Service manual
0463 723 001 GB 20201106
Valid for: 2001-xxxx
Weaving unit
W8000
TABLE OF CONTENTS
0463 723 001 © ESAB AB 2020
READ THIS FIRST
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3
BEFORE STARTING SERVICE
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4
Service aid
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4
INTRODUCTION
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5
Assembly
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5
Block diagram
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6
WIRING DIAGRAM
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7
TECHNICAL DATA
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11
TROUBLESHOOTING
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12
SPARE PARTS AND ACCESSORIES
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14
Rights reserved to alter specifications without notice.
READ THIS FIRST
0463 723 001
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© ESAB AB 2020
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 AND
ACCESSORIES" chapter in this manual.
This manual contains details of design changes that have been made up to and including
November 2019.
The manual is valid for:
• Weaving unit W8000 with serial number 1901-xxxx
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for safety and
function, of the specific set-up, lies with the integrator.
The Weaving unit W8000 is 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.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
BEFORE STARTING SERVICE
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© ESAB AB 2020
BEFORE STARTING SERVICE
Service aid
ESAB 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 sensitive
components from electrostatic discharge.
Contents:
• A conductive mat (size 610×610mm /
24×24in.)
• A 1.5m (3.28ft) long ground cable with
a crocodile clip
• An adjustable wrist strap and cable with
a built-in protective resistor
INTRODUCTION
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© ESAB AB 2020
INTRODUCTION
The Weaving unit W8000 can be used to mechanize your GMAW and SAW processes. It can
be used for weaving, gap bridging, filling and capping. It can store weaving speed, width,
hold time out, hold time in, and preheat. The W8000 has a maximum weaving width of 60
mm. The control unit is included.
Assembly
1. Height Slide 4. Torch bracket for adjusting torch position
2. Weaving unit 5. Torch clamp
3. Base plate
1. Control box 3. Connector supply
2. Connector weaving unit 4. Joystick
INTRODUCTION
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© ESAB AB 2020
Block diagram
The control box on Weaving unit W8000 consists of 2 units / circuit boards:
• Main board PLC
• Switch board with Display
The main board PLC has power connections, the microprocessor, a relay for starting and
stopping the wire feeder and a motor driver. The W8000 uses a stepper motor.
The PLC communicates with the display through a serial port. An analog input reads the
status of the switches.
The switch board has 4 switches, a 2-way joystick, a display and an opto isolated input filter
for the external start and stop. The graphical design on the display is preprogrammed
(internal software).
WIRING DIAGRAM
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© ESAB AB 2020
WIRING DIAGRAM
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
Connector diagram
PLC board
The PLC is a complete unit with power supply filter, two power switches, a motor driver, an
opto I/O filter and a microprocessor.
Power in is on J1 (5). Input is polarized with a rectifier. D1 (7) is for voltage protection (90 V).
F1 (6) is a PTC fuse.
The PLC board is a complete unit with a power supply filter, two power switches, a motor
driver, an opto I/O filter and a microprocessor.
IC1 (1) is a 24 V power switch, tuned to supply 28 V to the motor driver. IC2 (2) is a 5 V
power sw. for the display and the microprocessor.
Starting and stopping the wire feeder is possible through the PTC fuse F3 (4) (0,5 A) and the
K2 (3) normally closed relay.
NOTE!
This board is replaced as a complete unit. Do not solder or replace individual
components.
WIRING DIAGRAM
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© ESAB AB 2020
1. IC1 5. J1
2. IC2 6. F1
3. K2 7. D1
4. F3
Switch board
The microprocessor reads an anlog voltage from the switch board. When no switch is
pressed the voltage is +5 V on the 1 kohm pull up resistor (R1). There are 4 diodes in serial
(D1-D4), each with a voltage drop of approximatly 0.6 V is connected to the 4 switches. The
output voltage is from 1 V to 2.8 V depending of which key is pressed.
External start signal is on pin H and through an opto filter (OK1A) with open collector it sinks
the start signal to the microprocessor to 0 V when active. (+5 V when off via pull up resistor
(R8)).
OK1B is optional, it is not in use.
The display is controlled by a serial port TX / RX and powered by 5 V.
WIRING DIAGRAM
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© ESAB AB 2020
WIRING DIAGRAM
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© ESAB AB 2020
TECHNICAL DATA
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© ESAB AB 2020
TECHNICAL DATA
Weaving unit W8000
Supply 20 –49 VAC
30–70 VDC
Power 30W
Weight weaving unit (incl. bracket and slide) 4kg
Motor type Stepper motor
Weaving speed 1–40mm/s
Weaving width 0–60mm
Hold time (left and right position) 0.0–5.0s
Horizontal electrical adjustment Joystick
Horizontal mechanical adjustment 80mm
Slide adjustment vertical ±40mm
Maximum load weaving arm 5 kg
External start / stop input 20-30VDC
Relay to start wire feeder max 0.5 A
Enclosure class IP44
TROUBLESHOOTING
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© ESAB AB 2020
TROUBLESHOOTING
TROUBLESHOOTING
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© ESAB AB 2020
SPARE PARTS AND ACCESSORIES
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© ESAB AB 2020
SPARE PARTS AND ACCESSORIES
For spare parts, see the spare parts list for the product. For accessories, see the instruction
manual for the product. These documents can be downloaded from the Internet:
www.esab.com
Ordering number Denomination Type
0459 990 646 Weaving unit W8000
0463 722 * Instruction manual
0463 724 001 Spare parts list
The three last digits in the document number of the manual show the version of the manual.
Therefore they are replaced with * here. Make sure to use a manual with a serial number or
software version that corresponds with the product, see the front page of the manual.
Technical documentation is available on the Internet at: www.esab.com
SPARE PARTS AND ACCESSORIES
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