ESAB MechControl 4 User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
0740 801 023 Valid for serial no. 652-xxx-xxxx to 049-xxx-xxxx110504
MechControl 2
MechControl 4
Aristo
Service manual
- 2 -TOCe
Rights reserved to alter specifications without notice.
READ THIS FIRST 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MechControl 2 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MechControl 4 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Control unit 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upgrading of softwares 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1 Control panel WO 100 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP2 Printer 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections to the printer 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of the printer 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1 Power supply to motor & control units 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1:1 24V_A & 5V_A 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1:2 30V_C 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1:3 5V_B 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1:4 Auxiliary circuit for multi function control 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1 Component positions 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1 Sequence controller & welding data unit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1:1 Power supply 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery backup 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1:2 CAN bus 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1:3 RS232 to printer & WMS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1:4 Communication with the MMC unit 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1 Component positions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1 I/O board 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:1 Power supply 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:2 CAN bus 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:3 Stop 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:4 Cooling water connection monitoring 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:5 Gas flow monitoring 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:6 Torch switch 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:7 Gas valves 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1 Component positions 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 Motor control & drive 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1 Motor drive 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1:1 Power supply 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1:2 Rotation motor drive 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1:3 Wire feed motor drive 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1 Circuit board versions 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1 & 26AP4 Component positions 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2 Motor control 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:1 Power supply 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:2 CAN bus 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware reset 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:3 Rotation feedback 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:4 Wire feed feedback 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 3 -TOCe
Rights reserved to alter specifications without notice.
26AP2:5 Digital input 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2 & 26AP5 Component positions 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP3 & 26AP6 Filter board 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP3 & 26AP6 Component positions 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP4 Motor drive 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP4:1 Power supply 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP4:2 Weaving motor drive 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP4:3 AVC motor drive 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP5 Motor control 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare part boards 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP5:1 Power supply 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP5:2 CAN bus 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP5:3 Weaving feedback 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVENT LOG 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code description 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of event codes 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding data unit 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor control 1 & motor control 2 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O board 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service aid 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change unit type of motor control 26AP5 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suspension device 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the terminating resistor 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas flow meter 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USB connection 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water connection 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow guard, gas 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the paper roll 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol explanations 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S0740 801 023/E110504/P68
© ESAB AB 2007
- 4 -
cp01_00
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 diagrams 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 page 66.
This manual contains details of all design changes that have been made up to and
including April 2011.
The manual is valid for:
MechControl 2 and MechControl 4 with serial no. 652-xxx-xxxx, 049-xxx-xxxx.
The MechControl 2 and MechControl 4 are designed and tested in accordance with
international and European standards IEC/EN 60974.
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
MechControl 2 and MechControl 4 are control units intended for mechanized TIG welding
together with the welding power sources MechTig 4000i and MechTig 3000i.
The communication between most of the units of the MechControl is carried out by a CAN
bus (Controller Area Network).
Block diagram of the MechControl
S0740 801 023/E110504/P68
© ESAB AB 2007
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cp01_00
TECHNICAL DATA
MechControl 2 & MechControl 4
Mains voltage 42 V, 50/60 Hz
Wire feed speed See separate instruction manual for wire feed unit
Rotation speed See separate instruction manual for tool
Dimensions l x w x h 471 x 403 x 364 mm
Weight
MechControl 2
MechControl 4
17.4 kg
18.4 kg
Shielding gas
Max pressure
All types intended for TIG welding
0.5 MPa ( 5 bar)
Type of cooling
Max pressure
50 % water / 50 % mono-ethylene glycol
0.5 MPa ( 5 bar)
Enclosure class IP 23
Application class
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 designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
S0740 801 023/E110504/P68
© ESAB AB 2007
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cp01_00
WIRING DIAGRAM
The equipment is based on a number of function modules. These are described in the
component descriptions on the following pages. Wire numbers and component names in
the wiring diagram show to which module each component belongs.
Wires/cables within modules are marked 100 - 6999.
Circuit boards within each module have names such as 20AP1 - 20AP99.
15 = module association, 1-69
AP = circuit board
1 = individual identification number, 0-99
Components within modules are named in a similar way.
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
Component description
1AP1 Display panel (MMC panel).
1AP2 Printer.
1AP3 Pushbuttons.
1AP4 Encoder.
2AP1 Power supply board. See page 20.
10YV1 Gas valve, 42 V AC, controlled by the I/O board, see page 31.
10YV2 Gas valve, 42 V AC, controlled by the I/O board, see page 31.
10YV3 Gas valve, 42 V AC, controlled by the I/O board, see page 31.
10S1 Gas flow sensor, see page 30.
5S2 ELP, cooling water connection monitoring, see page 30.
7L1 Ferrite ring cores. One ferrite ring core is fitted to each one of the CAN cables.
23AP1 Sequence controller and welding data unit. See page 23.
24AP1 I / O board. See page 28.
26AP1 Power board, motor drive. See page 33.
26AP2 Controller circuit board, motor drive. See page 39.
S0740 801 023/E110504/P68
© ESAB AB 2007
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cp01_00
26AP3 Filter circuit board, motor drive. See page 44.
26AP4 Power board, motor drive. See page 45.
26AP5 Controller circuit board, motor drive. See page 50.
26AP6 Filter circuit board, motor drive. See page 44.
26BR1 Rectifier bridge. 42 V AC ----> 60 V DC
26R1 Charge resistor.
S0740 801 023/E110504/P68
© ESAB AB 2007
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cp01_01
DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components.
It is divided into sections, numbered to correspond to the circuit board numbers and
divisions into function blocks.
