ESAB Robust Feed Pulse User manual

Brand: ESAB

Model: Robust Feed Pulse

Type: User manual

This manual is also suitable for

Robust Feed U6

Aristo®

Service manual

0463 707 001 GB 20200716

Valid for: serial no. 014-, 019-xxx-xxxx

RobustFeedU6,

RobustFeedPulse

Ordering no. Denomination Note

0445 800 887 Robust Feed U6, Offshore, Water With EURO connector, torch cooling

system, heater, gas flow meter and MMA

0445 800 888 Robust Feed U6, Offshore, Water, ELP, Push

Pull

With EURO connector, torch cooling

system, ELP, heater, gas flow meter and

MMA

0445 800 889 Robust Feed U6, Offshore With Tweco 4 connector, heater, gas flow

meter and MMA

0445 800 890 Robust Feed U6, Offshore, Push Pull With Tweco 4 connector, heater, gas flow

meter and MMA

0445 800 895 Robust Feed U6, Offshore, Water, Push Pull, for

North American market

With EURO connector, torch cooling

system, heater and gas flow meter

0445 800 897 Robust Feed U6, Water With EURO connector, torch cooling

system

0445 800 891 Robust Feed Pulse, Offshore, Water With EURO connector, torch cooling

system, heater, gas flow meter and MMA

0445 800 892 Robust Feed Pulse, Offshore, Water, ELP, Push

Pull

With EURO connector, torch cooling

system, ELP, heater, gas flow meter and

MMA

0445 800 893 Robust Feed Pulse, Offshore, Push Pull With Tweco 4 connector, heater, gas flow

meter and MMA

0445 800 894 Robust Feed Pulse, Water With EURO connector, torch cooling

system

0463 708 001 Spare parts list Aristo® RobustFeedU6,

RobustFeedPulse

0463 707 001 Service manual Aristo® RobustFeedU6,

RobustFeedPulse

0446 253* Instruction manual Aristo® RobustFeedU6,

RobustFeedPulse, CE

0463 739* Instruction manual Aristo® RobustFeedU6,

RobustFeedPulse, CSA

0459 287 * Instruction manual Aristo® U6 control panel

0463 459 * Instruction manual MA25Pulse control panel

The three last digits in the document number of the manual show the version of the manual. Therefore they

are replaced with * here. Make sure to use a manual with a serial number or software version that corresponds

with the product, see the front page of the manual.

Spare parts may be ordered through your nearest ESAB dealer, see esab.com. When ordering, please state product

type, serial number, denominations and ordering numbers according to the spare parts list. This facilitates dispatch and

ensures correct delivery.

Maintenance and repair work should be performed by an experienced person, and electrical work only by a trained

electrician. Use only recommended spare parts.

For accessories to the product, see the instruction manual.

The three last digits in the document number of the manual show the version of the manual. Therefore they

are replaced with * here. Make sure to use a manual with a serial number or software version that corresponds

with the product, see the front page of the manual.

TABLE OF CONTENTS

0463 707 001 © ESAB AB 2020

READ THIS FIRST

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

BEFORE STARTING SERVICE

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

Service aid

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

Equipment required for the service actions described in this

manual

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

INTRODUCTION

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

ERROR DESCRIPTIONS IN THE SERVICE LOG

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

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

Fault code description .......................................................................... 10

MA25

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

Summary of fault codes........................................................................ 14

Fault code description ....................................................................... 15

WIRING DIAGRAM

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

Component description

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

RobustFeedU6, valid from serial no. 014-xxx-xxxx

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

RobustFeedU6PushPull, valid from serial no. 014-xxx-xxxx

.........

Robust Feed U6 Push Pull Euro variant, valid from serial no.

xxx-xxx-xxxx

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

RobustFeedPulse, valid from serial no. 014-xxx-xxxx

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

RobustFeedPulsePushPull, valid from serial no. 014-xxx-xxxx

....

