ESAB MA23 is a versatile welding control panel that offers precise control and a wide range of features for MIG/MAG and MMA welding applications. It boasts user-friendly operation with clear digital displays for voltage and wire feed speed, enabling you to monitor and adjust welding parameters with ease. Choose between synergic or manual mode to suit your welding preferences. Synergic mode provides optimized welding parameters based on material thickness, ensuring consistent and high-quality welds.
ESAB MA23 is a versatile welding control panel that offers precise control and a wide range of features for MIG/MAG and MMA welding applications. It boasts user-friendly operation with clear digital displays for voltage and wire feed speed, enabling you to monitor and adjust welding parameters with ease. Choose between synergic or manual mode to suit your welding preferences. Synergic mode provides optimized welding parameters based on material thickness, ensuring consistent and high-quality welds.
0740 800 176 070830
Origot
MA23
MA23A
Service manual
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Rights reserved to alter specifications without notice.
READ THIS FIRST 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power on 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1 Welding data board 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1:1 Power supply 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1:2 Communication 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1:3 LED and display control 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1:4 Pushbutton monitoring 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1:5 Encoder monitoring 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1 Component positions 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT CODES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault log 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault codes 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of fault codes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault code description 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service aid 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel MA23 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel MA23A 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote control unit 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MIG/MAG WELDING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol and function explanations 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hidden MIG/MAG functions 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MMA WELDING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol and function explanations 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hidden MMA functions 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WELDING DATA MEMORY 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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
August 2007.
CAUTION !
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
INTRODUCTION
This manual describes the control panels, MA23 and MA23A.
MA23A includes QSet and spot-welding by comparison with MA23.
Each control panel consists of an operator's control panel, a display board and a welding
data board.
The power source, the wire feed unit and control panel, each have their own
microprocessor for control. The control panel is the central unit in the system: in addition to
setting and controlling welding data, it also has overall control of the entire system.
Control panel MA23 and MA23A.
Knobs are used for setting the voltage and wire feed speed/welding current. Other settings
are made by pushbuttons.
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WIRING DIAGRAM
The MMC module consists of three main units:
1AP1 Welding data board - Processor and CAN communication board
1AP2 Display board - Display and encoder board
1AP3 Control panel - Operators control panel with push-buttons and LEDs
Wiring diagram for MMC module units MA23 and MA23A
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DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components
in the MMC module. It is divided into sections, numbered to correspond to the circuit board
numbers and divisions into function blocks.
Power on
When mains power is supplied the unit runs a self diagnostic program test to check:
internal RAM memory by a read/write test of each memory position.
If the test detects a fault, fault code E2 will be logged.
the program memory by a check-sum test.
If the test detects a fault, fault code E1 will be logged.
the LEDs on the control panel. Visual inspection of the LEDs is enabled. The test starts
with all LEDs dark, then the diodes are lit one at a time until all diodes lights. After that
will all LEDs be turned off (dark). If the test detects a fault, no fault code will be logged.
the display. Display test is made in the same way as the LED test but
for each digit in the display. If the test detects a fault, no fault code
will be logged.
After completed test the software version is displayed, and in this
example the program version is 0.17A
1AP1 Welding data board
Circuit board identity
The welding data board has a machine ID, a hardware ID and a unit type number. To read
this you need the ESAT service tool, see page 19.
The machine ID defines which type of control panel the board is intended for. If the
board is to be used for another type of control panel, 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 control board are:
MA23 machine ID = 17
MA23A machine ID = 18
Hardware ID = 3
Unit type = 0
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1AP1:1 Power supply
Circuit board 1AP1 receives a 12 V power supply from the control board in the
power source. This is regulated to 5 V, which supplies all the circuits of the
control panel. The 12 V and 5 V supplies are monitored by a reset circuit:
tolerance values are 12 V +2/-3 V and 5 V$0.25 V.
Monitoring the voltages makes sure that, in the event of loss of power, the
processor has time to save the current data and to shut down the current
processes in a controlled manner.
Loss of power supply does not generate a fault code on the display. If the 12 V
supply drops below 9 V, either momentarily or indefinitely, but does not fail
entirely, the display will show fault code 4. The machine must be turned off,
and then on again, to reset the system.
To store data which need to be saved even if the power supply is switched off,
there is a persistent flash memory area included in the processor. Data are
saved in this memory when the mains power supply is turned off or lost.
Circuit diagram for power supply and CAN bus
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1AP1:2 Communication
Communication between the control panel and other units is via the system's
CAN bus.
