ESAB MobileFeed 201 AVS User manual

Brand: ESAB

Model: MobileFeed 201 AVS

Category: Welding System

Type: User manual

This manual is also suitable for

MobileFeed 301 AVS

Service manual

0558 012 632 GB 20160229 Valid for: serial no. WORK427XXXX, WC-K508XXXX,

WxxK530XXXX, WxxK533XXXX

MobileFeed 201 AVS,

MobileFeed 301 AVS

TABLE OF CONTENTS

0558 012 632 © ESAB AB 2016

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

INTRODUCTION................................................................................................... 4

TECHNICAL DATA ............................................................................................... 5

WIRING DIAGRAM............................................................................................... 7

MobileFeed 201, MobileFeed 301........................................................................7

DESCRIPTION OF OPERATION.......................................................................... 9

Gas and contactor control ..................................................................................9

Tacho circuit ....................................................................................................... 10

Torch trigger circuit ........................................................................................... 11

Digital meter circuit............................................................................................12

Remote isolation circuit ....................................................................................14

FAULT INDICATIONS ......................................................................................... 15

SERVICE INSTRUCTIONS................................................................................. 17

What is ESD?......................................................................................................17

Maintenance ....................................................................................................... 17

Removing the MobileFeed 201 cover ...............................................................18

Removing the MobileFeed 301 cover ...............................................................19

Removing the bus bar and contactor...............................................................20

Mounting the hardware locations.....................................................................21

Removing the solenoid......................................................................................21

Inspection and cleaning .................................................................................... 22

SPARE PARTS ................................................................................................... 24

Rights reserved to alter specifications without notice.

READ THIS FIRST

0558 012 632

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READ THIS FIRST

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

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

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

help in connection with fault-tracing and repair.

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

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

description of operation. All component names in the wiring diagram are listed in the

component description.

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

March 2015.

The manual is valid for:

Ordering

number

Product Serial number

0558 101 910 MobileFeed 201 AVS w/meter WORK427XXXX, WxxK530XXXX

0558 101 911 MobileFeed 201 AVS w/meter-REM V WORK427XXXX, WxxK530XXXX

0558 102 194 MobileFeed 201 AVS w/meter TWECO WORK427XXXX, WxxK530XXXX

0558 101 918 MobileFeed 301 AVS w/meter WC-K508XXXX, WxxK530XXXX

0558 101 919 MobileFeed 301 AVS w/meter-REM V WC-K508XXXX, WxxK530XXXX

0558 102 195 MobileFeed 301 AVS w/meter TWECO WC-K508XXXX, WxxK530XXXX

0558 102 206 MobileFeed 201 CE WxxK533XXXX

0558 102 221 MobileFeed 201 CE w/Remote Voltage WxxK533XXXX

0558 102 207 MobileFeed 301 CE WxxK533XXXX

0558 102 222 MobileFeed 301 CE w/Remote Voltage WxxK533XXXX

The MobileFeed 201 and MobileFeed 301 are designed and tested in accordance with

international and European standards IEC/EN 60974-5 and IEC/EN 60974-10, Canadian

standard CAN/CSA-E60974-5 and US standard ANSI/IEC 60974-5. 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 standards.

INTRODUCTION

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INTRODUCTION

The wire feed units MobileFeed 201 AVS and MobileFeed 301 AVS are intended for

MIG/MAG (GMAW) welding together with welding power sources:

• Warrior 400i CC/CV

• Warrior 500i CC/CV

• CC/CV power supplies compatible with Off-the-Arc wire feeders

They come in different variants, see chapter "ORDERING NUMBERS" in the instruction

manual.

The wire feed units are sealed and contains a four-wheel drive wire feed mechanism as well

as control electronics.

Design structure of the wire feeding unit

The wire feeding unit consists of a drive unit and an electronic unit. The drive unit is the

mechanical unit that actually feeds the wire and the electronic unit is communicating with the

power source and controlling the drive unit.

TECHNICAL DATA

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TECHNICAL DATA

NOTE!

The MobileFeed 201 AVS and MobileFeed 301 AVS are not recommended for

short circuiting transfer using constant current power sources due to the limited

short circuit current available on constant current power sources.

MobileFeed 201 AVS



MobileFeed 301 AVS



Power supply voltage 14 - 100 VDC

Maximum voltage

while welding

45 VDC

Rated supply currrent I

6 A

Settings data

Wire feed speed 1.3 – 19.0 m/min

(50 – 750 in/min)

2/4 stroke 2 stroke or 4 stroke

Wire selection / Burnback None

Ramp start Always on

Gas purging Yes

Wire inching Yes

Torch connection TWECO or EURO

Maximum diameter wire

bobbin

8 inch (S200 mm)

15 lbs (6.8 kg)

12 inch (S300 mm)

33 lbs (15 kg)

Wire dimension

Fe 0.023 - 0.062 inch (0.6 - 1.5 mm)

Ss 0.023 - 0.062 inch (0.6 - 1.5 mm)

Al 0.039 - 0.062 inch (1.0 - 1.5 mm)

Cored wire 0.031 - 0.062 inch (0.8 - 1.5 mm)

Weight (with contactor,

without spool) 28 lbs (12.7 kg) 33 lbs (15 kg)

Dimensions (l × w × h) 14.5" × 7.4" × 18.5"

(369 × 188 × 470 mm)

17" × 8.3" × 21"

(432 × 210 × 534 mm)

Operating temperature +14° to +104°F (-10° to +40°C)

Shielding gas All types intended for MIG/MAG welding

Maximum pressure 0.5 MPa (5 bar / 72.5 psi)

Maximum welding current at

60% duty cycle 320 A

100% duty cycle 250 A

Enclosure class IP23S

Factory standard settings

The standard factory settings for the MobileFeed 201 AVS and MobileFeed 301 AVS are

inch/min and fully open gas valve.

