0740 800 198 20120710
Origot
A22
Service manual
S0740 800 198/E20120710/P18
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Rights reserved to alter specifications without notice.
READ THIS FIRST 3.................................................................
INTRODUCTION 3...................................................................
WIRING DIAGRAM 4.................................................................
DESCRIPTION OF OPERATION 5.....................................................
Self-test 5........................................................................
Circuit board identity 5............................................................
Display board and control panel board 6...........................................
1AP2:1 LEDs and display control 6.................................................
1AP2:2 Pushbutton monitoring 8...................................................
1AP2:3 Encoder monitoring 10.....................................................
FAULT CODES 11....................................................................
Fault log 11........................................................................
Fault codes 11.....................................................................
Summary of fault codes 12.........................................................
Fault code description 13...........................................................
SERVICE INSTRUCTIONS 15..........................................................
What is ESD? 15...................................................................
Service aid 16......................................................................
SPARE PARTS 17....................................................................
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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.
Use the wiring diagram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation.
This manual contains details of design changes that have been made up to and including
August 2008.
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
Control panel A22 is intended for MMA-welding and TIG-welding with “Live TIG-start”.
The control panel consists of an operator's control panel and a display board.
Pushbuttons are used for parameter selection and a knob for parameter settings (welding
current or percent).
The control board of the power source has a microprocessor that controls the welding
process. The control panel is connected with a cable to this board and used for setting and
displaying welding data. Welding data are stored by the control board.
Control panel A22
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WIRING DIAGRAM
The MMC module consists of two main units:
S 1AP2 Display board - Display and encoder board
S 1AP3 Control panel - Operators control panel with knob, pushbuttons and LEDs
Wiring diagram for control panel A22
Control board 20AP1 is not included in the operators panel, but is a part of the power
source. For that reason it is shown with a dot broken line in the diagrams
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DESCRIPTION OF OPERATION
This description of operation describes the function of the circuit board and other
components of the MMC module. It is divided into sections, numbered to correspond to the
circuit board number and divisions into function blocks.
Self-test
When mains power is supplied, the welding data unit runs a self diagnostic program test.
1. Internal RAM memory is checked by a read/write test of each memory position.
If the test detects a fault, fault code E2 will be logged.
2. The program memory of the welding data unit is checked by a check-sum test.
If the test detects a fault, fault code E1 will be logged.
3. LED test, display test and software version indication are enabled by visual inspection.
S The LED test starts with all LEDs dark, then the diodes are turned on and off, one
at a time, until all diodes have been tested. If the test detects a fault, no fault code
will be logged.
S Then the display test is made in the same way as the LED test but for each
segment of the digits in the display. If the test detects a fault, no fault code will be
logged.
S Finally the software version of the welding data unit is
displayed, in this example the version is 0.18
Circuit board identity
The control board 20AP1, is located in the power source. It can be divided in two parts, the
control part which controls the power source and the welding data part which contains the
welding data unit. Each unit has a machine ID, a hardware ID, a unit type and a unit
number. To read them you need the ESAT service tool, see page 16.
S The machine ID defines which type of power source/control panel the board is intended
for. If the board is to be used for another type of welding equipment, the machine ID
can be changed by ESAT.
S The hardware ID shows the design and type of circuit board.
S The unit type and unit number are used for identification on the CAN bus.
Note! The identification numbers of the control unit/welding data unit are found in the
service manual for the power source.
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Display board and control panel board
1AP2:1 LEDs and display control
The control panel, 1AP3, includes LEDs for visual indication. The display
board, 1AP2, has a three digit LED-display (DY1). Display contrast cannot be
adjusted. Both the LEDs and the display are matrix connected and they are
function tested at power on.
Circuit diagram for LEDs and display
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1AP2:2 Pushbutton monitoring
The control panel, 1AP3, includes matrix connected pushbuttons. Input A20 on
the display board 1AP2, which is in series with transistor Q5, is used for control
panel identification.