Resistor R3 is the terminating resistor (120 Ω) for the bus. See component
positions diagram on page 13.
Read more about the CAN bus in the service manual for the power source.
Starting sequence
At power-up, the board's micro processor sets the bus speed for the CAN
controller to 400 kbit/s.
The welding data board displays the starting sequence from power-up.
First LED1 lights red, then LED1, LED2 and LED3 lights green.
When the board has been initiated, and the power source is in the application
program, LED1 flashes continously with a green light.
LEDs on welding data board 1AP1
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1AP1:3 LED and display control
The panel board includes LEDs for visual indication. Besides LEDs the panel
has a window for a LED-display in two rows (DY1 and DY2) showing three
digits in each row. Display contrast cannot be adjusted. Both LEDs and the
display are matrix connected and they are function tested at power on.
Component positions for 1AP3 control panel MA23
Component positions for 1AP3 control panel MA23A
The component positions diagram for 1AP2 is on page 12.
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Circuit diagram for LEDs and display
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1AP1:4 Pushbutton monitoring
Besides LEDs and knobs the panel board also includes matrix connected
pushbuttons.
Component positions for 1AP3 control panel MA23
Component positions for 1AP3 control panel MA23A
The component positions diagram for display board 1AP2 is on page 12.
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Circuit diagram for pushbutton monitoring
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1AP1:5 Encoder monitoring
The MA23 and MA23A panels have pulse generators (encoders) for setting the
welding voltage and wire feed speed, with pushbuttons for other functions.
Turning the voltage adjustment pulse generator (SW2) briefly connects contact
2 (0 V) to contacts 1 and 3, but with a slight time difference between them.
This generates pulses that are displaced by about 90° relative to each other.
One square wave pulse is used as clock frequency and the other square wave
pulse defines the knob-turning direction by comparing the phase position
(positive or negative) compared to the clock frequency
When the pulse generator knob is not being turned, the voltage on contacts 1
and 3 is +5 V.
The wire feed speed pulse generator (SW1) operates in the same way.
Wiring diagram for encoder monitoring. Voltage and wire feed speed / current settings
Component positions for 1AP2 display board
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1AP1 Component positions
Component positions for 1AP1 welding data board
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FAULT CODES
Fault log
All faults that occur when using the welding equipment are documented as error messages.
When the fault log is full, the oldest message will automatically be erased when the next
fault occurs.
Only the most recent fault message is displayed on the control panel. To read the entire
fault log, the equipment must be connected to the ESAT service tool, see page 19.
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.
Fault codes
The control panel displays a unit number to indicate which unit has generated the fault. The
following unit numbers are used:
U0 = control panel U1 = cooling unit U2 = power source
U3 = wire feed unit U4 = remote control unit
Fault codes are used to indicate that a fault has occurred in the
equipment. They are given in the lower part of the display with an
E followed by a fault code number.
A unit number is displayed to indicate which unit has generated the
fault.
Fault code numbers and unit numbers are shown alternately.
Example: Fault indication indicates that the control panel (U 0) has
lost contact with the power source (E 18).
If several faults have been detected only the code for the last
occurring fault is displayed. Press any function button or turn any
knob to remove the fault indication from the display.
Note! If the remote control is activated, deactivate the remote control by pressing
to remove the fault indication.
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Summary of fault codes
Fault
code
Description Welding
data
unit
Cooling
unit
Power
source
Wire
feed
unit
Remote
control
unit
*1 Memory error, EPROM x x x x x
*2 Memory error, internal RAM x x x x
3 Memory error, external RAM x x x x
4 Power supply +5 V x x x
5 Intermediate DC voltage too high/low x
6 High temperature x x
*8 Power supply 1 x x x x
*9 Power supply 2 x x x
*10 Power supply 3 x
11 Wire feed speed x
12 Communication error (warning) x x x x x
14 Communication error (bus off) x
15 Lost messages 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 Incorrect setting values in external
RAM memory
x
*22 Transmitter buffer overflow x x x x
*23 Receiver buffer overflow x x x x
26 Program operating fault x x
27 Out of wire x
*28 Stack overflow x x x x
29 No cooling water flow x
32 No gas flow x
40 Incompatible units x
41 Lost contact with the cooling unit x
Fault codes marked with an asterisk ( * ) are not displayed by the control panel. but they
are stored in the fault log. To get access to the fault log use the ESAT service tool. See
page 19.
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Fault code description
This manual describes the fault codes for the welding data unit. The fault codes for the
other units are described in the manuals for these units.
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 1AP1 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 1AP1 that carries the
microprocessor chip.
