ESAB ESABFeed 30L-4i User manual

Brand: ESAB

Model: ESABFeed 30L-4i

Category: Welding System

Type: User manual

This manual is also suitable for

ESAB ESABFeed 30L-4i is a reliable wire feeder designed for professional welding applications. With its robust construction and advanced features, it offers precise wire feeding control and consistent arc performance. It handles a wide range of wire types and diameters, making it suitable for various welding tasks. The user-friendly control panel enables easy setting adjustments, enhancing productivity and ensuring optimal welding results.

Aristo®, Origo™

Service manual

0740 800 173 GB 20180921

Valid for: serial no. 535-, 548-, 613-, 616-, 425-, 810-xxx-xxxx

FeedL3004

YardFeed2000

TABLE OF CONTENTS

0740 800 173 © ESAB AB 2018

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

INTRODUCTION....................................................................................... 4

TECHNICAL DATA ................................................................................... 5

WIRING DIAGRAM................................................................................... 6

Valid for Feed L3004............................................................................... 6

Valid for AristoYardFeed200withserialnumber548-xxx-xxxx and

YardFeed2000withserialnumber613-xxx-xxxx ................................

Valid for YardFeed2000 with serial number 616-xxx-xxxx,

425-xxx-xxxx and 810-xxx-xxxx ............................................................

Component description ......................................................................... 12

DESCRIPTION OF OPERATION.............................................................. 13

1 MMC panel............................................................................................ 13

13AP1 Control board.............................................................................. 14

13AP1:1 Power supply ........................................................................ 14

13AP1:2 Start / Stop ............................................................................ 16

13AP1:3 Gas valve .............................................................................. 16

13AP1:4 Motor driving / braking .......................................................... 17

13AP1:5 Pulse generator input ........................................................... 18

13AP1:6 The CAN bus ........................................................................ 18

13AP1:7 Arc voltage sensing .............................................................. 19

13AP1:8 Monitoring the cooling water connection, ELP ..................... 20

13AP1 Component positions................................................................ 21

Pull motor option, Feed L3004 .............................................................. 22

Circuit board layout, CAN adapter and filter board............................... 23

Connection instructions ........................................................................ 23

Spare parts for connection sets Feed L3004 ....................................... 25

Spare parts for connection sets YardFeed 2000 ................................. 26

REMOTE CONTROLS .............................................................................. 27

FAULT CODES ......................................................................................... 28

Fault log................................................................................................... 28

Summary of fault codes......................................................................... 28

Fault code description ........................................................................... 29

SERVICE INSTRUCTIONS....................................................................... 31

What is ESD? .......................................................................................... 31

Service aid .............................................................................................. 31

Dismantling of YardFeed 2000 .............................................................. 32

SPARE PARTS ......................................................................................... 33

Rights reserved to alter specifications without notice.

READ THIS FIRST

0740 800 173

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READ THIS FIRST

Maintenance and repair work must 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.

Use the wiring diagram as a form of index for the description of operation. The circuit boards

are divided into numbered blocks, which are described individually in more detail in the

description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

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

August 2015.

The manual is valid for:

AristoFeed 30L-4 and ESABFeed 30L-4i with serial no. 535-xxx-xxxx.

Feed L3004 with serial no. 613-xxx-xxxx.

Aristo YardFeed 200 with serial no. 548-xxx-xxxx, 425-xxx-xxxx.

YardFeed 2000 with serial no. 613-xxx-xxxx, 616-xxx-xxxx, 425-xxx-xxxx and 810-xxx-xxxx.

The AristoFeed 30L-4, ESABFeed 30L-4i, Feed L3004, Aristo YardFeed 200 and YardFeed

2000 are designed and tested in accordance with the standards stated in the instruction

manual. On completion of service or repair work, it is the responsibility of the person(s)

performing the work to ensure that the product still complies with the requirements of the

involved standards.

INTRODUCTION

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INTRODUCTION

The AristoFeed, ESABFeed and Aristo YardFeed wire feeders are renamed:

New name Old name

Feed L3004 AristoFeed 30L-4 / ESABFeed 30L-4i

YardFeed 2000 Aristo YardFeed 200

There are two different product families, Aristo® and Origo™, to which the wire feeders

belong. The product family is depending on the type of control panel that is used. The control

panels are not described in this manual, this manual describes the wire feeders: Feed L3004

and YardFeed 2000.

