ESAB RoboFeed 3004HW FeedControl 3004HW User manual
- Category
- Welding System
- Type
- User manual
Aristo®
Service manual
0740 800 216 GB 20190116
Valid for: serial no. 201-, 325-, 410-, 647-xxx-xxxx
RoboFeed3004HW
FeedControl3004HW
TABLE OF CONTENTS
0740 800 216 © ESAB AB 2019
READ THIS FIRST.................................................................................... 3
INTRODUCTION....................................................................................... 4
WIRING DIAGRAM................................................................................... 5
Component Description......................................................................... 5
RoboFeed 3004HW & FeedControl 3004HW, valid for serial
no.201-xxx-xxxx.....................................................................................
6
RoboFeed 3004HW & FeedControl 3004HW, valid for serial
no.325-xxx-xxxx.....................................................................................
8
RoboFeed 3004HW & FeedControl 3004HW, valid for serial
nos.410-xxx-xxxx and 647-xxx-xxxx....................................................
10
TECHNICAL DATA ................................................................................... 12
DESCRIPTION OF OPERATION.............................................................. 13
13AP1 Control board.............................................................................. 13
13AP1:1 Power supply ......................................................................... 13
13AP1:2a Start/Stop............................................................................. 15
13AP1:2b Continuous water cooling (valid for serial nos.from
647-xxx-xxxx) .......................................................................................
15
13AP1:3 Gas valve............................................................................... 16
13AP1:4 Motor driving / braking ........................................................... 16
13AP1:5 Pulse generator input ............................................................ 17
13AP1:6 Monitoring gas pressure ........................................................ 18
13AP1:7 The CAN bus ......................................................................... 18
13AP1:8 I/O.......................................................................................... 19
13AP1:9 Arc voltage sensing ............................................................... 20
13AP1:10 Touch sense ........................................................................ 20
13AP1 Component positions................................................................ 21
13AP2 I/O board...................................................................................... 22
13AP2:1 Power supply ......................................................................... 22
13AP2:2 Input signals .......................................................................... 22
13AP2:3 Output signals........................................................................ 23
13AP2 Component positions................................................................ 23
FAULT CODES ......................................................................................... 24
Fault log................................................................................................... 24
Fault code description ........................................................................... 24
SERVICE INSTRUCTIONS....................................................................... 26
What is ESD? .......................................................................................... 26
Service aid .............................................................................................. 26
Cable connection and assembly........................................................... 27
Replacing the old gas flow guard ......................................................... 28
Adjusting the gas pressure pre-set value for the pressure guard .... 31
Reconnection for welding torch with self-cooling .............................. 31
SPARE PARTS ......................................................................................... 32
Rights reserved to alter specifications without notice.
READ THIS FIRST
0740 800 216
- 3 -
© ESAB AB 2019
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. 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 "SPARE PARTS", page32.
This manual contains details of design changes that have been made up to and including
November 2016.
The manual is valid for RoboFeed 3004HW and FeedControl 3004HW with serial numbers
201-xxx-xxxx, 325-xxx-xxxx, 410-xxx-xxxx and 647-xxx-xxxx.
The RoboFeed 3004HW and FeedControl 3004HW are designed and tested in accordance
with international and European standards IEC/EN 60974-5. 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 above standard.
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.
INTRODUCTION
0740 800 216
- 4 -
© ESAB AB 2019
INTRODUCTION
The wire feed unit consist of a drive unit (RoboFeed 3004HW, containing the drive
mechanism for the wire) and a separate electronic unit (FeedControl 3004HW, containing the
control electronics).
When a control panel is mentioned in the text it is the U8
2
or the robot control panel that is
intended.
The meaning of the name 3004HW is:
Four digits means that it is a CAN communicating device, that the feed rollers are 30 mm,
that there are four feed rollers and HW means that the wire feed unit is intended for mounting
on Hollow Wrist robotic equipment. The wire feed unit is intended for MIG/MAG welding.
NOTE!
The wire feed unit utilizes the robot's safety system to obtain maximum interference
protection.
Example of a robotic welding system.
WIRING DIAGRAM
0740 800 216
- 5 -
© ESAB AB 2019
WIRING DIAGRAM
Component Description
Component Description
13AP1 Main circuit board with control electronics, see "DESCRIPTION OF
OPERATION", page13.
