0740 801 024 Valid for serial no. 810-xxx-xxxx to 049-xxx-xxxx110811
Aristot
MechTig C2002i
Service manual
- 2 -TOCe
Rights reserved to alter specifications without notice.
READ THIS FIRST 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MechTig C2002i, motor-& control unit 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MechTig C2002i, power source 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Control unit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upgrading of softwares 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1 Control panel WO 100 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP2 Printer 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections to the printer 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of the printer 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Power supply 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1 Power supply to motor & control units 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1:1 24V_A & 5V_A 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1:2 30V_C 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1:3 5V_B 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1:4 Auxiliary circuit for multi function control 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1 Component positions 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP2 Pre-power supply to motor & control units 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP2:1 Primary circuit 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP2:2 Secondary circuit 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP2 Component positions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP3 Power supply to the welding power source 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP3:1 Interference suppressor circuit 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP3:2 Primary circuit 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP3:3 Secondary circuit 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP3 Component positions 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5AP1 Control board, cooling unit 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1 TIG board 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1 Component positions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1 Power board 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature monitoring 15ST1, 15ST2 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging circuit 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power factor corrector (PFC) 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gate driver stages 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching circuit 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply to 2AP3 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1 Component positions 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2 Secondary board 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2 Component positions 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Control board 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:1 Power supply 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:2 CAN bus 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication interruptions 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminating resistors 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:3 Water cooler 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:4 Pulse width modulator 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:5 Temperature monitoring 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:6 Shunt and current control amplifier 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:7 Arc voltage monitoring 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 3 -TOCe
Rights reserved to alter specifications without notice.
20AP1:8 TIG functions 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Component positions 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1 Sequence controller & welding data unit 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1:1 Power supply 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery backup 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1:2 CAN bus 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1:3 RS232 to printer & WMS 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1:4 Communication with the MMC unit 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23AP1 Component positions 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1 I/O board 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:1 Power supply 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:2 CAN bus 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:3 Stop 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:4 Cooling water connection monitoring 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:5 Gas flow monitoring 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:6 Torch switch 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1:7 Gas valves 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24AP1 Component positions 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 Motor control & drive 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1 Motor drive 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1:1 Power supply 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1:2 Rotation motor drive 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1:3 Wire feed motor drive 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1 Circuit board versions 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP1 Component positions 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2 Motor control 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit board identity 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:1 Power supply 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:2 CAN bus 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting sequence 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware reset 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:3 Rotation feedback 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:4 Wire feed feedback 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2:5 Digital input 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP2 Component positions 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP3 Filter board 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26AP3 Component positions 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVENT LOG 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code description 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of event codes 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding data unit 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor control 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O board 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service aid 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the semiconductor module of 15AP1 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking rectifier and freewheel diodes 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the gate pulses 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soft starting 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 4 -TOCe
Rights reserved to alter specifications without notice.
Mounting components on the heat sink 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting instructions 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the terminating resistor 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas flow meter 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USB connection 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water connection 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow guard, water 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow guard, gas 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol explanations 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and cleaning 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the coolant 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the paper roll 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT-TRACING 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
Use the wiring diagrams as a form of index for the description of operation. The circuit
boards are divided into numbered blocks, which are described individually in more detail in
the description of operation. Component names in the wiring diagram are listed in the
component description.
Use the spare parts list as a guide to where the components are located in the equipment.
The spare parts list is published as a separate document, see page 89.
This manual contains details of design changes that have been made up to and including
August 2011.
The manual is valid for: MechTig C2002i with serial number 810-xxx-xxxx.
Note! MechTig C2002i with serial number 652-xxx-xxxx differ from the description in this
manual. For this machine there is another service manual with filename 0740 801 015.
The MechTig C2002i is 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.
CAUTION
Read and understand the instruction manual before
installing or operating.
Before the power source is put into operation, the safety precautions in the instruction manual should
be read completely. This will help avoid possible injury due to misuse or improper installation.
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INTRODUCTION
MechTig C2002i is a welding power source intended for mechanized TIG welding.
The communication between most of the units of the power source is carried out by a CAN
bus (Controller Area Network).
The power module of the power source is a single forward converter, operating at a
switching frequency of 65 kHz. IGBT transistors are used as switching elements.
