ESAB A33 User manual

0740 800 187 20120710

Caddyt

A32, A33, A34

Service manualService manual

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Rights reserved to alter specifications without notice.

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

INTRODUCTION 3...................................................................

WIRING DIAGRAM 4.................................................................

DESCRIPTION OF OPERATION 5.....................................................

Self-test 5........................................................................

Circuit board identity 5............................................................

Display board and control panel board 6...........................................

1AP2:1 LEDs and display control 6.................................................

1AP2:2 Pushbutton monitoring 8...................................................

1AP2:3 Encoder monitoring 10.....................................................

FAULT CODES 11....................................................................

Fault log 11........................................................................

Fault codes 11.....................................................................

Summary of fault codes 12.........................................................

Fault code description 13...........................................................

SERVICVICE INSTRUCTIONS 15.......................................................

What is ESD? 15...................................................................

Service aid 16......................................................................

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READ THIS FIRST

Maintenance and repair work should be performed by an experienced person, and

electrical work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit

board is divided into numbered blocks, which are described individually in more detail in

the description of operation.

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

January 2009.

The A32, A33 and A34 panels 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

This manual describes the Caddytcontrol panels; A32, A33 and A34.

These panels are intended for MMA welding and DC TIG welding without pulsing but with

“Live TIG-start”

Each control panel consists of an operator's control panel and a display board.

The power source control board has a microprocessor for control. The control panel is

connected with a cable to this board and used for setting and displaying welding data.

Welding data are stored by the power source control board.

A32 A33 A34

Pushbuttons are used for parameter selection and one knob for parameter settings (current,

time etc.).

More control panel information is found in chapter Instructions, see page NO TAG.

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WIRING DIAGRAM

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

The MMC module consists of two main units:

S 1AP2 Display board - Display and encoder board

S 1AP3 Control panel - Operators control panel with knob, push-buttons and LEDs

Wiring diagram for the MMC unit

Control board 20AP1 is not included in the operators panel, but is a part of the power

source. For that reason it is shown with a dot broken line in the diagrams

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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.

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

S 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.

S 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.

S Finally the software version of the welding data unit is

displayed, and in this example the version is 0.18

Circuit board identity

The control board 20AP1, is located in the power source. It can be divided in two parts, the

control part which controls the power source and the welding data part which contains

welding data. Each part has a machine ID, a hardware ID and a unit type number. To read

them you need the ESAT service tool, see page 16.

S The machine ID defines which type of power source/control panel the board is intended

for. If the board is to be used for another type of welding equipment, the machine ID

can be changed by ESAT.

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

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

Note! The ID numbers for the control board/welding data unit are found in the service

manual for the power source.

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Display board and control panel board

1AP2:1 LEDs and display control

The panel board includes LEDs for visual indication. The panel has a window

for a three digit LED-display (DY1). Display contrast cannot be adjusted. Both

LEDs and the display are matrix connected and they are function tested at

power on.

Wiring diagram for LEDs and display

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Component positions for 1AP3 control panel A32

Component positions for 1AP3 control panel A33

Component positions for 1AP3 control panel A34

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1AP2:2 Pushbutton monitoring

The panel board includes matrix connected pushbuttons. Inputs A23, A24, A29

and A30 on the display board, 1AP2, are used for control panel identification.

Wiring diagram for pushbutton monitoring and control panel identification.

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Component positions for 1AP3 control panel A32

Component positions for 1AP3 control panel A33

Component positions for 1AP3 control panel A34

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1AP2:3 Encoder monitoring

The panels have a pulse generator (encoder) for setting welding current, time

etc. Other settings are made with pushbuttons. Turning the encoder (SW1)

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.

Wiring diagram for encoder monitoring. Voltage, current and time settings

Component positions for the display board

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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 page 16.

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

U4 = Remote control unit

Fault codes are used to indicate that a fault has occurred in the

equipment. They are displayed with an E followed by a 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 welding data unit (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 remove the fault indication.

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Summary of fault codes

Fault

code

Description Welding

data

unit

Power

source

Remote

control

unit

*1 Memory error, EPROM x x x

*2 Memory error, internal RAM x x

3 Memory error, external RAM x

4 Power supply +5 V x

5 Intermediate DC voltage too high/low x

6 High temperature x

7 High temperature x

*8 Power supply 1 x x

*9 Power supply 2 x x

*10 Power supply 3 x

12 Communication error (warning) x x x

14 Communication error (bus off) x

15 Lost messages x x x

16 High open-circuit voltage VRD x

18 Lost contact with the power source x

19 Incorrect setting values in external RAM memory x

20 High inductance in the welding circuit x

*22 Transmitter buffer overflow x x

*23 Receiver buffer overflow x x

26 Program operating fault x x

*28 Stack overflow x 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

page 16.

