ESAB Feed 4804 - Origo™ User manual

Brand: ESAB

Model: Feed 4804 - Origo™

Category: Welding System

Type: User manual

This manual is also suitable for

Aristo®, Origo™

Service manual

0740 800 181 GB 20161005

Valid for: serial no. 745-, 910-, 236-, 540-, 628-xxx-xxxx

Feed3004, Feed4804

TABLE OF CONTENTS

0740 800 181 © ESAB AB 2016

READ THIS FIRST........................................................................................... 3

INTRODUCTION.............................................................................................. 4

WIRING DIAGRAM.......................................................................................... 5

Component Description................................................................................ 5

Feed 3004, Feed 4804.................................................................................... 6

TECHNICAL DATA .......................................................................................... 8

DESCRIPTION OF OPERATION..................................................................... 9

1 MMC panel................................................................................................... 9

13AP1 Control board..................................................................................... 10

13AP1:1 Power supply ................................................................................ 11

13AP1:2 Start / Stop.................................................................................... 12

13AP1:3 Gas valve...................................................................................... 12

13AP1:4 Motor driving / braking .................................................................. 13

13AP1:5 Pulse generator input ................................................................... 14

13AP1:6 Monitoring the cooling water connection ...................................... 14

13AP1:7 Monitoring wire and gas ............................................................... 15

13AP1:8 The CAN bus ................................................................................ 15

13AP1:9 Arc voltage sensing ...................................................................... 16

13AP1:10 Push Pull & I/O ........................................................................... 17

13AP1 Component positions....................................................................... 18

CAN adapter option....................................................................................... 20

MiggyTrac, RailTrac..................................................................................... 20

Welding gun with pull motor ........................................................................ 21

Circuit board layout, CAN adapter and filter board...................................... 21

Connection instructions ............................................................................... 22

REMOTE CONTROLS ..................................................................................... 23

FAULT CODES ................................................................................................ 24

Fault log.......................................................................................................... 24

Summary of fault codes................................................................................ 24

Fault code description .................................................................................. 25

SERVICE INSTRUCTIONS.............................................................................. 27

What is ESD? ................................................................................................. 27

Service aid ..................................................................................................... 28

SPARE PARTS ................................................................................................ 29

Rights reserved to alter specifications without notice.

READ THIS FIRST

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READ THIS FIRST

Maintenance and repair work must 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 the "SPARE PARTS" chapter

in this manual.

This manual contains details of design changes that have been made up to and including

October 2015.

The manual is valid for:

Feed 4804 with serial no. 745-xxx-xxxx

Feed 3004 with serial no. 745-xxx-xxxx, 910-xxx-xxxx, 540-xxx-xxxx and 628-xxx-xxxx

CAUTION!

Read and understand the instruction manual before

installing or operating.

The Feed 3004 and Feed 4804 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.

INTRODUCTION

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INTRODUCTION

The Feed 3004 and Feed 4804 wire feed units are intended for use with power sources

equipped with CAN bus communication.

WIRING DIAGRAM

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WIRING DIAGRAM

Component Description

1 MMC panel Control panel. See the description in chapter "Description of

Operation".

13AP1 Main circuit board, with the control electronics. See the description in

chapter "Description of Operation".

13AP2 Circuit board, contact interfacing.

13C2 - 13C6 Capacitor, 0.1 µF.

13CXX Capacitor, 4700 µF. Must be fitted when the wire feed unit is used

under difficult applications (e.g. low mains voltage, long cables etc.).

13G1 Pulse generator (encoder). 1ncorporated in motor 13M1 or 13M2.

13M1 Feed 3004: Motor.

13M2 Feed 4804: Motor.

13M3 Feed 4804: Motor.

13S1 Micro-switch, cooling water supply connection monitoring.

13XP . . Plug connectors.

13XS . . Socket connectors.