Block diagram of the MechTig C2002i
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TECHNICAL DATA
MechTig C2002i
Mains voltage 230 V $10%, 1∼ 50/60 Hz
Mains supply Z
max
0.35 Ω
Primary current I
max
22 A
Setting range 5 A - 200 A
Permitted load
25% duty cycle
35% duty cycle
60 % duty cycle
100% duty cycle
200 A / 18 V
180 A / 17 V
140 A / 16 V
110 A / 14 V
Power factor at maximum current 0.98
Efficiency at maximum current 73 %
Open-circuit voltage 92 V
Operating temperature -10 to +40° C
Transportation temperature -20 to + 55° C
Constant A-weighted sound pressure < 70 dB
Dimensions l x w x h 470 x 479 x 472 mm
Weight 30 kg
Enclosure class IP 23
Application class
Cooling unit
Cooling power
at 50 Hz
at 60 Hz
670 W at 40° C temp. difference and flow 1.0 l/min
650 W at 40° C temp. difference and flow 1.0 l/min
Type of cooling 50 % water / 50% monoethylene glycol
Coolant quantity 2.0 l
Maximum water flow
at 50 Hz
at 60 Hz
1.22 l/min
1.44 l/min
Maximum water pressure
at 50 Hz
at 60 Hz
0.32 MPa (3.2 bar)
0.42 MPa (4.2 bar)
Mains supply, Z
max
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40° C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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WIRING DIAGRAM
The equipment is based on a number of function modules. These are described in the
component descriptions on the following pages. Wire numbers and component names in
the wiring diagram show to which module each component belongs.
Wires/cables within modules are marked 100 - 6999.
Circuit boards within each module have names such as 20AP1 - 20AP99.
15 = module association, 1-69
AP = circuit board
1 = individual identification number, 0-99
Components within modules are named in a similar way.
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic-
sensitive devices.
S Use proper static-proof bags and boxes.
ESD
Component description
1AP1 Display panel (MMC panel).
1AP2 Printer.
1AP3 Pushbuttons.
1AP4 Encoder.
2AP1 Power supply board, control unit. See page 22.
2AP2 Power supply board, control unit. See page 25.
2AP3 Power supply board, power source. See page 28.
2L1 Ferrite ring core.
2L2 Ferrite ring core. The yellow/green cable must be wound two turns through the
ferrite ring.
2L4 - 2L9 Ferrite ring cores.
2QF1 Mains switch.
2XS1 Flat pin sockets. Important: to obtain a proper electric connection, the
complete cord set must be replaced if the sockets have to be replaced.
5AP1 Controller circuit board, cooling unit. See page 31.
5EV1 Motor, cooling fan.
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5M1 Motor, cooling water pump.
5S2 ELP, cooling water connection monitoring, see page 52.
7L1 - 7L5 Ferrite ring cores.
10AP1 TIG board. See page 32.
10TV1 HF transformer.
10YV1 Gas valve, 230 V AC, controlled by the I/O board, see page 53.
10YV2 Gas valve, 230 V AC, controlled by the I/O board, see page 53.
10YV3 Gas valve, 230 V AC, controlled by the I/O board, see page 53.
10S1 Gas flow sensor, see page 52.
15AP1 Power board. See page 34.
15AP2 Secondary board. See page 37.
15C1 Smoothing capacitor, 2000 uF.
15D1 Diode module with rectifier and freewheel diodes.
15EV1 Fan.
15L1 Inductor.
15RS1 Shunt. 60 mV at 100 A.
15ST1 Thermal switch, fitted in the winding of main transformer 15TM1. See page 42.
15ST2 Thermal switch, fitted on the heat sink. See page 42.
15TM1 Main transformer.
20AP1 Controller circuit board, power source. See page 38.
23AP1 Sequence controller and welding data unit. See page 45.
24AP1 I / O board. See page 50.
26AP1 Power board, motor drive. See page 55.
26AP2 Controller circuit board, motor drive. See page 61.
26AP3 Filter circuit board, motor drive. See page 66.
26R1 Charge resistor.
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DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components.
It is divided into sections, numbered to correspond to the circuit board numbers and
divisions into function blocks.
1 Control unit
Upgrading of softwares
The MechTig system differs from other ESAB systems in that it has a graphical user
interface. Hence the system can not be handled in the same way as the other systems
regarding software upgrade.
System overview
PS Power source Internal in MechTig C2002i, external in MechControl 2 and
MechControl 4.
