNCTIONS

Menu for test functions in the setting unit. The test to be performed is indicated by a

number.

There are at present nine tests for the setting unit.

The results of most tests are indicated by the display windows showing RESULT: OK if the

test has been approved, or RESULT: FAILED if it has not.

Select the test by using the +/-- keys to increment or decrement the number in the window.

Press ENTER to perform the test. When the test has finished, press QUIT to be able to

select a new test.

SERVICE FUNCTION IN WELD DATA UNIT

EXECUTE TEST FUNCTION: 1

QUIT ENTER

Menu for test functions in the setting unit

The following tests are available for the setting unit:

Internal RAM

Tests the processor’s internal memory.

Flash memory

Verifies the check sum in the program memory and checks that it is equal to zero. If it

is not zero, then RESULT = FAILED. This can indicate that the program memory has

lost information. This is a serious fault, and must be corrected.

See the fault codes on page 12.

External RAM

Tests the RAM memory outside the processor (62256 -- 32K).

3 V battery

Tests the voltage of the lithium battery on the board. The minimum acceptable level is

2.4 V: if the voltage is lower, then RESULT=FAILED.

The voltage can also be read off from the previous display, i.e. before coming to RUN

TEST FUNCTIONS.

Sounder (b uzzer)

Press ENTER. The buzzer will sound and the display will show EXECUTED.

Keyboard

This function is used only during the manufacturing stage, when it is used to test the

I/O bus that is connected to the keys.

PC card address bus

The address connections to the PC card are tested.

Display test

Press ENTER: all pixels in the display are turned on and off 3 times.

LED test

All LED’s on the weld data board a re switched on and then off.

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Service functions in the power source

SERVICE FUNCTION IN POWER SOURCE

DISPLAY STATE IN I/O PORTS

DISPLAY STATE IN ANALOGUE INPUTS

CHANGE STATE IN DEDICATED I/O PINS

OUTPUT CURRENT REFERENCE

OUTPUT MAX. CURRENT

RUN TEST FUNCTIONS

QUIT ENTER

Menu for service functions in the power unit.

DISPLAY STATE IN I/O PORTS

PORT BIN HEX DEC

1 00000000 00 0

3 00000000 00 0

4 00000000 00 0

5 00000000 00 0

QUIT

Status of the power unit processor input and output ports

The information in the display is constantly updated.

This function is used when developing and testing software.

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ESAB U8 Aristo Aristo®Pendant U8 User manual

ESAB U8 Aristo Aristo<sup>®</sup>Pendant U8 User manual

ESAB U8 Aristo Aristo<sup>®</sup>Pendant U8 User manual

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