ESAB Robust Feed U6 User manual

Type
User manual

This manual is also suitable for

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
....................................................................................
6
BEFORE STARTING SERVICE
................................................................
7
Service aid
..............................................................................................
7
Equipment required for the service actions described in this
manual
.....................................................................................................
7
INTRODUCTION
.......................................................................................
8
ERROR DESCRIPTIONS IN THE SERVICE LOG
...................................
9
U6
.............................................................................................................
9
Fault code description .......................................................................... 10
MA25
........................................................................................................
13
Summary of fault codes........................................................................ 14
Fault code description ....................................................................... 15
WIRING DIAGRAM
...................................................................................
19
Component description
.........................................................................
19
RobustFeedU6, valid from serial no. 014-xxx-xxxx
...........................
21
RobustFeedU6PushPull, valid from serial no. 014-xxx-xxxx
.........
24
Robust Feed U6 Push Pull Euro variant, valid from serial no.
xxx-xxx-xxxx
...........................................................................................
27
RobustFeedPulse, valid from serial no. 014-xxx-xxxx
......................
30
RobustFeedPulsePushPull, valid from serial no. 014-xxx-xxxx
....
33
RobustFeedPulsePush Pull Euro variant, valid from serial no.
xxx-xxx-xxxx
...........................................................................................
36
TECHNICAL DATA
...................................................................................
39
FUNCTIONAL DESCRIPTION
.................................................................
41
Interface board (13AP2)
.........................................................................
41
Push Pull board (13AP10)
......................................................................
41
SOFTWARE UPDATE
...............................................................................
42
Updating the ESAT configuration file
...................................................
42
Selecting the correct machine and hardware IDs for the wire feed
unit
...........................................................................................................
43
Changing the machine ID..................................................................... 43
Changing the hardware ID ................................................................... 43
Selecting the correct region
..................................................................
44
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
..............................................................................
45
Pre power up checks
.............................................................................
45
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
.....................
53
Power up checks
....................................................................................
54
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 ...............................
72
Restoring the wire feed unit after power up checks
...........................
74
CALIBRATION AND VALIDATION
...........................................................
75
Measurement methods and tolerances
................................................
75
Requirements specifications and standards
.......................................
75
Accuracy out of tolerance
.....................................................................
76
DISASSEMBLY AND REASSEMBLY
......................................................
77
REPLACEMENT INSTRUCTIONS
...........................................................
82
Replacing the welding data board (13AP3) (applicable only for
Robust Feed Pulse)
................................................................................
82
Replacing the push pull board (13AP10) in a Robust Feedunit,
equipped with a U6 control panel and with Push Pull functionality
..
82
Replacing the push pull board (13AP10) in a Robust Feedunit,
equipped with an MA25Pulse control panel and with Push Pull
functionality
............................................................................................
83
Replacing the interface board (13AP2)
................................................
84
Replacing the control board (13AP1)
...................................................
86
Replacing the panel control board (13AP4)
.........................................
86
Replacing the remote adaptor (boards 13AP8 and 13AP9)
(applicable only for Robust FeedU6 with push pull)
..........................
88
Replacing LED circuit board 13AP6 located by the feeder
mechanism
..............................................................................................
89
Replacing LED circuit board 13AP5 located by the wire bobbin
.......
90
Replacing the current sensor switch board (13AP7)
..........................
90
Replacing the fan (13EV2)
.....................................................................
91
Replacing the bobbin brake hub
...........................................................
91
Replacing the torch copper bar
............................................................
92
Replacing the solenoid valve
................................................................
93
Replacing the feeder mechanism
.........................................................
94
Replacing separate parts inside the feeder mechanism
....................
96
Replacing the torch connector
..............................................................
97
IN-SERVICE, MAINTENANCE AND PERIODIC INSPECTION
PROCEDURE
...........................................................................................
99
Visual inspection in accordance with 5.1 IEC 60974-4
.......................
99
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
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© ESAB AB 2020
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
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© ESAB AB 2020
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
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© ESAB AB 2020
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
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© ESAB AB 2020
ERROR DESCRIPTIONS IN THE SERVICE LOG
U6
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
X
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
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© ESAB AB 2020
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)
X
15 Lost messages X X X X
16 High open-circuit voltage X
17 Lost contact with the wire
feed unit
o
18 Lost contact with the
power source
o
19 Incorrect setting values in
external RAM
X
20 High inductance in the
welding circuit
X
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
X
32 No gas flow X
40 Incompatible units X
41 Lost contact with the
cooling unit
X
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
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© ESAB AB 2020
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
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© ESAB AB 2020
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
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© ESAB AB 2020
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
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© ESAB AB 2020
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
X
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
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
ERROR DESCRIPTIONS IN THE SERVICE LOG
0463 707 001
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© ESAB AB 2020
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
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 (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
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© ESAB AB 2020
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
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© ESAB AB 2020
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
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© ESAB AB 2020
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
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© ESAB AB 2020
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
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© ESAB AB 2020
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 U6 User manual

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