Software upgrade via ESAT.
IO IO module Internal hardware module.
Software upgrade via ESAT.
MCA Motor controller Internal hardware module. 1 or 2 modules depending on number of
axis.
Software upgrade via ESAT.
WDA Welding data unit Internal hardware module. This module resides the CompactFlash
memory card.
Software upgrade via ESAT.
CF CompactFlash card Removable CompactFlash card.
The CompactFlash card must manually be removed from the WDA
card and get the software replaced on a PC. See below for detailed
description.
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USB Interface for USB
memory stick
This interface communicates with the display computer.
Can be used for program installation (EMMA and image), saving
user defined programs and Q-data logs.
EMMA Computer with
Windows applica
tion
EMMA is the Windows application for managing the MechTig
system.
Software upgraded via the USB port
Image Windows image A software that includes the operating system configured for
MechTig.
Software upgrade via the USB port.
Update following programs via ESAT
MCA
WDA
IO
WPS, Power source
Change the bus speed to 500 kbit/sec before you start to upgrade.
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Update EMMA via USB
For this procedure you need a PC an a USB memory stick.
Get the installation package for the desired EMMA version. This package contains all files
needed to upgrade the EMMA application with a USB memory.
1. Unpack the package if it comes as a zip file
2. The file structure should look like this:
3. Copy the directory (with all included files) to the USB memory. The structure on the
USB memory should be the same as above.
4. Put the USB memory in the USB connector on the machine (on the left side below the
screen).
5. Start the system and press the Menu button while booting
6. When message ”Installation script found...” follow the instructions on the screen
7. Click Next...
8. Restart the system and check the login view that the system has been upgraded.
You will now have a system with the EMMA application upgraded.
Note! It is recommended to always use a dedicated ”clean” USB memory to avoid problems
with virus etc.
Note! You can't use the same launcher.commands.xml as for EMMA installation for this
image upgrade, they are different and you need the right one for each program.
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Update image via USB
See description above for a brief explanation on “image”. This installation must be followed
by an EMMA installation.
For this procedure you need a PC an a USB memory stick.
Get the installation package for the desired image version. This package contains all files
needed to upgrade the image with a USB memory.
1. Copy the included files, FormatCF.exe, NK.bin and the
Launcher.commands.xml to the USB memory (root directory)
2. The file structure should look like this:
3. Put the USB memory in the USB connector on the machine. (Below the screen on the
left side.)
4. Start the system and press the Menu button while booting.
5. When message ”Installation script found...” follow the instructions on the screen.
6. Click Next...and let the installation proceed. This will take aprox 5 min.
7. Restart the system. The system will now say ”Could not launch EMMA”. This is correct.
Now the system must get an installation of EMMA. See the section above for this
procedure.
Note! It is recommended to always use a dedicated ”clean” USB memory to avoid problems
with virus etc.
Note! You can't use the same launcher.commands.xml as for EMMA installation for this
image upgrade, they are different and you need the right one for each program.
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Update CompactFlash card.
For this procedure you need a PC with a CompactFlash card reader.
The CompactFlash card is a removable memory card for ESAB defined programs, Qdata
logs, tooldata and auto programming information. User defined programs are not stored on
the CompactFlash card.
Location of the CompactFlash card
1. Open the MechTig C2002i or MechControl and take out the CompactFlash card. The
card is located behind the front screen, see the picture above. Insert the CompactFlash
card in a card reader and change content to the new one.
2. The content of the CompactFlash should be like this:
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3. The content of the ftpsrv directory should be like this:
Note! The file vssver.scc is optional (not needed on the system) and not present on all
installations.
4. Reinstall the CF card in the machine and close the MechTig C2002i or MechControl.
5. Reboot the machine.
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1AP1 Control panel WO 100
See the separate instruction manual for a detailed description of the control
panel.
Cleaning
To ensure proper and reliable functionality over time, the unit shall be wiped
cleaned of dirt and dust. Use a suitable light damp rag to clean the unit.
CAUTION!
Never use alkaline, alcoholic or other chemicals for cleaning which
can damage the unit.
Connections to the rear side of the panel
No. Description Connected to
X1 Power supply 2AP1:CN3
X2 Ethernet 23AP1:CN4
X5 MISC -COM, Digital In and/or 2AP1:CN5
X8 USB 1 XS10 USB
X9 USB 2, not used not connected
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