TECHNICAL DATA

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TECHNICAL DATA

Feed L3004 YardFeed 2000

Power supply 42 V 50-60 Hz 42 V 50-60 Hz

Power requirement 180 VA 180 VA

Motor current I

max

3.5 A 3.5 A

Wire feed speed 0.8 - 25.0 m/min 0.8 - 25.0 m/min

Torch connection EURO EURO

Max. diameter wire bobbin 300 mm (440 mm*) 200 mm

Wire dimension

Fe & Ss

Al

Cored wire



0.6 - 1.2 mm

1.0 - 1.2 mm

0.8 - 1.2 mm



0.6 - 1.2 mm

1.0 - 1.2 mm

0.8 - 1.2 mm

Weight 15 kg 11.3 kg

Dimensions (l x w x h) 690 x 275 x 420 mm 593 x 210 x 312 mm

Shielding gas



max pressure

All types intended for

MIG/MAG welding

5 bar

All types intended for

MIG/MAG welding

5 bar

Type of cooling



max pressure

Use only ESAB ready

mixed coolant

5 bar

Use only ESAB ready

mixed coolant

5 bar

Maximum permissible load at

60% duty cycle



365 A



365 A

Enclosure class

with sealed bobbin holder

without sealed bobbin holder



IP23

IP23X

IP23

* Accessory

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. The duty cycle is valid for 40°C/104°F, or below.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP23 is intended for indoor and outdoor use.

Equipment marked IP2X is intended for indoor use.

WIRING DIAGRAM

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WIRING DIAGRAM

Valid for Feed L3004

WIRING DIAGRAM

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WIRING DIAGRAM

0740 800 173

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Valid for AristoYardFeed200withserialnumber548-xxx-xxxx and

YardFeed2000withserialnumber613-xxx-xxxx

WIRING DIAGRAM

0740 800 173

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WIRING DIAGRAM

0740 800 173

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Valid for YardFeed2000 with serial number 616-xxx-xxxx,

425-xxx-xxxx and 810-xxx-xxxx

WIRING DIAGRAM

0740 800 173

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WIRING DIAGRAM

0740 800 173

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Component description

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

This component description should be read in conjunction with the wiring diagram. The

description of operation contains a more detailed description of the functions of the

components.

1 MMC panel Control panel. See the description in chapter "DESCRIPTION OF

OPERATION".

13AP1 Main circuit board, with the control electronics.

See the description in chapter "DESCRIPTION OF OPERATION".

13C2 - 13C5 Interference suppression capacitor.

13G1 Pulse generator. Incorporated in motor 13M1.

See the description in chapter "DESCRIPTION OF OPERATION".

13L1, 13L2 Ferrite ring core.

13M1 Motor with pulse generator.

13R1 Resistor, used as heating element (option). Only YardFeed 2000.

13S1 Micro-switch, cooling water supply connection monitoring.

See the description in chapter "DESCRIPTION OF OPERATION".

13S2 "Safety contact switch", 3 position switch. Only YardFeed 2000.

See the description in the instruction manual.

13XP . . Plug connectors.

13XS . . Socket connectors.

13YV1 Solenoid valve.

See the description in chapter "DESCRIPTION OF OPERATION".

DESCRIPTION OF OPERATION

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DESCRIPTION OF OPERATION

1 MMC panel

The MMC module consists of an operator's control panel and a welding data board.

The power source, the wire feed unit and the control panel each have their own

microprocessor for control, with the control panel being the central unit in the system. In

addition to storing and issuing welding data, it also exercises overall control of the system as

a whole.

The control panels are described in separate manuals.

YardFeed 2000: Control panels Aristo™ MA6, U6 or Origo™ MA23

MA6

Knobs for setting the voltage and wire feed speed /

welding current. Other parameters are controlled by

push-buttons, with text in the display panel.

Panel U6 will replace panel MA6.

MA23

Knobs for setting the voltage and wire feed speed /

welding current. Other settings by pushbuttons.