13YV1 Solenoid valve.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

WIRING DIAGRAM

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Feed 3004, Feed 4804

WIRING DIAGRAM

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TECHNICAL DATA

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TECHNICAL DATA

Feed 3004 Feed 4804

Mains voltage 42 V 50-60 Hz 42 V 50-60 Hz

Power requirement 336 VA 378 VA

Motor current I

max

8 A 9 A

Wire feed speed 0.8 - 25.0 m/min 0.8 - 25.0 m/min

Torch connection EURO EURO

Max. diameter wire bobbin 300 mm (*440 mm) 300 mm (*440 mm)

Wire dimension

Fe 0.8 - 1.6 mm 0.8 - 2.4 mm

Ss 0.8 - 1.6 mm 0.8 - 2.4 mm

Al 1.0 & 1.6 mm 1.0 & 2.4 mm

Cored wire 0.9 - 1.6 mm 0.9 - 2.4 mm

Weight 15 kg 19 kg

Dimensions (l x w x h) 690 x 275 x 420 mm 690 x 275 x 420 mm

Operating temperature -10 to +40°C -10 to +40°C

Shielding gas All types intended for

MIG/MAG welding

All types intended for

MIG/MAG welding

max pressure 0.5 MPa ( 5 bar) 0.5 MPa ( 5 bar)

Coolant ESAB's ready mixed coolant ESAB's ready mixed coolant

max pressure 0.5 MPa ( 5 bar) 0.5 MPa ( 5 bar)

Maximum permissible load at

60% duty cycle 630 A 630 A

100% duty cycle 500 A 500 A

Enclosure class IP23 IP23

*Accessory

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 IP23 is intended for indoor and outdoor use.

DESCRIPTION OF OPERATION

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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.

1 MMC panel

The MMC panel consists of a control panel 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.

The wire feed unit is supplied with one of the following control panels:

The empty panel, for use with double wire feed units or

for use with an external control panel.

Empty panel

The U6 panel, with knobs for setting the voltage and the

wire feed speed / current. Other parameters are

controlled by push-buttons, with text in the display panel.

Control panel U6

The MA23 panel, with knobs for settings of voltage / wire

feed speed / current. Other settings by push-buttons, with

corresponding symbols on the display panel.

Control panel MA23

DESCRIPTION OF OPERATION

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The MA24 panel, with knobs for all settings of voltage /

QSet™ / Synergic welding / wire feed speed / current.

Other settings by push-buttons, with corresponding

symbols on the display panel.

Control panel MA24

The MA25 Pulse panel, with knobs for all settings of

voltage / QSet™ / Synergic welding / wire feed speed /

current. Other settings by push-buttons, with

corresponding symbols on the display panel.

Control panel MA25 Pulse

Detailed descriptions of the control panels can be found in separate manuals.

13AP1 Control board

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, see chapter "Service Instructions".

• The machine ID determines which motor type and wire feeder mechanism the board is

intended for.

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

• The unit type is used for identification on the CAN bus.

The ID numbers of the wire feeders are:

Feed 3004 Machine ID = 8 For serial number 745-xxx-xxxx

Feed 3004 Machine ID = 37 From serial number 910-xxx-xxxx (due to change of motor)

Feed 3004 Machine ID = 47 From serial number 540-xxx-xxxx (due to change of motor)

Feed 4804 Machine ID = 9

Hardware ID = 4

Unit type = 3 (wire feeder unit)

Changes to the circuit board

From serial no. 910-xxx-xxxx there are four spare part versions of the board:

• Non configured board, must be configured by ESAT.

• Configured for Feed 3004 with machine ID 8

• Configured for Feed 3004 with machine ID 37

• Configured for Feed 4804

DESCRIPTION OF OPERATION

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From serial no. 540-xxx-xxxx there are five spare part versions of the board:

• Non configured board, must be configured by ESAT.