RobustFeedPulsePush Pull Euro variant, valid from serial no.

xxx-xxx-xxxx

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

TECHNICAL DATA

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

FUNCTIONAL DESCRIPTION

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

Interface board (13AP2)

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

Push Pull board (13AP10)

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

SOFTWARE UPDATE

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

Updating the ESAT configuration file

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

Selecting the correct machine and hardware IDs for the wire feed

unit

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

Changing the machine ID..................................................................... 43

Changing the hardware ID ................................................................... 43

Selecting the correct region

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

Robust Feed unit equipped with a U6control panel............................. 44

For GMA welding............................................................................... 44

For MMA welding .............................................................................. 44

Robust Feed unit equipped with a Pulsecontrol panel ........................ 44

TROUBLESHOOTING

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

Pre power up checks

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

Control board 13AP1 measurements ................................................... 46

Push Pull board 13AP10 measurements ............................................. 49

TABLE OF CONTENTS

0463 707 001 © ESAB AB 2020

Interface board 13AP2 measurements................................................. 51

Restoring the wire feed unit after pre power up checks

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

Power up checks

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

Control board 13AP1 measurements ................................................... 54

Push Pull board 13AP10 measurements ............................................. 58

Interface board 13AP2 measurements................................................. 61

Additional control board 13AP1 measurements, in case of incorrect

measurement result when testing interface board ...............................

Restoring the wire feed unit after power up checks

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

CALIBRATION AND VALIDATION

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

Measurement methods and tolerances

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

Requirements specifications and standards

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

Accuracy out of tolerance

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

DISASSEMBLY AND REASSEMBLY

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

REPLACEMENT INSTRUCTIONS

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

Replacing the welding data board (13AP3) (applicable only for

Robust Feed Pulse)

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

Replacing the push pull board (13AP10) in a Robust Feedunit,

equipped with a U6 control panel and with Push Pull functionality

Replacing the push pull board (13AP10) in a Robust Feedunit,

equipped with an MA25Pulse control panel and with Push Pull

functionality

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

Replacing the interface board (13AP2)

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

Replacing the control board (13AP1)

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

Replacing the panel control board (13AP4)

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

Replacing the remote adaptor (boards 13AP8 and 13AP9)

(applicable only for Robust FeedU6 with push pull)

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

Replacing LED circuit board 13AP6 located by the feeder

mechanism

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

Replacing LED circuit board 13AP5 located by the wire bobbin

.......

Replacing the current sensor switch board (13AP7)

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

Replacing the fan (13EV2)

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

Replacing the bobbin brake hub

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

Replacing the torch copper bar

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

Replacing the solenoid valve

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

Replacing the feeder mechanism

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

Replacing separate parts inside the feeder mechanism

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

Replacing the torch connector

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

IN-SERVICE, MAINTENANCE AND PERIODIC INSPECTION

PROCEDURE

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

Visual inspection in accordance with 5.1 IEC 60974-4

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

Intermediate cables .............................................................................. 99

Enclosure ............................................................................................. 99

Return clamp ........................................................................................ 99

TABLE OF CONTENTS

0463 707 001 © ESAB AB 2020

Welding gun/torch................................................................................. 99

Welding circuit ...................................................................................... 100

General condition ................................................................................. 100

Wire feeder/ wear parts ........................................................................ 100

Magnetic gas valve............................................................................... 100

Controls and indicators......................................................................... 100

Cleaning the equipment

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

101

Labelling and report

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

101

Maintenance and inspection procedure

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

102

SPARE PARTS AND ACCESSORIES

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

103

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 707 001

- 6 -

READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

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

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

help in connection with fault-tracing and repair.

Before and after service, repair and maintenance work are performed, the safety procedure

described in the Safety test manual must be followed! The Safety test manual can be

downloaded from the Internet: manuals.esab.com

The circuit boards are divided into numbered blocks. Component names in the wiring

diagram are listed in the component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

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

April 2020.

The manual is valid for: RobustFeedU6 and RobustFeedPulse with serial numbers

014-xxx-xxxx and 019-xxx-xxxx.

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

RobustFeedU6 and RobustFeedPulse are designed and tested in accordance with the

standards stated in the instruction manual. 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 involved standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

BEFORE STARTING SERVICE

0463 707 001

- 7 -

BEFORE STARTING SERVICE

Service aid

ESAB 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 610×610mm /

24×24in.)

• A 1.5m (3.28ft) long ground cable with

a crocodile clip

• An adjustable wrist strap and cable with

a built-in protective resistor

Equipment required for the service actions described in this manual

• Multimeter (provided with DC and AC

voltage, resistance, diode and

capacitance test functions, See

"Recommended measuring devices",

page7.)