Circuit diagram for pushbutton monitoring and control panel identification
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1AP2:3 Encoder monitoring
The panel has a pulse generator (encoder) for setting the welding current.
Turning the encoder (SW1) 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.
Circuit diagram for encoder monitoring.
Component positions for 1AP2 display board
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FAULT CODES
Fault log
All faults that occur when using the welding equipment are documented as error messages
in the fault log. 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: see service tools on page 16.
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 type to indicate which unit has generated the fault. The
following unit types are used:
U0 = welding data unit U2 = power source U4 = remote control unit
Fault codes are used to indicate that a fault has occurred in the
equipment. They are displayed with an E followed by a code number.
A unit type number is displayed to indicate which unit has generated
the fault.
Fault code numbers and unit type numbers are shown alternately.
Example: Fault indication indicates that the welding data unit (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 erase the fault indication.
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Summary of fault codes
Fault
code
Description Welding
data
unit
Power
source
Remote
control
unit
*1 Memory error, EPROM x x x
*2 Memory error, internal RAM x x
3 Memory error, external RAM x x
4 Power supply +5 V x x
5 Intermediate DC voltage too high/low x
6 High temperature x
*8 Power supply 1 x x
*9 Power supply 2 x x
*10 Power supply 3 x
12 Communication error (warning) x x x
14 Communication error (bus off) x
15 Lost messages x x x
16 High open-circuit voltage x
18 Lost contact with the power source x
19 Incorrect setting values in external RAM memory x
20 High inductance in the welding circuit x
*22 Transmitter buffer overflow x x
*23 Receiver buffer overflow x x
26 Program operating fault x x
*28 Stack overflow x 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 16.
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Fault code description
This manual describes the fault codes for the welding data unit, which is a part of the
control board, 20AP1, in the power source. 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 equipment. If the fault persists, load new software via ESAT. If the fault
still persists, replace the control board 20AP1.
*2 Microprocessor RAM error
The microprocessor is unable to read/write from/to a particular memory address in its
internal memory. This test is performed only as part of initiation at power on. This fault does
not disable any functions.
Action: Restart the equipment. If the fault persists, replace the control board 20AP1.
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 control board 20AP1.
12 Communication error (warning)
Minor interference on the system's CAN bus.The load on the bus is temporarily too high.
Action: Check that there are no faulty units connected to the CAN bus. Check the cables.
14 Communication error (bus off)
Major interference on the system's CAN bus.The communication has temporarily ceased,
due to excessive load on the bus. The current welding process is stopped.
Action: Check that there are no faulty units connected to the CAN bus. Check the cables.
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.
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 between the welding data unit and the
control unit in the power source.
This fault should not happen, because both units are located on the same circuit board.
Action: If it still happens replace the control board 20AP1
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 equipment is started, there is a fault in the persistent
memory. Replace control board, 20AP1, in the power source.
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Fault
code
Description
*22 Transmitter buffer overflow
The welding data unit 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 welding data unit 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 welding
data unit.
Action: Turn off the mains power supply to reset the unit.
26 Program operating fault
Something has prevented the processor from performing its normal tasks in the program.
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.
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 16.
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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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ci16_f2
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 sensitive
components from electrostatic discharge.
Contents:
S A conductive mat (size 610 x 610 mm)
S A 1.5 metre long ground cable with a
crocodile clip
S 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:
S CAN adapter with connection cables
S CD with software
S Instruction manual for ESAT
Ordering no:
0458 847 881 USB2CAN for connection to the USB port of the PC
www.esab.com
110915© ESAB AB
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
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ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
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Tel: +351 8 310 960
Fax: +351 1 859 1277
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Tel: +40 316 900 600
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Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
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ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
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ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
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Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
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ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
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Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
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ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
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Fax: +62 21 461 2929
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Fax: +81 45 670 7001
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ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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