ESAB MA44 Aristo User manual

Brand: ESAB

Model: MA44 Aristo

Category: Welding System

Type: User manual

This manual is also suitable for

MA43

ESAB MA44 Aristo is a versatile welding control panel that offers precise control over MIG/MAG and MMA welding processes. With its user-friendly interface, you can easily set and monitor welding parameters such as voltage, wire feed speed, and welding current. The MA44 also features advanced functions like QSet and synergic welding, making it ideal for both basic and complex welding tasks.

0740 800 209 101102

Aristo

MA43

MA44

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self-test 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit board identity 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display board and front panel 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1AP2:1 LEDs and display control 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1AP2:2 Pushbutton monitoring 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1AP2:3 Encoder monitoring 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT CODES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault log 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault codes 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault code description 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is ESD? 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service aid 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS MA43 and MA44 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control panel MA43 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control panel MA44 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbol and function explanations 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hidden MIG/MAG functions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WELDING DATA MEMORY 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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

September 2010.

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 MA43 and MA44, who are used for setting and

displaying welding data in MIG/MAG- and MMA welding. MA44 includes all MA43 functions

and some additional features like QSetand synergic welding.

Each control panel consists of a front panel and a display board. It is connected, via a 34

part ribbon cable, to a microprocessor-equipped control board in a wire feeder unit.

The wire feeder control board contains the MMC control unit, and stores the welding data.

MA43 MA44

Pushbuttons are used for parameter selection and knobs for parameter settings (voltage,

wire feed speed, welding current, time etc.).

More control panel information is found in chapter Instructions, see page 15.

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WIRING DIAGRAM

The MMC control panel consists of two main units:

 1AP2 Display board - contains displays and encoders

 1AP3 Front panel - contains push-buttons and LEDs

Wiring diagram for MMC modules MA43 and MA44

Control board 13AP1 is not included in the control panel, but is a part of the wire feeder

control board. 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 circuit board 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.

Self-test

When mains power is switched on the welding data unit runs a self diagnostic program test.

1. 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.

2. LED test, display test and software version indication are enabled by visual inspection

 The LED test starts with all LEDs dark, then they are turned on and off, one at a

time, until all LEDs have been tested. No fault code will be logged if this test

detects a fault.

 The display segments are tested in the same way as the LEDs.

No fault code will be logged if this test detects a fault.

 Finally the software version is displayed. In this example the

version is 0.17A.

Circuit board identity

The control board, 13AP1, is located in the wire feeder unit. It is functionally divided into two

parts: the wire feeder control unit and the MMC control unit (welding data unit) which

contains welding data.

Each part 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 14.

 The machine ID defines which type of wire feed/MMC unit 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.

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

 The unit type and unit number are used for identification on the CAN bus.

Note! The ID numbers for the control board/welding data unit are found in the service

manual for the wire feeder.

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Display board and front panel

1AP2:1 LEDs and display control

The front panel includes LEDs for visual indication. The panel has a window for

two three digit LED-displays. Display contrast cannot be adjusted. Both the

LEDs and the displays are matrix connected, and multiplexed by the wire

feeder control board. They are function tested at power on.

Wiring diagram for LEDs and display control

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Component positions for 1AP3, front panel MA43

Component positions for 1AP3, front panel MA44

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1AP2:2 Pushbutton monitoring

The front panel includes matrix connected pushbuttons. It also includes a

smart panel feature that makes the control board recognize the type of panel

attached.

The pushbuttons and the smart panel feature are multiplexed by the wire

feeder control board.

Wiring diagram for pushbutton monitoring

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1AP2:3 Encoder monitoring

The panels have pulse generators (encoders) for setting the welding voltage

and current, wire feed speed etc. Other settings are made with pushbuttons.

Turning the voltage adjustment pulse generator (SW2) briefly connects pin 2

(0V) to pins 1 and 3, but with a slight time difference between them. This

generates an A pulse and a B pulse that are displaced about 90° relative to

each other.

One square wave pulse train is used as clock frequency and the other square

wave pulse train defines the knob-turning direction by comparing the phase

position (positive or negative) to the clock pulse train.

When the pulse generator knob is not being turned, the voltage on pins 1 and

3 measures either 0V or 5V.

The wire feed speed pulse generator (SW1) operates in the same way.

Wiring diagram for encoder monitoring.

Component positions for 1AP2, display board

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FAULT CODES

Fault codes are used in order to indicate and identify a fault in the equipment.