• Permanent magnet (for

testing/measurements of torch trigger,

fan, gas valve, contactor and

TMRsensor functions)

• Torx screwdriver T10

• Torx screwdriver T20

• Torx screwdriver T25

• Torx screwdriver T30

• Screwdriver Pozidriv PZ2

• 6mm Hex Allen key

• 7mm Hex socket

• 8mm Hex socket

• 9mm Hex socket

• 10mm Hex socket

• 13mm Hex socket

• 16mm Hex socket

• 17mm fixed wrench

• 27mm fixed wrench

• Hammer

• Pin punch 2.5mm

• Hose clamp pliers

• Cable binder pliers

• Lock ring pliers

• Circlip pliers

Recommended measuring devices

• For general measurements: Fluke175, Fluke177, Fluke179 or any other multimeter

with equal performance

• For safety test: Fluke1503, Fluke1507, Fluke1577, Fluke1587 or any other

multimeter with equal performance

INTRODUCTION

0463 707 001

- 8 -

INTRODUCTION

The RobustFeedequipped with a U6 orPulse control panel, is intended for MIG/MAG

welding together with 400A, 500A and 600A CAN based welding power sources.

The wire feed unit comes in different variants (see page2 in this service manual).

NOTE!

Wire feed unit variants equipped with ESAB Logic Pump (ELP), is intended to be

used together with welding power sources equipped with ELP.

The wire feed units are sealed and contain four-wheel drive wire feed mechanisms as well as

control electronics.

They can be used together with wire from ESAB's Marathon Pac™ or from wire bobbin

(standard Ø 200 mm and Ø 300 mm).

The wire feed unit can be placed on a trolley, suspended above the workplace or on the floor

(standing up or laying down and with or without a wheel set).

Circuit board identity

The control board has a machine ID, a hardware ID and a unit type number. To read this you

need the ESAT service kit, see "SOFTWARE UPDATE", page42.

• The machine ID determines which type of wire feed unit the board is intended for.

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

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

The ID numbers of the Robust feed unit and the control panels are as follows:

Wire feeder

Machine ID = 50

Node ID = 3

Hardware ID = 6

U6 panel

Machine ID = 36

Node ID = 0

Hardware ID = 1

MA25 Pulse panel

Machine ID EU (global) = 54

Machine ID NA (CSA) = 55

Node ID = 0

Hardware ID = 4

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 9 -

ERROR DESCRIPTIONS IN THE SERVICE LOG

Fault log

All faults that occur when using the welding equipment are documented as error messages in

the fault log. 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 (see "SOFTWARE UPDATE", page

42).

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

Fault codes are used to indicate that a fault has occurred in the equipment. They are shown

in the display in the form of a symbol as follows:

The upper numeral in the symbol is the number of the particular fault code.

The lower figure indicates which unit type has generated the fault. The

following unit types are used:

0 = welding data unit 1 = cooling unit 2 = power source

3 = wire feed unit 4 = remote control unit

The above symbol shows that the welding data unit (0) has lost contact with the power

source.

Symbols may be steady or flashing, depending on the type of fault. Flashing symbols are

indicaded with “o” in the table below.

Press any of the function keys in order to clear the symbol from the display.

Summary of fault codes

Fault

code

Description Welding

data unit

Cooling

unit

Power

source

Wire

feed unit

Remote

control

unit

1 Memory error, EPR0M X X X X X

2 Memory error, RAM X X X X

3 Memory error, external

RAM

X X X

4 +5 V power supply X X

5 Intermediate DC voltage

outside limits

6 High temperature X

8 Power supply 1 X X X X X

9 Power supply 2 X X X

10 Power supply 3 X

11 Wire feed speed X

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 10 -

Fault

code

Description Welding

data unit

Cooling

unit

Power

source

Wire

feed unit

Remote

control

unit

12 Communication error

(warning)

X X X X X

14 Communication error (bus

off)

15 Lost messages X X X X

16 High open-circuit voltage X

17 Lost contact with the wire

feed unit

18 Lost contact with the

power source

19 Incorrect setting values in

external RAM

20 High inductance in the

welding circuit

22 Transmitter buffer

overflow

X X X X

23 Receiver buffer overflow X X X X

26 Program operating fault X X X

27 Out of wire o

28 Stack overflow X X X X

29 No cooling water flow o

31 No reply from the display

unit

32 No gas flow X

40 Incompatible units X

41 Lost contact with the

cooling unit

Fault code description

This manual describes the fault codes for Robust Feed U6, Robust Feed Pulse.

The fault codes for other units are described in the manuals for these units.

 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.

1. Restart.

2. If the fault persists, load new software via ESAT.

3. If the fault still persists, replace the welding data board 13AP3.

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 11 -

 2  Failed RAM test in microprocessor

The microprocessor is unable to read/write from/to a certain memory position in its

internal memory.

This error does not disable any functions.

1. Restart.

2. If the error persists, send for a service technician.

 3  Failed external RAM test

The microprocessor is unable to read/write from/to a certain memory position in its

internal memory.

This error does not disable any functions.