13AP2 I/O circuit board, see "DESCRIPTION OF OPERATION", page13.
13C1 - 13C3 Capacitor, 0.1 μF
13G1 Pulse generator, incorporated in motor 13M2
13HL1 Lamp, indicating power supply on
13M1 Wire feed motor with pulse generator
13RE1 Contactor for inactivation of touch sense
13RE2 Contactor for activation of reversed wire feed
13SB1 Push button, gas purging
13SB2 Push button, inching
13SL1 Micro-switch, pressure guard
13XP .. Plug connectors
13XS .. Socket connectors
13YV1 Solenoid valve for welding gas, 42V
13YV2 Solenoid valve for air, 42V
WIRING DIAGRAM
0740 800 216
- 6 -
© ESAB AB 2019
RoboFeed 3004HW & FeedControl 3004HW, valid for serial
no.201-xxx-xxxx
WIRING DIAGRAM
0740 800 216
- 7 -
© ESAB AB 2019
WIRING DIAGRAM
0740 800 216
- 8 -
© ESAB AB 2019
RoboFeed 3004HW & FeedControl 3004HW, valid for serial
no.325-xxx-xxxx
WIRING DIAGRAM
0740 800 216
- 9 -
© ESAB AB 2019
WIRING DIAGRAM
0740 800 216
- 10 -
© ESAB AB 2019
RoboFeed 3004HW & FeedControl 3004HW, valid for serial
nos.410-xxx-xxxx and 647-xxx-xxxx
WIRING DIAGRAM
0740 800 216
- 11 -
© ESAB AB 2019
TECHNICAL DATA
0740 800 216
- 12 -
© ESAB AB 2019
TECHNICAL DATA
RoboFeed 3004HW FeedControl 3004HW
Power supply - 42 V 50-60 Hz
Power requirement - 378 VA
Motor voltage 60 VDC PWM (Pulse Width
Modulation)
-
Motor current I
max
8.0 A 8.0 A
Wire feed speed 0.8 - 30.0 m/min -
Torch connection EURO -
Wire dimension
- Steel (Fe) 0.8-1.6 mm -
- Stainless steel (Ss) 0.8-1.6 mm -
- Aluminum (Al) 1.0-1.6 mm -
- Cored wire (FCW) 0.8-1.6 mm -
Operating temperature -10 to +40°C -10 to +40°C
Transport temperature -20 to +55°C -20 to +55°C
Weight 5.4 kg 4.9 kg
Dimensions (l × b × h) 251 × 182 × 221 mm 330 × 118 × 320 mm
Shielding gas Gases for MIG/MAGwelding Gases for MIG/MAGwelding
- max pressure 0.5 Mpa (5 bar) 0.5 Mpa (5 bar)
Coolant - ESAB's ready-mixed coolant
- max pressure - 0.5 Mpa (5 bar)
Maximum permissible load at
- 60% duty cycle 500 A 500 A
- 100% duty cycle 280 A 280 A
Enclosure class IP2X IP2X
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP2X is intended for indoor use.
Coolant
It is very important to use the ESAB ready-mixed coolant! If other coolants are used the
equipment could be damaged or in worst case the chassis could become live. You can find
the ordering number of ESAB's ready-mixed coolant in the "ACCESSORIES" chapter of the
instruction manual.
DESCRIPTION OF OPERATION
0740 800 216
- 13 -
© ESAB AB 2019
DESCRIPTION OF OPERATION
13AP1 Control board
Spare part boards
CAUTION!
This circuit board looks identical to the control board used in other wire feed units,
but there may be differences both in hardware and software. If wrong board is used,
it might be damaged. Make sure that the replacement board has correct article
number, see the spare parts list.
Circuit board identity
The control board has a machine ID, a hardware ID and a unit type number. To read this you
need the ESAT service kit.
• The machine ID determines which type of wire feed unit the board is intended for.
• The hardware ID shows the design and type of circuit board.
• The unit type is used for identification on the can bus.
• The unit number indicates the number of units of the same type in the system.
Should be 0 if there is only one wire feed unit in the system.