3 Error in external RAM
Read/write test of the processor's internal external RAM. This test is preformed only as part
of initiation after power-up. The microprocessor is unable to read/write from/to a particular
memory address in its external memory. This fault does not disable any functions.
Action: Restart the machine. If the fault persists, replace circuit board 1AP1, which carries
the microprocessor chip.
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 1AP1.
12 Communication error (warning)
The load on the system's 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.
15 Lost messages
The bus CAN controller 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 cabling.
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Fault
code
Description
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 cabling.
19 Memory error in data memory
Information in persistent data memory is incorrect. Basic data will be used.
Action: This fault corrects itself. Turn off the mains power supply to reset the unit. Stored
data in the current memory section will be lost. If the fault recurs each time the unit is
started, there is a fault in the persistent memory. Replace the welding data board, 1AP1, in
the control panel
*22 Transmitter 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. Turn 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.
26 Program operating fault
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 not happen. Contact ESAB if the fault yet occurs
*28 Stack overflow
The program execution does not work.
This fault should not happen. The fault code is intended as an aid during development work.
Contact ESAB if the fault yet occurs.
29 No cooling water flow
The flow monitor switch has tripped.
The current welding process is stopped and starting is prevented.
Action: Check the cooling water circuit and the pump.
40 Incompatible units
Incorrect wire feed unit is connected. Start is prevented
Action: Connect the correct wire feed unit.
41 Lost contact with the cooling unit
The control panel has lost contact with the cooling unit.
Action: Check the wiring. Turn off the mains power supply to reset the unit.
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SERVICE INSTRUCTIONS
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD stands for
Electrostatic Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components, but is not dangerous to people.
ESD damage occurs when an ungrounded person or object with a static charge comes into
contact with a component or assembly that is grounded. A rapid discharge can occur,
causing damage. This damage can take the form of immediate failure, but it is more likely
that system performance will be affected and the component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static electricity is prevented from building
up on you or on anything at your work station, then there cannot be any static discharges.
Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static
charge, so you should not bring unnecessary nonconductive items into the work area.
It is obviously difficult to avoid all such items, so various means are used to drain off any
static discharge from persons to prevent the risk of ESD damage. This is done by simple
devices: wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only antistatic
packaging materials. Overall, handling of ESD-sensitive devices should be minimized to
prevent damage.
CAUTION !
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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Service aid
We can offer a number of service tools that will simplify the service.
Antistatic service kit
Ordering no. 0740 511 001
The kit makes it easier to protect sensitve
components from electrostatic discharge.
Contents:
A conductive mat (size 610 x 610 mm)
A 1.5 metre long ground cable with a
crocodile clip
An adjustable wrist strap and cable with
an inbuilt protective resistor
Antistatic service kit
ESAT service kit
The software update is made from a PC, it has to be managed by a trained serviceman. For
this a PC program called ESAT, ESAB Software Administration Tool, is needed. The PC is
connected to the welding equipment by a cable connector and a CAN reader. From the
ESAT it is possible to update the software. ESAT also contains service functions by which it
is possible to control, change or read the different functions of the equipment.
For the installation and use of the ESAT you need a PC with operating system Windows.
The ESAT service kit contents:
CAN adapter with connection cables
CD with software
Instruction manual for ESAT
Ordering no:
0458 847 880 PPCAN for connection to the print port of the PC
0458 847 881 USB2CAN for connection to the USB port of the PC
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INSTRUCTIONS
This chapter is an extract from the instruction manual for the MA23 and MA23A control
panels.
Control panel MA23
1 Knob for setting the arc voltage
2 Knob for setting the wire feed speed/current (m/minute or percent, ampere)
3 Display
4 Pushbutton for selection of welding method, MIG/MAG or MMA
6 Pushbutton for selection of 2-stroke or 4-stoke control mode
7 Pushbutton for parameter setting from panel, by program change 1-3 with welding gun trigger
switch or by parameters from a remote control unit
8 Pushbutton for gas flushing (purging)
9 Pushbutton for wire inching
10 Indication of selected parameter in the display. Volt, ampere, m/min or percent
11 Pushbutton for setting the inductance. Also used for hidden functions
12 Pushbuttons for different welding data program sets, 1-3
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ESAB MA23 is a versatile welding control panel that offers precise control and a wide range of features for MIG/MAG and MMA welding applications. It boasts user-friendly operation with clear digital displays for voltage and wire feed speed, enabling you to monitor and adjust welding parameters with ease. Choose between synergic or manual mode to suit your welding preferences. Synergic mode provides optimized welding parameters based on material thickness, ensuring consistent and high-quality welds.
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