1. Restart.

2. If the error persists, send for a service technician.

 3  External RAM error

The microprocessor is unable to read/write from/to a particular memory address in

its internal memory. This test is preformed only as part of initiation at power on.

This error does not disable any functions.

1. Restart.

2. If the fault persists, replace the welding data board 13AP3.

 4  5V power supply 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.

1. Turn off the mains power supply to reset the unit.

2. If the fault persists, replace the welding data board 13AP3.

 8  Low battery voltage +3 V

Battery voltage too low. If the battery is not replaced, all stored data will be lost.

This error does not disable any functions.

1. Replace the battery on circuit board 13AP3. If it is not replaced, the entire

contents of the battery backed-up memory will be lost.

 12  Communication error (warning)

The load on the system CAN bus is temporarily too high.

1. Check the equipment to ensure that only one wire feed unit or remote control

unit is connected.

 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.

1. Check that there are no faulty units connected to the CAN bus.

2. Check the cables.

3. Turn off the mains power supply to reset the unit.

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 12 -

 15  Lost messages

The bus CAN controller indicates that a message has been lost. No functions are

disabled by this fault.

1. Check CAN bus connections.

 17  Lost contact with the wire feed unit

Current activities will be stopped and welding start is prevented.

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.

1. Check the CAN cabling.

 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

board in the MMC unit and the control board in the power source.

1. Check the CAN cabling.

 19  Memory error in data memory

This fault will be detected if the information in the battery-backed memory has

become corrupted.

1. The fault will correct itself, but the data stored in the current memory position

will be lost.Turn off the mains power supply to reset the unit.

2. If the battery voltage is correct, and if the fault recurs each time the unit is

started, there is a fault in the persistent memory. Replace the welding data

board, 13AP3, in the MMC unit.

 22  Transmitter buffer overflow

The welding data unit is unable to transmit information to the other units at a

sufficiently high speed.

1. A break in the bus line can cause this fault.

2. Check the CAN cabling.

3. 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.

1. 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.

1. This fault should not happen. Contact ESAB if the fault yet occurs.

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 13 -

 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.

1. This fault should not happen. Contact ESAB if the fault yet occurs.

 29  No cooling water flow

The flow monitor switch has tripped.

The current welding process is stopped and starting is prevented.

1. Check the cooling water circuit and the pump.

 31  No reply from the display unit

The microprocessor is not in contact with the display board.

1. Check the ribbon cable and connectors between the welding data board

(13AP3) and the display board (13AP2).

 40  Incompatible units

Incorrect wire feed unit is connected. Start is prevented.

1. Connect the correct wire feed unit.

 41  Lost contact with the cooling unit

The welding data board has lost contact with the cooling unit. The welding process

is stopped and starting is prevented.

1. Check the CAN cabling.

2. Turn off the mains power supply to reset the unit.

MA25

Fault log

All faults that occur when using the welding equipment are documented as error messages in

the fault log. 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 (see "SOFTWARE UPDATE", page

42).

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.

The control panel displays a unit number to indicate which unit has generated the fault. The

following unit numbers are used:

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

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 14 -

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 (U0) has lost

contact with the power source (E18).

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

6 High temperature X

*8 Power supply 1 X X X

*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

18 Lost contact with the power

source

19 Incorrect setting values in

external RAM memory

*22 Transmitter buffer overflow X X X

*23 Receiver buffer overflow X X X

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 15 -

Fault code Description Welding

data unit

Power

source

Wire feed

unit

Remote

control

unit

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

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 (see "SOFTWARE

UPDATE", page42).

Fault code description

This manual describes the fault codes for the wire feed unit. The fault codes for other units

are described in the manual for each unit.

 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.

1. Restart.

2. If the fault persists, load new software via ESAT.

3. If the fault still persists, replace the welding data board 13AP3.

 2  Microprocessor RAM error

This fault code is not displayed by the control panel, but it is stored in the fault log.

The microprocessor is unable to read/write from/to a particular memory address in

its internal memory. This test is performed only on initiation after power−up. This

fault does not disable any functions.

1. Restart.

2. If the fault persists, replace the welding data board 13AP3.

 3  External RAM error

The microprocessor is unable to read/write from/to a particular memory address in

its internal memory. This test is preformed only as part of initiation at power on.

This error does not disable any functions.

1. Restart.

2. If the fault persists, replace the welding data board 13AP3.

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 16 -

 4  5V power supply 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.

1. Turn off the mains power supply to reset the unit.

2. If the fault persists, replace the welding data board 13AP3.

 12  Communication error (warning)

The load on the system CAN bus is temporarily too high.

