ESAB RoboFeed 3004HW FeedControl 3004HW User manual

Brand: ESAB

Model: RoboFeed 3004HW FeedControl 3004HW

Category: Welding System

Type: User manual

Aristo®

Service manual

0740 800 216 GB 20190116

Valid for: serial no. 201-, 325-, 410-, 647-xxx-xxxx

RoboFeed3004HW

FeedControl3004HW

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

RoboFeed 3004HW & FeedControl 3004HW, valid for serial

no.325-xxx-xxxx.....................................................................................

RoboFeed 3004HW & FeedControl 3004HW, valid for serial

nos.410-xxx-xxxx and 647-xxx-xxxx....................................................

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) .......................................................................................

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

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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. 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", page32.

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

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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

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

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WIRING DIAGRAM

Component Description

13AP1 Main circuit board with control electronics, see "DESCRIPTION OF

OPERATION", page13.

13AP2 I/O circuit board, see "DESCRIPTION OF OPERATION", page13.

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, 42V

13YV2 Solenoid valve for air, 42V

WIRING DIAGRAM

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RoboFeed 3004HW & FeedControl 3004HW, valid for serial

no.201-xxx-xxxx

WIRING DIAGRAM

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WIRING DIAGRAM

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RoboFeed 3004HW & FeedControl 3004HW, valid for serial

no.325-xxx-xxxx

WIRING DIAGRAM

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WIRING DIAGRAM

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RoboFeed 3004HW & FeedControl 3004HW, valid for serial

nos.410-xxx-xxxx and 647-xxx-xxxx

WIRING DIAGRAM

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TECHNICAL DATA

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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/MAGwelding Gases for MIG/MAGwelding

- 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

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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

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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

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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", page31.

DESCRIPTION OF OPERATION

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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

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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

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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

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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

mounted together with the U8

, the W8

needs to be modified. There is an built in

terminating resistor that needs to disconnected. See the service manual for W8

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", page22.

DESCRIPTION OF OPERATION

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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.

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ESAB RoboFeed 3004HW FeedControl 3004HW User manual

Brand: ESAB

Model: RoboFeed 3004HW FeedControl 3004HW

Category: Welding System

Type: User manual

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ESAB RoboFeed 3004HW FeedControl 3004HW User manual

ESAB RoboFeed 3004HW FeedControl 3004HW User manual

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