The ID numbers of this board are:
Machine ID = 8
Hardware ID = 6
Unit type = 3
Unit number = 0
13AP1:1 Power supply
The wire feed unit is supplied at 42 VAC from the control current power supply transformer in
the welding power source. The wire feed unit can briefly draw up to about 8 A when
accelerating the wire.
DESCRIPTION OF OPERATION
0740 800 216
- 14 -
© ESAB AB 2019
DC supplies
The diodes D13 - D16 rectify the 42 V AC supply. The rectified voltage is used to power the
wire feed motor and also powers the switched voltage regulator.
IC21, IC8, Q12, L1 and D37 forms a switched voltage regulator. The +24 V output voltage of
the regulator supplies the +15 V and +5 V regulators, VR2 and VR1. It also supplies the
reference circuit IC22, which generates +2.5 V reference voltage, this is used by the
analogue inputs of the processor.
Voltage monitoring
If the +60 V supply drops below 42 V or exceeds 78 V, the control panel displays fault code
9. This fault does not disable any functions.
The +24 V is monitored by IC12 and potential divider R129/R130. If the voltage drops to 19.5
V or less, IC12 generates a warning signal to the processor, which responds by stopping the
wire feed and then all communication on the bus. The control panel displays fault code 4.
The +15 V is monitored by the processor and voltage divider R152/R153. If the 15 V supply
drops below 13 V or exceeds 17 V, the control panel panel displays fault code 8. This fault
does not disable any functions.
DESCRIPTION OF OPERATION
0740 800 216
- 15 -
© ESAB AB 2019
13AP1:2a Start/Stop
The Start and Stop commands come from the robot, via the CAN bus.
Terminals E1 and E2 are intended for Start / Stop signal from a manual welding torch, this is
not used by the FeedControl 3004HW.
13AP1:2b Continuous water cooling (valid for serial nos.from 647-xxx-xxxx)
To attain continuous water cooling when welding, connector 13XS80 is connected to
terminal E in FeedControl units with serial numbers from 647-xxx-xxxx. The connector
contains a jumper between terminals E3 and E4, which results in continuous operation of
the water pump when welding.
NOTE!
If the control board is replaced, connector 13XS80 must be removed from the old
board and connected to the new board. Otherwise the welding torch will have
no cooling!
NOTE!
If the wire feeder is used together with a self-cooled welding torch, connector
13XS80 must be removed. Otherwise the water pump will operate continuously
and will ultimately break down! For details, see "Reconnection for welding torch
with self-cooling", page31.
DESCRIPTION OF OPERATION
0740 800 216
- 16 -
© ESAB AB 2019
13AP1:3 Gas valve
The gas valve is controlled by the microprocessor. In normal operation the gas valve opens
when the start signal is activated by the robot. The gas valve can also be opened by the
robot via the CAN bus or by using the push button on the wire feed unit.
13AP1:4 Motor driving / braking
Schematic diagram of the motor drive stage
Driving
The motor is powered from the smoothed 60 V DC supply. Pulse-width modulation of
transistor Q4 varies the effective motor voltage. Pulse frequency is 39 kHz, and the
maximum conduction period is 97 % of the pulse period.
The freewheel diode D44 provides current path during the pulse off periods.
The feed roller speed at the maximum wire feed speed of 25 m/min is 167 r/min.
DESCRIPTION OF OPERATION
0740 800 216
- 17 -
© ESAB AB 2019
Current monitoring
Resistor R114 generates a voltage signal proportional to the motor current. This voltage is
applied to voltage divider R105/R106 and the output is compared with a reference voltage at
voltage comparator IC14:11. The reference voltage is provided by the microprocessor via
R104.
The current limit is between 15 A and 18 A on starting. After one second, it is reduced to a
lower value. The current limit is related to the pulse peak current.
If the current exceeds the current limit, IC14:2 interrupts the gate pulse to Q4 after which the
current falls, and Q4 conducts on the next gate pulse, which is again interrupted if the
current is still too high. This sequence continues until the motor current has fallen below the
current limit.
Speed monitoring
Wire feed speed is monitored by the microprocessor on the circuit board.
Wire feed is stopped if the feed speed deviates from the set speed by more than 1.5 m/min
for more than 3 seconds. The control panel displays fault code 11. After five seconds a
restart is allowed.
