Origo™
Service manual
0740 800 182 GB 20161017
MA23, MA24, MA25 Pulse
TABLE OF CONTENTS
0740 800 182 © ESAB AB 2016
READ THIS FIRST........................................................................................... 3
INTRODUCTION.............................................................................................. 4
WIRING DIAGRAM.......................................................................................... 5
DESCRIPTION OF OPERATION..................................................................... 6
Self-test .......................................................................................................... 6
1AP1 Welding data board ............................................................................. 6
1AP1:1 Power supply .................................................................................. 7
1AP1:2 Communication............................................................................... 7
1AP1:3 LED and display control.................................................................. 8
1AP1:4 Pushbutton monitoring.................................................................... 10
1AP1:5 Encoder monitoring ........................................................................ 13
1AP1 Component positions......................................................................... 15
FAULT CODES ................................................................................................ 16
Fault log.......................................................................................................... 16
Fault codes..................................................................................................... 16
Summary of fault codes................................................................................ 16
Fault code description .................................................................................. 17
SERVICE INSTRUCTIONS.............................................................................. 20
What is ESD? ................................................................................................. 20
Service aid ..................................................................................................... 20
SPARE PARTS ................................................................................................ 22
Rights reserved to alter specifications without notice.
READ THIS FIRST
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© ESAB AB 2016
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”, page22.
This manual contains details of design changes that have been made up to and including
June 2016.
The MA23, MA24 and MA25 Pulse are designed and tested in accordance with international
and European standard 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
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© ESAB AB 2016
INTRODUCTION
This manual describes the control panels, MA23, MA24 and MA25 Pulse for MIG/MAG- and
MMA welding. MA24 and MA25 Pulse includes features like QSet™ and synergic welding by
comparison with MA23.
Each control panel consists of an operator's control panel, a display board 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.
MA23 MA24 MA25 Pulse
Pushbuttons are used for parameter selection and knobs for parameter settings (voltage,
wire feed speed/welding current, time etc.).
More control panel information is found in the Instruction manual.
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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© ESAB AB 2016
WIRING DIAGRAM
The MMC module consists of three main units:
• 1AP1 Welding data board - Processor and CAN communication board
• 1AP2 Display board - Display and encoder board
• 1AP3 Control panel - Operators control panel with push-buttons and LEDs
Wiring diagram for the MMC units MA23, MA24 and MA25 Pulse
DESCRIPTION OF OPERATION
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© ESAB AB 2016
DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components in
the MMC module. It is divided into sections, numbered to correspond to the circuit board
numbers and divisions into function blocks.
Self-test
When mains power is switched on the welding data unit runs a self diagnostic program test.
1. Internal RAM memory is checked by a read/write test of each memory position. If the
test detects a fault, fault code E2 will be logged.
2. The program memory of the welding data unit is checked by a check-sum test. If the
test detects a fault, fault code E1 will be logged.
3. LED test, display test and software version indication are enabled by visual inspection
• The LED test starts with all LEDs dark, then the diodes are turned on and off, one
at a time, until all diodes have been tested. If the test detects a fault, no fault code
will be logged.
• Then the display test is made in the same way as the LED
test but for each segment of the digits in the display. If the
test detects a fault, no fault code will be logged.
• Finally the software version is displayed, and in this example
the version is 0.17A
1AP1 Welding data board
Circuit board identity
The welding data board has an equipment ID, a hardware ID and a unit type number. To read
this you need the ESAT service tool, see “Service aid”, page20.
• The equipment ID defines which type of control panel the board is intended for. If the
board is to be used for another type of control panel, the equipment ID can be changed
by ESAT.
• The hardware ID shows design and type of circuit board.
• The unit type is used for identification of the board on the CAN bus.
The ID numbers of the welding data boards are:
MA23 equipment ID = 17
MA24 equipment ID = 28
MA25 Pulse Al equipment ID = 48
MA25 Pulse Steel equipment ID = 49
MA25 Pulse Al - NA equipment ID = 51
MA25 Pulse Steel - NA equipment ID = 52
Hardware ID = 3
Unit type = 0
DESCRIPTION OF OPERATION
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© ESAB AB 2016
1AP1:1 Power supply
Circuit board 1AP1 receives a 12 V power supply from the control board in the power source.