• Configured for Feed 3004 with machine ID 8

• Configured for Feed 3004 with machine ID 37

• Configured for Feed 3004 with machine ID 47

• Configured for Feed 4804

From circuit board print number 487186-002 the supply to the brake circuit is changed, see

section "13AP1:4 Motor driving/braking". Component positions diagram with print number are

in section "13AP1 Component positions".

13AP1:1 Power supply

The wire feeder unit is supplied at 42 V from the control current power supply transformer in

the welding power source. The feeder unit can briefly draw up to about 9 A (the Feed 4804),

or up to about 8 A (the Feed 3004) when accelerating the wire.

DC supplies

Diodes D13 - D16 rectify the 42 V AC supply. The rectified voltage is used to power the wire

feeder motor(s). It also powers the switched voltage regulator. 1C21, 1C8, 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 1C22, 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 MMC panel displays fault code 9.

This fault does not disable any functions.

The +24 V is monitored by 1C12 and potential divider R129, R130, R180. If the voltage drops

to 18 V or less, 1C12 generates a warning signal to the processor, which responds by first

stopping the wire feed and then all communication on the bus. The MMC panel displays fault

code 4.

The +15 V is monitored by the processor and potential divider R152/R153. If the 15 V supply

drops below 13 V or exceeds 17 V, the MMC panel displays fault code 8. This fault does not,

however, disable any functions.

DESCRIPTION OF OPERATION

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13AP1:2 Start / Stop

The welding torch switch contact is supplied at 42 V AC.

Closing the switch contact activates optocoupler 1C7, pulling C47 low.

When gas pre-flow starts, wire feed also starts and the power source generates welding

voltage. If this is not followed by a flow of welding current within three seconds, the power

source shuts down the welding power supply, although wire feed continues until the welding

torch switch is released.

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 welding torch switch.

DESCRIPTION OF OPERATION

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13AP1:4 Motor driving / braking

Schematic diagram of the motor drive stage, the print numbers above refers to section

"13AP1 Component positions".

Driving

The motor is powered from the smoothed +60 V supply. Pulse-width modulation of transistor

Q4 varies the effective motor voltage. Pulse frequency is 39 kHz, and the maximum

conduction period is 99 % of the pulse period. Freewheel diode D27 provides current path

during the pulse off periods.

Feed 3004: The feed roller speed at the maximum wire feed speed of 25 m/min is 273 r/min.

Feed 4804: The feed roller speed at the maximum wire feed speed of 25 m/min is 167 r/min.

Current monitoring

Resistor R114 generates a voltage signal proportional to motor current. This voltage is

applied to potential divider R105/R106 and the output is compared with a reference voltage

at voltage comparator 1C14:11. The reference voltage is provided by the microprocessor via

R104.

The current limit is 20 A on starting. After one second, this is reduced to 8 A for the Feed

3004 and 15 A for the Feed 4804. The current limit is related to the pulse peak current.

If the current exceeds the current limit, 1C14:2 interrupts the gate pulse to Q4. 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 5.1 seconds. The MMC panel displays fault code 11.

DESCRIPTION OF OPERATION

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From software version 3.13A (ser.no. 910-xxx-xxxx) the max speed deviation is ±0.9 m/min.

Braking

Capacitor C67 is charged via diode D31 when the motor starts. Zener diodes D33 and D34

limit the voltage to 16 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.

13AP1:5 Pulse generator input

The pulse generator, 13G1, is fitted to drive motor 13M1 (Feed 3004), or 13M2 (Feed 4804).

It generates 60 pulses per revolution, which means that, at a wire feed speed of 25 m/min,

the pulse frequency is 6552 Hz in the Feed 3004 and 8192 Hz in the Feed 4804.

From serial no. 910-xxx-xxxx: the pulse frequency for the Feed 3004 is 10230 Hz, at a wire

feed speed of 25 m/min.

13AP1:6 Monitoring the cooling water connection

The wire feed unit with water connection is equipped with a detection system ELP (ESAB

Logic Pump) which checks that the water hoses are connected. When connecting a

water-cooled welding torch, the water pump starts.