1. Check the equipment to ensure that only one wire feed unit or remote control

unit is connected.

 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.

1. Check that there are no faulty units connected to the CAN bus.

2. Check the cables.

3. 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.

1. Check CAN bus connections.

 17  Lost contact with the wire feed unit

Current activities will be stopped and welding start is prevented.

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.

1. Check the CAN cabling.

 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.

1. Check the CAN cabling.

 19  Memory error in data memory

This fault will be detected if the information in the battery-backed memory has

become corrupted.

1. The fault will correct itself, but the data stored in the current memory position

will be lost.Turn off the mains power supply to reset the unit.

2. If the fault recurs each time the unit is started, there is a fault in the persistent

memory. Replace the welding data board, 13AP3, in the control panel.

 22  Transmitter buffer overflow

This fault code is not displayed by the control panel, but it is stored in the fault log.

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 17 -

The welding data unit is unable to transmit information to the other units at a

sufficiently high speed.

1. A break in the bus line can cause this fault.

2. Check the CAN cabling.

3. Turn off the mains power supply to reset the unit.

 23  Receiver buffer overflow

This fault code is not displayed by the control panel, but it is stored in the fault log.

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.

1. 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.

1. This fault should not happen. Contact ESAB if the fault yet occurs.

 28  Stack overflow

NOTE!

This fault code is stored in the fault log, but not displayed by the

control panel.

The program execution does not work. This fault should not happen. The fault

code is intended as an aid during development work.

1. This fault should not happen. Contact ESAB if the fault yet occurs.

 29  No cooling water flow

The flow monitor switch has operated.

The current welding process is stopped, and cannot be restarted.

1. Check the cooling water circuit and the pump.

 29  No cooling water flow

The flow monitor switch has tripped.

The current welding process is stopped and starting is prevented.

1. Check the cooling water circuit and the pump.

 40  Incompatible units

Incorrect wire feed unit is connected. Start is prevented.

1. Connect the correct wire feed unit.

ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 707 001

- 18 -

 41  Lost contact with the cooling unit

The welding data board has lost contact with the cooling unit. The welding process

is stopped and starting is prevented.

1. Check the CAN cabling.

2. Turn off the mains power supply to reset the unit.

WIRING DIAGRAM

0463 707 001

- 19 -

WIRING DIAGRAM

The wire feed unitis function module 13. The names of the circuit boards and components

included in the wire feed unit contains the number 13 to indicate that they belong to the wire

feed unit. The circuit boards and components are listed in the component description below.

Wires/cables within modules are marked 100 - 6999.

Wires/cables between modules are marked 7000 - 7999.

Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors

XS1 - XS99 (S = socket), XT1 - XT99 (T = terminal).

Circuit boards within each module have names such as 13AP1 - 13AP99.

13 = module association, 1-69

AP = circuit board

1 = individual identification number, 0-99

Transistors within particular modules have identification numbers such as 13Q1 - 13Q99.

13 = module association, 1-69

Q = transistor

1 = individual identification number, 0-99

Component description

Component Description

13 Wire feeder module Wire numbers 1300–1499

13AP1 Control board

13AP2 Interface board

13AP3 Welding data board (Pulse)

13AP4 Panel control board

13AP5 Cabinet LED board, Wire bobbin

13AP6 Cabinet LED board, Mechanism

13AP7 Current sensor switch board

13AP8 Filter board (U6 with push pull)

13AP9 CAN adapter board (U6 with push pull)

13AP10 Push Pull board

13C1–13C2 Capacitors to chassis

13EV1 Push motor interface

13EV2 Fan

13G1 Pulse encoder motor interface

13L1–13L3 Inductors

13M1 Motor supply

13R1 Power resistor, Heat kit option

13S1 Rotary switch, Heat kit option

13S2 Switch, Euro connector welding torch trigger

13S3 LID switch (PNP NO)

WIRING DIAGRAM

0463 707 001

- 20 -

Component Description

13S4 Switch, Wire inching/Gas purging

13S5 Switch, Tweco connector welding torch trigger

13S6 ELP switch (only on variants with ELP, ESAB LogicPump)

13S7 CAN switch

13XP... Pin connectors included in the wire feeder module

13XS... Socket connectors in the wire feeder module

13YV1 Solenoid gas valve

13R2 Push pull resistor

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

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ESAB Robust Feed Pulse User manual

Brand: ESAB

Model: Robust Feed Pulse

Type: User manual

This manual is also suitable for

Robust Feed U6

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ESAB Robust Feed Pulse User manual

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ESAB Robust Feed Pulse User manual

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