0740 800 208 101102
Aristo
A44
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1 Welding data board 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP2 Component positions 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT CODES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault log 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault codes 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault code description 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service aid 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel A44 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote control unit 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MMA WELDING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol and Function explanations 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hidden function MMA welding 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MIG/MAG WELDING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol and Function explanations 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIG WELDING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settings 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol and Function explanations 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hidden function TIG welding 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VRD (Voltage Reducing Device) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WELDING DATA MEMORY 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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
boards are 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
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
Control panel A44 is intended for MMA-welding and TIG-welding with “Live TIG-start”. It is
also intended for MIG/MAG-welding with an Arc Voltage Controlled (AVC) feeder, both with
gas shielded welding and self-shielded flux cored wire welding (FCAW-S). A44 can also be
used for arc-air gouging.
The 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 A44
Pushbuttons are used for parameter selection and the knob for parameter settings (voltage,
welding current, time etc.).
More control panel information is found in chapter Instructions, see page 19.
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WIRING DIAGRAM
The MMC module consists of three main units:
S 1AP1 Welding data board - Processor and CAN communication board
S 1AP2 Display board - Display and encoder board
S 1AP3 Front panel - Front panel with pushbuttons and LEDs
Wiring diagram for control panel A44
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DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components
in the equipment. 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.
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
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1AP1 Welding data board
Circuit board identity
The welding data board has a machine ID, a hardware ID, a unit type and a unit number. To
read them you need the ESAT service kit, see page 18.
S The machine ID determines which type of control panel the board is intended for.
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.
The identification numbers of this board are:
Machine ID 31
Hardware ID 4
Unit type 0
Unit number 1
Note! If more than one welding data unit is connected to the CAN bus, the welding data unit
with the lowest
unit number is then in command of the system. The other unit is inactive.
Example:
A power source with control panel A44 (unit number = 1) is connected to a wire feeder with
control panel MA44 (unit number = 0). The MA44 welding data board will then control the
system.
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.
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LEDs on welding data board 1AP1
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Circuit diagram for power supply and CAN bus
1AP1:2 Communication
Communication between the control panel and other units is via the system's
CAN bus.
Note! The welding data board in the A44 control panel does not have a
terminating resistor.
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 is running the application
program, LED1 flashes continuously
with a green light.
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1AP1:3 LED and display control
The front 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 multiplexed
by the welding data board. They are function tested at power on.
Circuit diagram for LEDs and display
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1AP1:4 Pushbutton monitoring
The front panel includes matrix connected pushbuttons. It also includes a
smart panel feature that makes the welding data board recognize the type of
panel attached.
The pushbuttons and the smart panel feature are multiplexed by the welding
data board.
Circuit diagram for pushbutton monitoring and control panel identification
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1AP1:5 Encoder monitoring
The panel has a pulse generator (encoder) for setting the welding current.
Turning the encoder (SW1) briefly connects pin 2 (0 V) 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 by 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) compared to the clock frequency.
Circuit diagram for encoder monitoring.
1AP1 Component positions
Component positions for the welding data board
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1AP2 Component positions
Component positions for the 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 erase 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 18.
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
(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 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 (E18).
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 of control panel A44.
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.
*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 after power-up. This fault
does not disable any functions.
Action: Restart the machine. If the fault persists, replace circuit board 1AP1.
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 systems CAN bus is temporarily overloaded, or there is electric noise on the bus.
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 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 the wire feed unit
Current activities will be stopped.
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.
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 in the
control panel and the control unit in the power source.
Action: Check the CAN cabling.
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Fault
code
Description
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.
*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 program duties. The
program restarts automatically. The current welding process will be stopped. This fault does
not disable any functions.
Action: Contact ESAB if the fault occurs.
*28 Stack overflow
The program execution does not work.
This fault code is intended as an aid during development work. Contact ESAB if the 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.
40 Incompatible units
Incorrect wire feed unit is connected. Start is prevented
Action: Connect the correct wire feed 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 18.
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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:
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 847 880 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 A44 control panel.
SAFETY
CAUTION!
Read and understand the instruction manual before
installing or operating.
INSTALLATION
Control panel A44
1 Display
2 Indication of selected parameter in the display (current, voltage or percent)
3 Pushbutton for selection of display indication during welding (current or voltage)
4 Knob for setting the current (A) or percentage (%)
5 Pushbuttons for selection and storage of the welding data program sets, 1--2
6 Pushbutton for selection of “Hot start” or “Arc force“ when MMA welding
or inductance when MIG/MAG welding. Button is also used for hidden functions
7 Pushbutton for selection of welding method MMA or TIG
8 Pushbutton for selection of electrode type “Basic“, “Rutile“ or “Cellulose“ when MMA welding
9 Pushbutton for parameter setting from panel or from a remote control unit
10 Indication of VRD function (reduced open-circuit voltage). LED lights when VRD is active
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Remote control unit
Using a remote control unit, the primary parameters of the welding process can be
controlled from a device other than the control panel.
When the remote control unit is connected, everything is controlled from the remote control
unit, and the knob on the control panel is out of operation.
MMA WELDING
Settings
Function Setting range Default value
Current 4 A - max
1)
100 A
Active panel 0 = Off 1 = On On
Remote control unit 0 = Off 1 = On Off
Hot start 0 - 99% 0
Arc force 0 - 99% 5
Drop welding
2)
0 = Off 1 = On 0
Welding data memory
3)
1 and 2 -
1)
The setting range is dependent on the power source used.
2)
Hidden function
3)
See page 25
Symbol and Function explanations
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.
Active panel
Settings are made from the control panel.
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.
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