1 Control unit
Upgrading of softwares
The MechTig system differs from other ESAB systems in that it has a graphical user
interface. Hence the system can not be handled in the same way as the other systems
regarding software upgrade.
System overview
PS Power source Internal in MechTig C2002i, external in MechControl 2 and
MechControl 4.
Software upgrade via ESAT.
IO IO module Internal hardware module.
Software upgrade via ESAT.
MCA Motor controller Internal hardware module. 1 or 2 modules depending on number of
axis.
Software upgrade via ESAT.
WDA Welding data unit Internal hardware module. This module resides the CompactFlash
memory card.
Software upgrade via ESAT.
CF CompactFlash card Removable CompactFlash card.
The CompactFlash card must manually be removed from the WDA
card and get the software replaced on a PC. See below for detailed
description.
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USB Interface for USB
memory stick
This interface communicates with the display computer.
Can be used for program installation (EMMA and image), saving
user defined programs and Q-data logs.
EMMA Computer with
Windows applica
tion
EMMA is the Windows application for managing the MechTig
system.
Software upgraded via the USB port
Image Windows image A software that includes the operating system configured for
MechTig.
Software upgrade via the USB port.
Update following programs via ESAT
MCA
WDA
IO
WPS, Power source
Change the bus speed to 500 kbit/sec before you start to upgrade.
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Update EMMA via USB
For this procedure you need a PC an a USB memory stick.
Get the installation package for the desired EMMA version. This package contains all files
needed to upgrade the EMMA application with a USB memory.
1. Unpack the package if it comes as a zip file
2. The file structure should look like this:
3. Copy the directory (with all included files) to the USB memory. The structure on the
USB memory should be the same as above.
4. Put the USB memory in the USB connector on the machine (on the left side below the
screen).
5. Start the system and press the Menu button while booting
6. When message ”Installation script found...” follow the instructions on the screen
7. Click Next...
8. Restart the system and check the login view that the system has been upgraded.
You will now have a system with the EMMA application upgraded.
Note! It is recommended to always use a dedicated ”clean” USB memory to avoid problems
with virus etc.
Note! You can't use the same launcher.commands.xml as for EMMA installation for this
image upgrade, they are different and you need the right one for each program.
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Update image via USB
See description above for a brief explanation on “image”. This installation must be followed
by an EMMA installation.
For this procedure you need a PC an a USB memory stick.
Get the installation package for the desired image version. This package contains all files
needed to upgrade the image with a USB memory.
1. Copy the included files, FormatCF.exe, NK.bin and the
Launcher.commands.xml to the USB memory (root directory)
2. The file structure should look like this:
3. Put the USB memory in the USB connector on the machine. (Below the screen on the
left side.)
4. Start the system and press the Menu button while booting.
5. When message ”Installation script found...” follow the instructions on the screen.
6. Click Next...and let the installation proceed. This will take aprox 5 min.
7. Restart the system. The system will now say ”Could not launch EMMA”. This is correct.
Now the system must get an installation of EMMA. See the section above for this
procedure.
Note! It is recommended to always use a dedicated ”clean” USB memory to avoid problems
with virus etc.
Note! You can't use the same launcher.commands.xml as for EMMA installation for this
image upgrade, they are different and you need the right one for each program.
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Update CompactFlash card.
For this procedure you need a PC with a CompactFlash card reader.
The CompactFlash card is a removable memory card for ESAB defined programs, Qdata
logs, tooldata and auto programming information. User defined programs are not stored on
the CompactFlash card.
Location of the CompactFlash card
1. Open the MechTig C2002i or MechControl and take out the CompactFlash card. The
card is located behind the front screen, see the picture above. Insert the CompactFlash
card in a card reader and change content to the new one.
2. The content of the CompactFlash should be like this:
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3. The content of the ftpsrv directory should be like this:
Note! The file vssver.scc is optional (not needed on the system) and not present on all
installations.
4. Reinstall the CF card in the machine and close the MechTig C2002i or MechControl.
5. Reboot the machine.
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1AP1 Control panel WO 100
See the separate instruction manual for a detailed description of the control
panel.
Cleaning
To ensure proper and reliable functionality over time, the unit shall be wiped
cleaned of dirt and dust. Use a suitable light damp rag to clean the unit.
CAUTION!
Never use alkaline, alcoholic or other chemicals for cleaning which
can damage the unit.
Connections to the rear side of the panel
No. Description Connected to
X1 Power supply 2AP1:CN3
X2 Ethernet 23AP1:CN4
X5 MISC -COM, Digital In and/or 2AP1:CN5
X8 USB 1 XS10 USB
X9 USB 2, not used not connected
Rear view of the control panel
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1AP2 Printer
The printer is a thermal printer. If the printer is faulty the entire printer has to be
replaced.
Connections to the printer
There are two cables connected to the printer: the RS232 data connection
from the welding data unit and the power supply from power board 2AP1.
Rear view of the printer
Removal of the printer
The printer is secured to the front panel by the “Easylock” fixing system.
To remove the fixing hook: use a flat screwdriver to lift the flap (1) and at the
same time take away the hook (2).
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2AP1 Power supply to motor & control units
The board produces three output voltages generated by switched voltage regulators:
+5V_A, +24V_A and +5V_B. There is also an unregulated output voltage, +30V_C.
The A, B and C voltages are galvanic separated from each other.
2AP1:1 24V_A & 5V_A
Voltage Tolerance Maximum current at 40_C
5V_A +5 V $0.25 V 0.5 A
24V_A +24 V $1 V 1.0 A
2AP1:2 30V_C
Voltage Tolerance Maximum current at 40_C
30V_C +30 V $4.0 V 0.3 A
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ESAB MechControl 4 User manual
- Category
- Welding System
- Type
- User manual
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