ESAB ESABFeed 30L-4i User manual

ESABFeed 30L-4i
ESAB
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.

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 ................................
8
Valid for YardFeed2000 with serial number 616-xxx-xxxx,
425-xxx-xxxx and 810-xxx-xxxx ............................................................
10
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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© ESAB AB 2018
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
0740 800 173
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© ESAB AB 2018
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
0740 800 173
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© ESAB AB 2018
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
0740 800 173
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© ESAB AB 2018
WIRING DIAGRAM
Valid for Feed L3004
WIRING DIAGRAM
0740 800 173
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© ESAB AB 2018
WIRING DIAGRAM
0740 800 173
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© ESAB AB 2018
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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© ESAB AB 2018
WIRING DIAGRAM
0740 800 173
- 10 -
© ESAB AB 2018
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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© ESAB AB 2018
WIRING DIAGRAM
0740 800 173
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© ESAB AB 2018
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
0740 800 173
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© ESAB AB 2018
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
U6
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
U6
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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
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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© ESAB AB 2018
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
0740 800 173
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© ESAB AB 2018
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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© ESAB AB 2018
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
0740 800 173
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© ESAB AB 2018
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

ESABFeed 30L-4i
ESAB
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.

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