Feed L3004: Control panels Aristo™ MA6, U6 or Origo™ MA23, MA23A or empty panel.

MA6

Knobs for setting the voltage and wire feed speed /

welding current. Other parameters are controlled by

push-buttons, with text in the display panel.

Panel U6 will replace panel MA6.

MA23

Knobs for setting the voltage and wire feed speed /

welding current. Other settings by pushbuttons.

The design of the panel may be as to the left or as

above.

DESCRIPTION OF OPERATION

0740 800 173

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MA23A

Knobs for setting the voltage / QSet™ and wire feed

speed / welding current. Other settings by push-buttons.

Empty panel for use with double wire feed units or with

use of control box U8.

13AP1 Control board

Sections 13AP1:1 to 13AP1:8 below refer to the diagram in chapter "WIRING DIAGRAM",

section "Feed L3004".

Circuit board identity

The control board has a machine ID, a hardware ID and a unit type number. To read this you

need the ESAT service kit, see section "ESAT service kit" in chapter "SERVICE

INSTRUCTIONS".

• The machine ID determines which motor type and wire feed mechanism the board is

intended for. If the board is to be used for another type of motor or mechanism, the

machine ID can be changed by ESAT.

• The hardware ID shows design and type of circuit board.

• The unit type is used for identification on the can bus.

The ID numbers of the Feed L3004 and YardFeed 2000 are:

Machine ID = 29; Hardware ID = 5; Unit type = 3 (wire feed unit)

Spare part boards must be configured if the unit has an ELP switch, see section "13AP1:8" in

this chapter.

13AP1:1 Power supply

Feed L3004

DESCRIPTION OF OPERATION

0740 800 173

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The feeder obtains a 42 V AC supply from the power source.

42 V AC is used for the welding torch trigger switch and as the power supply to the gas

solenoid valve.

Rectifier BR1 rectifies the 42 V supply to 60 V. This voltage supplies the wire feeder motor.

Transistor Q8 is a pre-regulator which reduces the voltage from 60 V to 20 V.

Q8 is current-limited to about 200 mA. If the 20 V supply drops below 13 V, the wire feed

unit stops.

YardFeed 2000 from serial no. 616-xxx-xxxx

Voltage monitoring

If the +60 V supply drops below 42 V or exceeds 78 V, the MMC panel displays fault code 9.

This fault does not disable any functions.

The +20 V is monitored by a reset circuit. If the voltage drops to 13 V or less, this circuit

generates a reset signal to the processor, which responds by stopping the wire feed and

then all communication on the bus. This fault does not generate a fault code.

The +15 V is monitored by the processor. If the 15 V supply drops below 13 V or exceeds 17

V, the MMC panel displays fault code 8. This fault does not disable any functions.

YardFeed 2000 with serial no. 548-xxx-xxxx and 613-xxx-xxxx

The power supply works as described above, with one exception: switch 13S2 on the front

panel. When the switch is in position 'Welding OFF' or 'Heat ON', there is no voltage supply

to the control board.

See: "Safety contact switch YardFeed 2000" in instruction manual.

YardFeed 2000 with serial no. 548-xxx-xxxx and 613-xxx-xxxx

DESCRIPTION OF OPERATION

0740 800 173

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13AP1:2 Start / Stop

YardFeed 2000 with serial no. 548-xxx-xxxx and 613-xxx-xxxx and Feed L3004

The welding torch switch is supplied with 42 V AC. Closing the switch activates optocoupler

IC1, causing the voltage across C35 to go low.

When wire feed starts, the power source generates welding voltage. If this is not followed by

a flow of welding current within three seconds, the power source shuts down the welding

power supply, although wire feed continues until the welding torch switch is released.

YardFeed 2000 from serial no. 616-xxx-xxxx

When switch 13S2 on the front panel is in position 'Welding OFF' or 'Heat ON', there is no

voltage supply to the start switch of the welding torch. See: "Safety contact switch YardFeed

2000" in instruction manual.

13AP1:3 Gas valve

The gas valve is controlled by the microprocessor. In normal operation the gas valve opens

when the start signal is activated by the welding torch switch.