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 machine must be connected to the ESAT: see service tools on page 14.

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 = welding data unit

(MMC)

U1 = cooling unit U2 = power source

U3 = wire feed unit U4 = remote control unit U5 = pre reg unit

(multivoltage)

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, you must press

(deactivating the remote control) to erase the fault indication.

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Fault code description

This manual describes the fault codes for the welding data unit (MMC). The fault codes for

the other units are described in the manuals for these units.

Code Description

*1 Flash check sum error - program memory error

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 13AP1, where the flash memory is located.

4 Power supply too low

The power supply for the pcb is too low to keep the processor operating. 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

48VDC power supply.

*8 +3.3V and +5 V power supply on circuit board 13AP1

One or both of these voltages is too high or too low. They must be within the range

3.25 ~ 3.35V and 4.9 ~ 5.35V. This fault does not disable any functions.

*9 ±15V power supply on circuit board 13AP1

One or both of these voltages is too high or too low. They must be within the range

14.5 ~ 15.5V and -13.0 ~ -17.0V. This fault does not disable any functions.

*10 +24 V power supply on circuit board 13AP1

This voltage is too high or too low. It must be within the range 23.0 ~ 25.0V.

This fault does not disable any functions.

12 Communication error (warning)

The systems CAN bus is temporarily overloaded.

Action: Check the equipment to ensure that only one wire feed unit and/or remote control

unit are connected.

14 Communication error (bus off)

The systems CAN bus has temporarily ceased to work due to excessive load.

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 CAN bus circuit indicates that a message has been lost. No functions are disabled by

this fault.

Action: Check that all units are correctly connected to the CAN bus.

17 Lost contact with wire feed unit

Current activities will be stopped.

This fault can be caused by a break in the connection between the welding data unit and the

wire feed control unit.

Action: Replace circuit board 13AP1, since both units are located on 13AP1.

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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 between the welding data unit and the

control unit in the power source.

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. Data

stored 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 circuit board 13AP1.

*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.

Action: Turn off the mains power supply to reset the unit.

26 Program operating fault (watchdog)

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.

Action: Contact ESAB if this fault occurs.

*29 No cooling water flow

The flow monitor has tripped.

The current welding process is stopped and starting is prevented.

Action: Check the cooling water circuit and the pump.

30 Lost contact with pre reg unit

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

pre reg unit in the power source.

Action: Check the CAN cabling.

41 Lost contact with cooling unit

The welding data unit has lost contact with the cooling unit. The welding process stops.

Action: Check the wiring. Turn off the mains power supply to reset the unit.

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 14.

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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 MA43 and MA44

This chapter is an extract from the instructions for the MA43 and MA44 control panels.

For detailed instructions, please see the instruction manuals.

CAUTION!

Read and understand the instruction manual before

installing or operating.

Control panel MA43

Setting voltage

Setting the wire feed speed,

current, (ampere, m/minute or

percent)

Display

Choice of welding method

MIG/MAG or MMA

Choice of 2-stroke or 4-stroke

Setting from panel , program change with welding gun trigger switch

or connecting remote control unit

Display of VRD function (reduced open-circuit voltage) is active or inactive.

Note! Not valid for all power sources.

Gas flushing (purging)

Wire inching

Indication of which parameter is shown in the display. Volts, amperes, m/min,

percent.

Setting the inductance . Also used for hidden functions.

Buttons for weld data memory.

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Control panel MA44

Setting voltage / QSet

Setting the wire feed speed,

current, (ampere, m/minute

percent or seconds)

Display

Choice of welding method

MIG/MAG or MMA

Choice of QSet , manual setting or synergy

Selection of creep start or crater filling

Choice of 2-stroke or 4-stroke

Setting from panel , program change with welding gun trigger switch

or connecting remote control unit

Display of VRD function (reduced open-circuit voltage) is active or inactive.

Note! Not valid for all power sources.

Gas flushing (purging)

Wire inching

Indication of which parameter is shown in the display. Volts, synergy, QSet,

amperes, m/min, seconds or percent.

Setting the inductance or crater filling time

synergy selection . Also used for hidden functions.

Buttons for weld data memory.

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Symbol and function explanations

MIG/MAG welding

MIG/MAG welding melts a continuously supplied filler wire, with the weld pool being protected

by shielding gas.

MMA welding

MMA welding may also be referred to as welding with coated electrodes. Striking the arc melts

the electrode, and its coating forms protective slag.