This is regulated to 5 V, which supplies all the circuits of the control panel. The 12 V and 5 V
supplies are monitored by a reset circuit: tolerance values are 12 V +2/-3 V and 5 V ±0.25 V.
Monitoring the voltages makes sure that, in the event of loss of power, the processor has
time to save the current data and to shut down the current processes in a controlled manner.
Loss of power supply does not generate a fault code on the display. If the 12 V supply drops
below 9 V, either momentarily or indefinitely, but does not fail entirely, the display will show
fault code 4. The equipment must be turned off, and then on again, to reset the system.
To store data which need to be saved even if the power supply is switched off, there is a
persistent flash memory area included in the processor. Data are saved in this memory when
the mains power supply is turned off or lost.
Circuit diagram for power supply and CAN bus
1AP1:2 Communication
Communication between the control panel and other units is via the system's CAN bus.
Resistor R3 is the terminating resistor (120 Ω) for the bus.
Read more about the CAN bus in the service manual for the power source.
Starting sequence
At power-up, the board's micro processor sets the bus speed for the CAN controller to
400kbit/s.
The welding data board displays the starting sequence from power-up.
First LED1 lights red, then LED1, LED2 and LED3 lights green.
When the board has been initiated, and the power source is in the application program,
LED1 flashes continously with a green light.
DESCRIPTION OF OPERATION
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© ESAB AB 2016
LEDs on welding data board 1AP1
1AP1:3 LED and display control
The panel board includes LEDs for visual indication. Besides LEDs the panel has a window
for a LED-display in two rows (DY1 and DY2) showing three digits in each row. Display
contrast cannot be adjusted. Both LEDs and the display are matrix connected and they are
function tested at power on.
Component positions for 1AP3 control panel MA23
DESCRIPTION OF OPERATION
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© ESAB AB 2016
Component positions for 1AP3 control panel MA24
Component positions for 1AP3 control panel MA25 Pulse
The component positions diagram for 1AP2 is in “1AP1:5 Encoder monitoring”, page13.
The component positions diagram for 1AP1 is in “1AP1 Component positions”, page15.
DESCRIPTION OF OPERATION
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© ESAB AB 2016
Circuit diagram for LEDs and display
1AP1:4 Pushbutton monitoring
The panel board includes matrix connected pushbuttons. Input A23 (MA23) or A21 (MA24)
on the display board 1AP2 is, in series with transistor Q5, used for control panel
identification.
DESCRIPTION OF OPERATION
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© ESAB AB 2016
Component positions for 1AP3 control panel MA23
Component positions for 1AP3 control panel MA24
DESCRIPTION OF OPERATION
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© ESAB AB 2016
Circuit diagram for pushbutton monitoring
1AP1:5 Encoder monitoring
The panels have pulse generators (encoders) for setting the welding voltage and wire feed
speed, with pushbuttons for other functions. Turning the voltage adjustment pulse generator
(SW2) briefly connects contact 2 (0 V) to contacts 1 and 3, but with a slight time difference
between them. This generates pulses that are displaced by about 90° relative to each other.
One square wave pulse is used as clock frequency and the other square wave pulse defines
the knob-turning direction by comparing the phase position (positive or negative) compared
to the clock frequency.
The wire feed speed pulse generator (SW1) operates in the same way.
DESCRIPTION OF OPERATION
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© ESAB AB 2016
Wiring diagram for encoder monitoring. Voltage and wire feed speed / current settings
Component positions for 1AP2 display board
DESCRIPTION OF OPERATION
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© ESAB AB 2016
1AP1 Component positions
Component positions for 1AP1 welding data board
FAULT CODES
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© ESAB AB 2016
FAULT CODES
Fault log
All faults that occur when using the welding equipment are documented as error messages.
