ESAB MechControl 4 User manual

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

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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 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

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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.

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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.

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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.

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MechControl 2

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MechControl 4

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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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