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Fault code description

This manual describes the fault codes for the welding data unit, which is a part of control

board, 20AP1, in the power source. The fault codes for the other units are described in the

manuals for these units.

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 at power on. 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 machine. If the fault persists, load new software via ESAT. If the fault

still persists, replace circuit board 20AP1.

*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 at power on. This fault does

not disable any functions.

Action: Restart the machine. If the fault persists, replace circuit board 20AP1.

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 20AP1.

12 Communication error (warning)

Minor interference on the system's CAN bus.The load on the bus is temporarily too high.

Action: Check that there are no faulty units connected to the CAN bus. Check the cables.

14 Communication error (bus off)

Major interference on the system's CAN bus.The communication has temporarily ceased,

due to excessive load on the bus. The current welding process is stopped.

Action: Check that there are no faulty units connected to the CAN bus. Check the cables.

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.

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 and the

control unit in the power source

This fault should not happen, because both units are located on the same circuit board.

Action: If it still happens replace the circuit board 20AP1.

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Fault

code

Description

19 Memory error in data memory

Information in persistent data memory is incorrect. Basic data will be used.

Fault code 19 appears, among other things, after a software update.

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 circuit board, 20AP1, in the power source.

Note: Fault code 19 may appear if the “Early warning power shut down” signal (+24 V) from

circuit board 2AP1 is missing when the power source is on.

*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 tasks in the program.

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.

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

page 16.

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SERVICVICE INSTRUCTIONS

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.

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

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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:

S A conductive mat (size 610 x 610 mm)

S A 1.5 metre long ground cable with a

crocodile clip

S An adjustable wrist strap and cable with

an inbuilt protective resistor

Antistatic service kit

ESAT service kit

The software update is made from a PC, it has to be managed by a trained serviceman. For

this a PC program called ESAT, ESAB Software Administration Tool, is needed. The PC is

connected to the welding equipment by a cable connector and a CAN reader. From the

ESAT it is possible to update the software. ESAT also contains service functions by which it

is possible to control, change or read the different functions of the equipment.

For the installation and use of the ESAT you need a PC with operating system Windows.

The ESAT service kit contents:

S CAN adapter with connection cables

S CD with software

S Instruction manual for ESAT

Ordering no:

0458 847 881 USB2CAN for connection to the USB port of the PC

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www.esab.com

110915© ESAB AB

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H

Vienna-Liesing

Tel: +43 1 888 25 11

Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.

Brussels

Tel: +32 2 745 11 00

Fax: +32 2 745 11 28

BULGARIA

ESAB Kft Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.

Vamberk

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Herlev

Tel: +45 36 30 01 11

Fax: +45 36 30 40 03

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel: +33 1 30 75 55 00

Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

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Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

HUNGARY

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Budapest

Tel: +36 1 20 44 182

Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A.

Bareggio (Mi)

Tel: +39 02 97 96 8.1

Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V.

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Tel: +31 33 422 35 55

Fax: +31 33 422 35 44

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AS ESAB

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Tel: +47 33 12 10 00

Fax: +47 33 11 52 03

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ESAB Sp.zo.o.

Katowice

Tel: +48 32 351 11 00

Fax: +48 32 351 11 20

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Fax: +351 1 859 1277

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ESAB Romania Trading SRL

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Tel: +40 316 900 600

Fax: +40 316 900 601

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Tel: +7 (495) 663 20 08

Fax: +7 (495) 663 20 09

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Fax: +421 7 44 88 87 41

SPAIN

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Tel: +34 91 878 3600

Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB

Gothenburg

Tel: +46 31 50 95 00

Fax: +46 31 50 92 22

ESAB international AB

Gothenburg

Tel: +46 31 50 90 00

Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC

Kiev

Tel: +38 (044) 501 23 24

Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem-MG

Tel: +55 31 2191 4333

Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 02 20

Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products

Florence, SC

Tel: +1 843 669 44 11

Fax: +1 843 664 57 48

Asia/Pacific

AUSTRALIA

ESAB South Pacific

Archerfield BC QLD 4108

Tel: +61 1300 372 228

Fax: +61 7 3711 2328

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Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 45 670 7073

Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd

USJ

Tel: +603 8023 7835

Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 6861 43 22

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt

Dokki-Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd

Durbanvill 7570 - Cape Town

Tel: +27 (0)21 975 8924

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

ESAB A33, A32, A34 Caddy User manual

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