When the fault log is full, the oldest message will automatically be erased when the next fault
occurs.
Only the most recent fault message is displayed on the control panel. To read the entire fault
log, the equipment must be connected to the ESAT service tool, see “Service aid”, page
20.
Faults are monitored/detected in two ways: by test routines that are run on initiation and by
functions that can detect a fault when it occurs.
Fault codes
The control panel displays a unit number to indicate which unit has generated the fault. The
following unit numbers are used:
U0 = Welding data unit U2 = power source
U3 = wire feed unit U4 = remote control unit
Fault codes are used to indicate that a fault has occurred in the equipment.
They are given in the lower part of the display with an E followed by a fault
code number.
A unit number is displayed to indicate which unit has generated the fault.
Fault code numbers and unit numbers are shown alternately.
Example: Fault indication indicates that the control panel (U 0) has lost
contact with the power source (E 18).
If several faults have been detected only the code for the last occurring
fault is displayed. Press any function button or turn any knob to remove the
fault indication from the display.
NOTE!
If the remote control is activated, deactivate the remote control by pressing
to erase the fault indication.
Summary of fault codes
Fault
code
Description Welding
data unit
Power
source
Wire
feed unit
Remote
control
unit
*1 Memory error, EPROM X X X X
*2 Memory error, internal RAM X X X
3 Memory error, external RAM X X X
4 Power supply +5 V X X X
5 Intermediate DC voltage too high/low X
6 High temperature X
*8 Power supply 1 X X X
FAULT CODES
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© ESAB AB 2016
Fault
code
Description Welding
data unit
Power
source
Wire
feed unit
Remote
control
unit
*9 Power supply 2 X X X
*10 Power supply 3 X
11 Wire feed speed X
12 Communication error (warning) X X X X
14 Communication error (bus off) X
15 Lost messages X X X
16 High open-circuit voltage X
17 Lost contact with the wire feed unit X
18 Lost contact with the power source X
19 Incorrect setting values in external RAM
memory
X
*22 Transmitter buffer overflow X X X
*23 Receiver buffer overflow X X X
26 Program operating fault X X
27 Out of wire X
*28 Stack overflow X X X
29 No cooling water flow X
32 No gas flow X
40 Incompatible units X
41 Lost contact with the cooling unit X
Fault codes marked with an asterisk ( * ) are not displayed by the control panel. but they are
stored in the fault log. To get access to the fault log use the ESAT service tool. See “Service
aid”, page20.
Fault code description
This manual describes the fault codes for the welding data unit. The fault codes for the other
units are described in the manuals for these units.
FAULT CODES
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© ESAB AB 2016
Fault
code
Description
*1 EPROM check sum error - program memory error
This indicates a fault in the check sum test of the program memory, which is run
only when initiating the unit after power-up. This fault does not disable any
functions.
The program memory is damaged. This is a serious fault, that can have
unforeseen effects.
Action: Restart the equipment. If the fault persists, load new software via ESAT.
If the fault still persists, replace circuit board 1AP1.
*2 Microprocessor RAM error
The microprocessor is unable to read/write from/to a particular memory address
in its internal memory. This test is performed only as part of initiation after
power-up. This fault does not disable any functions.
Action: Restart the equipment. If the fault persists, replace circuit board 1AP1.
3 Error in the external RAM
Read/write test of the external RAM of the processor. This test is performed only
on initiation after power-up.
The microprocessor is unable to read/write from/to a particular memory address
in its external memory. This fault does not disable any functions.
Action: Restart the equipment. If the fault persists, replace circuit board 1AP1.
4 5 V power supply too low
The unregulated power supply voltage for the processor is too low: the smoothing
capacitors cannot keep the voltage up enough for the processor to continue to
operate. The processor stops all normal activities, expecting to be shut down.
Action: Turn off the mains power supply to reset the unit. If the fault persists,
check the power supply to circuit board 1AP1.
12 Communication error (warning)
The load on the system's CAN bus is temporarily too high.
Action: Check the equipment to ensure that only one wire feed unit and/or
remote control unit is connected.