Synergy

Each combination of wire type, wire diameter and gas mixture requires a unique

relationship between wire feed speed and voltage (arc length) to obtain a stable

functioning arc. The voltage (arc length) automatically conforms in accordance with

the pre-programmed synergic line you selected, which makes it much easier to find

the correct welding parameters. The connection between the wire feed speed and

the other parameters is called the synergic line. See the different synergic lines in

the Instruction manual.

QSett

QSet , is used to facilitate setting welding parameters.

 Turning the knob clockwise increases (+) the arc length.

 Turning the knob anti-clockwise reduces (-) the arc length.

SHORT ARC

When first starting welding with a wire type / gas type QSetautomatically sets all

the necessary welding parameters. After that QSetstores all the data to produce

a good weld. The voltage then automatically conforms to changes in the wire feed

speed.

SPRAY ARC

When approaching the spray arc area the value for QSet must be increased.

Disengage the QSet function when welding with pure spray arc, All settings are

inherited from QSet, with the exception of the voltage which must be set.

Recommendation: Make the first weld (6 seconds) with QSet on a test piece to

obtain all the correct data.

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Manual

Manual operation. The operator must set appropriate values for the wire feed and

voltage.

Creep start

Creep starting feeds out the wire at 50% of the set speed until it makes electrical

contact with the workpiece.

Crater filling Crater filling time

Crater filling helps to avoid pores, thermal cracking and crater formation in the weld

when welding stops.

2-stroke

With 2-stroke gas pre-flow (if used) starts when the welding gun trigger switch is

pressed. The welding process then starts. Releasing the trigger switch stops weld

ing entirely and starts gas post-flow (if selected).

4-stroke

With 4 stroke, the gas pre-flow starts when the welding gun trigger switch is

pressed in and the wire feed starts when it is released. The welding process

continues until the switch is pressed in again, the wire feed then stops and when

the switch is released the gas post-flow starts (if selected).

Active panel

Settings are made from the control panel.

Changing welding data

This function permits changing between different welding data memories by a press

on the trigger of the welding gun.

To change without ongoing welding press quickly. If the trigger is held depressed for

too long, the program interprets this as a welding start.

Changing welding data during welding with 2-stroke

During ongoing welding the welding gun's trigger is depressed. To change welding

data memory, release the trigger and depress it quickly.

Changing welding data during welding with 4-stroke

During ongoing welding with 4-stroke the welding gun's trigger is released. To

change welding data memory, depress the trigger and release it quickly.

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Remote control unit

Settings are made from the remote control unit.

The remote control unit must be connected to the remote control unit socket on the

machine before activation. When the remote control unit is activated the panel is

inactive.

With the remote control unit function activated one can change between different

welding data memories using a welding gun with program selector (RS3).

VRD (Voltage Reducing Device)

The VRD function ensures that the open-circuit voltage does not exceed 35 V when

welding is not being carried out. This is indicated by a lit VRD LED.

The VRD function is blocked when the system senses that welding has started.

If the VRD function is activated and the open-circuit voltage exceeds the 35 V limit,

this is indicated by an error message (16) appearing in the display and welding

cannot be started whilst the error message is displayed.

Gas purging

Gas purging is used when measuring the gas flow or to flush any air or moisture

from the gas hoses before welding starts. Gas purging occurs for as long as the

button is held depressed and occurs without voltage or wire feed starting.

Wire inching

Wire inching is used when one needs to feed wire without welding voltage being

applied. The wire is fed as long as the button is depressed.

Inductance

Higher inductance results in a wider weld pool and less spatter. Lower inductance

produces a harsher sound but a stable, concentrated arc.

Hidden MIG/MAG functions

There are hidden functions in the control panel.

To access these hidden functions hold the button depressed for 5 seconds. The

display will show a letter and a value. The knob for wire feed is used to change the

value of the selected function.

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WELDING DATA MEMORY

Three different welding data programs can be stored in the control panel memory.

Hold button

, or pressed in for 5 seconds to store welding data in

the memory. The welding data is stored when the green indicator lamp starts to

flash.

To switch between the different welding data memories press button ,

or .

The welding data memory has a back-up battery so that the settings remain even if

the machine has been switched off.

SPARE PARTS

The spare parts list is published in a separate document that can be downloaded from the

internet: www.esab.com

Filename Product

0459 839 051 MA43, MA44

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ESAB MA44 Aristo User manual

Brand: ESAB

Model: MA44 Aristo

Category: Welding System

Type: User manual

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