DESCRIPTION OF OPERATION

0740 800 173

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13AP1:4 Motor driving / braking

Schematic diagram of the motor drive stage

Driving

The motor is powered from the smoothed +60 V supply. Motor speed is controlled by pulse

width modulation of transistor Q1. The pulse frequency is 39 kHz. The maximum conducting

time of the pulses is 99% of the pulse cycle time. During the pulse spaces, the motor current

freewheels through diode D8.

A wire feed speed of 25 m/min. requires a roller speed of 271 r/min, the motor voltage is

then about 40 V.

Current limit

Resistor R19 produces a voltage drop proportional to the motor current. If the current

exceeds the current limit, IC5 turns off the gate pulses to Q1. When the current falls, Q1

conducts again at the next gate pulse.

The wire feeder has a dynamic current limit controlled by the processor. The current limit is

11 A on starting. When the set speed is achieved, this is reduced to 7 A.

Braking

When the motor starts, capacitor C43 charges up via diode D28: the voltage is limited to 15

V by Zener diodes D10 and D21. When the motor is to brake, the LED in optocoupler IC8

lights, causing the transistor in IC8 to conduct and discharge capacitor C43 (15 V) to the

gate of transistor Q3. The transistor conducts and short-circuits the motor voltage through

resistors R51 and R64, which limit the current to about 20 A.

Speed monitoring

Wire feed speed is monitored by the microprocessor on the circuit board. Wire feed is

stopped if the feed speed deviates from the set speed by more than 1.5 m/min for more than

5.1 seconds. The MMC panel displays fault code 11.

DESCRIPTION OF OPERATION

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13AP1:5 Pulse generator input

The pulse generator, 13G1, is fitted to drive motor 13M1.

It generates 60 pulses per revolution, which means that, at a wire feed speed of 25 m/min,

the pulse frequency is 10180 Hz.

Valid for Yardfeed 2000 with serial number 810-xxx-xxxx

At a wire feed speed of 25 m/min, the pulse generator produces a pulse frequency of

6430Hz.

13AP1:6 The CAN bus

Feed L3004

The circuit board includes a driver for the CAN bus, IC12, which looks after communication

with the other units in the system.

Although the CAN bus supplies a +12 V power supply, this is not used on circuit board

13AP1. 0 V on the circuit board is connected to 0 V CAN.

DESCRIPTION OF OPERATION

0740 800 173

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YardFeed 2000

Starting sequence

On power-up, the board's CAN controller reads in the bus

speed from the micro processor: 400kbit/s.

The circuit board displays the starting sequence from

power-up.

LED1 lights red. Then LED1, LED2 and LED3 lights

green.

When the board has been initiated, and the wire feed unit

is in the application program, LED1 flashes continuously

with a green light.

LEDs on circuit board 13AP1

There is more information about the operation of the CAN bus in the service manual for the

power source.

13AP1:7 Arc voltage sensing

In order to avoid spurious volt drops when measuring the welding arc voltage, the power

source senses the arc voltage via the filler wire and the feeder unit motor.

DESCRIPTION OF OPERATION

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13AP1:8 Monitoring the cooling water connection, ELP

The wire feed unit with water connection is equipped with a detection system ELP (ESAB

Logic Pump) which checks that the water hoses are connected.

When connecting a water-cooled welding torch, the water pump starts.

Micro-switch 13S1 senses whether a water-cooled welding torch is connected to the wire

feed unit: a closed switch indicates that the cooling water hoses are connected, and so

provides a Start Enable signal to the system for the water pump.

The resistors connected to the input form a potential divider of the 15 V supply, to produce

about +6 V for an open input.

NOTE!

When a spare part board is installed in a wire feed unit with water connection,

the board must be configured for ELP.

Use the service function selection of Esat and select:

Service function / Assign ELP exist / Argument 2: Set ELP exist.

For more information on ESAT, see chapter "SERVICE INSTRUCTIONS".

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ESAB ESABFeed 30L-4i User manual

Brand: ESAB

Model: ESABFeed 30L-4i

Category: Welding System

Type: User manual

This manual is also suitable for

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ESAB ESABFeed 30L-4i User manual

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