Braking
Capacitor C67 is charged via diode D31 when the motor starts. Zener diodes D33 and D34
limit the voltage to 15 V.
When optocoupler IC11 is energised, its output transistor conducts and connects capacitor
C67 to the gate of transistor Q2, which conducts and short-circuits the motor supply via
dynamic braking resistors R71 and R79. The resistors limit the current to about 20 A.
Reversed feed
Activation of contactor 13RE2 reverses the feed direction, see "Input signals" section. This
can only be done remotely.
13AP1:5 Pulse generator input
The pulse generator, 13G1, is fitted to drive motor 13M1. It generates 60 pulses per
revolution, which means that, at a wire feed speed of 25 m/min, the pulse frequency is 8192
Hz.
DESCRIPTION OF OPERATION
0740 800 216
- 18 -
© ESAB AB 2019
13AP1:6 Monitoring gas pressure
The FeedControl 3004HW is prepared for monitoring gas supply. The control panel displays
fault code 32 if the input is open.
13AP1:7 The CAN bus
The circuit board includes a driver for the CAN bus, IC2, which looks after communication
with the control panel and with other units in the system. Although the welding power source
supplies a 12 V power supply to the control panel, this is not used on circuit board 13AP1.
OV on the circuit board is connected to OV in the control panel.
DESCRIPTION OF OPERATION
0740 800 216
- 19 -
© ESAB AB 2019
Starting sequence
On power-up, the boards CAN controller
reads the bus speed from the micro
processor: 400 kbit/s.
The circuit board displays the starting
sequence from power-up.
LED1 lights red. Then LED1, LED2 and LED3
lights green.
LEDs on circuit board 13AP1
When the board has been initiated, and the wire feed unit is in the application program,
LED1 flashes continuously with a green light.
There is more information about the operation of the CAN bus in the service manual for the
power source.
Communication interruptions
The control panel displays fault codes 12 and/or 14 if communication fails between the
control panel and the FeedControl 3004HW or the power source. In case there is a w8
2
mounted together with the U8
2
, the W8
2
needs to be modified. There is an built in
terminating resistor that needs to disconnected. See the service manual for W8
2
.
Check the following points in the event of problems with CAN communication:
• That a terminating resistor is fitted: see the instructions on page NO TAG.
• Measure the resistance between CAN H and CAN L (pin K and L in connector 13XS1).
The value should be 60 ohm with the terminating resistor mounted.
• The control cable:
○ Check that the correct type of cable is being used, i.e. the same as the one
between the power source and the wire feed unit when the equipment was
delivered.
○ Check that the cores are correctly connected. CAN H and CAN L must be carried
by the twinned pair.
• Check that all shield connections are correct.
• FeedControl 3004HW: Check that there is good contact at the connections to capacitor
13C3. See the main wiring diagram.
• Power source: Check that there is good contact between the chassis connection and
the control circuit board, the interference suppression board and the interference
suppression capacitors.
• Check the power supply voltages on circuit board 13AP1.
• If there are no faults in any of the above, replace circuit board 13AP1.
13AP1:8 I/O
Terminal BA is the interface connection to the I/O board. See "13AP2 I/O board", page22.
DESCRIPTION OF OPERATION
0740 800 216
- 20 -
© ESAB AB 2019
13AP1:9 Arc voltage sensing
In order to avoid spurious voltage drops when measuring the welding arc voltage, the power
source senses the arc voltage via the filler wire and the feeder unit motor.
13AP1:10 Touch sense
The Touch sense relay (13RE1) is controlled by the microprocessor. In normal operation the
relay closes and deactivates the Touch sense function when the start signal is activated by
the robot.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
-
21
-
22
-
23
-
24
-
25
-
26
-
27
-
28
-
29
-
30
-
31
-
32
-
33
-
34
ESAB RoboFeed 3004HW FeedControl 3004HW User manual
- Category
- Welding System
- Type
- User manual
Ask a question and I''ll find the answer in the document
Finding information in a document is now easier with AI
Related papers
-
ESAB RoboFeed 3004w Aristo RoboFeed 30-4 User manual
-
-
ESAB RoboFeed 3004HW User manual
-
-
-
-
-
-
-
ESAB Powercut 700 User manual