14 Communication error (bus off)
The system's CAN bus has temporarily ceased to work due to excessive load.
The current welding process is stopped.
Action: Check the equipment to ensure that only one wire feed unit and/or
remote control unit is connected. Turn off the mains power supply to reset the
unit.
15 Lost messages
The bus CAN controller indicates that a message has been lost. No functions are
disabled by this fault.
Action: Check that all units are correct connected to the CAN bus.
17 Lost contact with the wire feed unit
Current activities will be stopped: see Fault Code 18.
This fault can be caused by a break in the connection (i.e. the CAN cable)
between the wire feed unit and the control panel.
Action: Check the CAN cabling.
FAULT CODES
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© ESAB AB 2016
Fault
code
Description
18 Lost contact with the power source
Current activities will be stopped and welding start is prevented.
This fault can be caused by a break in the connection between the welding data
unit in the control panel and the control unit in the power source.
Action: Check the CAN cabling.
19 Memory error in data memory
Information in persistent data memory is incorrect. Basic data will be used.
Action: This fault corrects itself. Turn off the mains power supply to reset the
unit. Stored data in the current memory section will be lost. If the fault recurs
each time the unit is started, there is a fault in the persistent memory. Replace
the welding data board, 1AP1, in the control panel.
*22 Transmitter buffer overflow
The welding data unit is unable to transmit information to the other units at a
sufficiently high speed.
Action: A break in the bus line can cause this fault. Check the CAN cabling. Turn
off the mains power supply to reset the unit.
*23 Receiver buffer overflow
The welding data unit is unable to process information from the other units at a
sufficiently high speed. This fault is caused by abnormal loading of the
microprocessor in the welding data unit.
Action: Turn off the mains power supply to reset the unit.
26 Program operating fault
Something has prevented the processor from performing its normal program
duties. The program restarts automatically. The current welding process will be
stopped. This fault does not disable any functions.
This fault should not happen. Contact ESAB if the fault yet occurs.
*28 Stack overflow
The program execution does not work.
This fault should not happen. The fault code is intended as an aid during
development work. Contact ESAB if the fault yet occurs.
29 No cooling water flow
The flow monitor has tripped.
The current welding process is stopped and starting is prevented.
Action: Check the cooling water circuit and the pump.
40 Incompatible units
Incorrect wire feed unit is connected. Start is prevented.
Action: Connect the correct wire feed unit.
41 Lost contact with the cooling unit
The control panel has lost contact with the cooling unit. Switch off the power
source.
This fault can be caused by a break in the connection between the welding data
unit in the control panel and the control unit in the cooling unit.
Action: Check the CAN cabling.
SERVICE INSTRUCTIONS
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© ESAB AB 2016
SERVICE INSTRUCTIONS
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling
electrostatic-sensitive devices.
• Use proper static-proof bags and boxes.
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD stands
for Electrostatic Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components, but is not dangerous to people.
ESD damage occurs when an ungrounded person or object with a static charge comes into
contact with a component or assembly that is grounded. A rapid discharge can occur,
causing damage. This damage can take the form of immediate failure, but it is more likely
that system performance will be affected and the component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static electricity is prevented from building
up on you or on anything at your work station, then there cannot be any static discharges.
Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static
charge, so you should not bring unnecessary nonconductive items into the work area. It is
obviously difficult to avoid all such items, so various means are used to drain off any static
discharge from persons to prevent the risk of ESD damage. This is done by simple devices:
wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only antistatic
packaging materials. Overall, handling of ESD-sensitive devices should be minimized to
prevent damage.
Service aid
We can offer a number of service tools that will simplify the service.
Antistatic service kit
Ordering no. 0740 511 001
The kit makes it easier to protect sensitive
components from electrostatic discharge.
Contents:
• A conductive mat (size 610x610mm /
24×24in.)
• A 1.5 metre (3.28 ft) long ground cable
with a crocodile clip
• An adjustable wrist strap and cable with an
inbuilt protective resistor
Antistatic service kit
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ESAB MA25 Pulse User manual
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