Micro-switch 13S1 senses whether a water-cooled welding torch is connected to the wire

feed unit: a closed switch indicates that the cooling water hoses are connected, and so

provides a Start Enable signal to the system for the water pump.

The resistors connected to input E3 form a potential divider of the 15 V supply, to produce

about +6 V for an open input.

DESCRIPTION OF OPERATION

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13AP1:7 Monitoring wire and gas

Circuit board 13AP1 is prepared for future monitoring of wire and gas supply. The MMC

panel displays a fault code if either of the inputs is closed.

Fault code 27 = out of wire. Fault code 32 = no gas flow.

13AP1:8 The CAN bus

The circuit board includes a driver for the CAN bus, 1C2, which looks after communication

with the MMC panel and with other units in the system.

Although the welding power source supplies a +12 V power supply to the MMC panel, this is

not used on circuit board 13AP1. 0 V on the circuit board is connected to 0 V in the MMC

panel.

DESCRIPTION OF OPERATION

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Starting sequence

0n power-up, the board's CAN controller reads in 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 MMC panel displays fault codes 12 and/or 14 if communication between the panel and

the wire feed unit or power source fails.

Check the following points in the event of problems with the CAN communication:

• The connection of the termination resistors, see the instructions in the service manual

for the power source.

• The control cable:

Check that the correct type of cable is being used, i.e. the same as that 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 screen connections are sound.

• The feed unit: Check that there is good contact at the connections to capacitors 13C2

and 13C3. See the main wiring diagram in chapter "Wiring Diagram".

• The power source: Check that there is good contact with the chassis connection to 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.

13AP1:9 Arc voltage sensing

In order to avoid spurious volt drops when measuring the welding arc voltage, the power

source senses the arc voltage via the filler wire and the feeder unit motor.

DESCRIPTION OF OPERATION

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13AP1:10 Push Pull & I/O

Terminals D, J, X and G and are used for the manual push pull, mechanized push pull,

MiggyTrack and RailTrack options: see section "CAN adapter options".

Terminal BA is for present not used for any standard options.

DESCRIPTION OF OPERATION

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13AP1 Component positions

Control board 0487 187 88x with print number 487186-001

DESCRIPTION OF OPERATION

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Control board 0487 187 8xx with print number 487186-002

DESCRIPTION OF OPERATION

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CAN adapter option

The CAN adapter option is used when MiggyTrac, RailTrac or a welding gun with pull motor

is connected to the wire feeder.

Connection instructions for the option are included in the delivery. There is a copy of the

instructions in section "Connection instructions".

The adapter board has a software identity, machine ID. The ID defines how the welding

equipment reacts on the commands from the connected equipment. The CAN adapter

options are delivered with correct machine ID. Spare part boards are delivered without

machine ID. To read or change the machine ID you need the ESAT service kit, see chapter

"Service Instructions".

The CAN adapter board has a built-in terminating resistor. The resistor is disconnected on

delivery of this option. In most operating cases it should be disconnected. It can however be

connected by a jumper over terminal J1 on the CAN adapter board. See the component

position diagram in section "Circuit board layout, CAN adapter and filter board".

MiggyTrac, RailTrac

Can adapter board, filter board and cable set connected to the control board of the wire

feeder

Adapter option for MiggyTrac / RailTrac 0459 681 880

The adapter board is delivered with machine ID 2.

Switch 13S2 is used for activating / deactivating the external control functions. When the

switch is in position B, the external controls are active and the control panel of the feeder is

inactive. In position A the control panel is active and the external controls inactive.

If the wire feeder is controlled by an U8, switch 13S2 has to be in position B. Then external

or internal control can be selected by the U8.

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ESAB Feed 4804 - Origo™ User manual

Brand: ESAB

Model: Feed 4804 - Origo™

Category: Welding System

Type: User manual

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ESAB Feed 4804 - Origo™ User manual

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