TECHNICAL DATA

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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 104°F (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 IP 23S is intended for indoor and outdoor use; however, should not be

operated in precipitation.

WIRING DIAGRAM

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WIRING DIAGRAM

MobileFeed 201, MobileFeed 301

WIRING DIAGRAM

0558 012 632

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DESCRIPTION OF OPERATION

0558 012 632

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DESCRIPTION OF OPERATION

Gas and contactor control

The Mobilefeed gas and contactor controls are two identical circuits. The controls consist of

U12 and U13 which are universal relay drivers driving the transistors Q5 and Q6 respectively.

Each combination of universal relay driver and drive transistor forms a PWM constant current

source to operate the coils of the gas solenoid and the contactor.

Resistors R92 and R95 are used to measure the peak current through Q6 and Q5

respectively.

The external components around U12 and U13 are used to program the current that is

applied to the gas solenoid and contactor coils. For initial engagement a DC current of 4 A is

supplied to the coils, after which the current is reduced to a sustaining current of 1 A. This

programmed current insures positive engagement while greatly reducing the continuous

power dissipation in the control coils.

DESCRIPTION OF OPERATION

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Tacho circuit

The MobileFeed tachometer is a six pole magnetic pickup which generates an AC signal

which is approximately 1 Hz/IPM (inches per minute). This signal is processed by U6 which

converts the AC frequency to a proportional DC voltage.

Trim potentiometer R39 is used to calibrate the signal to +1 V/100 IPM at TP6.

The wire speed reference voltage is buffered by U4 and appears at TP5. This signal is

inverted and appears at U4 pin 8. The -1 V/100 IPM reference signal is compared to the +1

V/100 IPM tacho signal at U4 pin 6 with the error signal appearing at U4 pin 7.

This tacho error signal is used by the motor speed control circuit to modify the motor voltage

command. The wire speed control is based on a motor voltage control with a tachometer

error signal which has limited ability to modify the motor voltage command.

As a result of this limited ability of the tachometer error signal to modify the motor voltage

command, a loss of the tachometer signal will result in a speed increase but will not result in

a total run away of the wire speed.

DESCRIPTION OF OPERATION

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Torch trigger circuit

The torch trigger circuit consists of the torch switch input as well as a torch trigger latching

circuit. The torch trigger input enters the control board on pins J1-1 and J1-2. This signal is

buffered by U7 and appears at U7 pins 2 and 15. A transition from logic high +12 V to logic

low 0 V will simultaneously activate the contactor, the gas solenoid and the wire feed circuits.

The trigger latching function is accomplished by U11 and D16. When the trigger latch switch

is in the OFF (open) position, the (S) pin of U11 is held at logic High resulting in Q being set

to logic High and Q’ being set to logic Low. If the trigger lock switch is placed in the ON

position, and the current detect switch is closed, the (S) pin is pulled to logic Low allowing

U11 to respond to changes in the state of the CLK (clock) input. When pin (S) is at logic low,

the Q and Q’ outputs will change state on the rising edge of the CLK input.

When the torch trigger is activated, U7 pin 15 is pulled low activating the contactor, the gas

solenoid and the wire feed circuits. When the torch trigger is released, the rising edge of the

CLK input causes Q to switch to logic Low which, through D16, keeps those circuits

activated. Operating and releasing the torch trigger causes Q to switch to logic High, reverse

biasing D16 and allowing the contactor, the gas and wire feed to stop.

DESCRIPTION OF OPERATION

0558 012 632

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Digital meter circuit

The display on the MobileFeed wire feeder receives its operating power from the regulated

+12 VDC supplied by the main control pcb. The bridge rectifier D1 allows the meter circuit to

operate from AC or DC power up to 35 V peak. U1 is a linear voltage regulator with

adjustable output voltage, nominally +5 VDC. U2 is an 8 bit CMOS microprocessor which

receives two analog signals from the feeder main control board representing the wire feed

speed and the welding arc voltage. The scaling of the two signals are, 1 V/100 IPM, and arc

voltage/10. Maximum readings are 760 IPM, and 76 V. Values in excess of the maximum will

result in the displays reading the maximum.

Dip switch SW1 allows the wire feed display to read m/min instead of inches/min. The AD

converter in U2 uses the +5 V as its reference voltage, therefore adjusting R21 will adjust the

value of the +5 V and can be used to make minor adjustments to the AD converter. U2

converts the analog input signals into digital signals and energizes segments “A” through “G”

of each display digit. Output pins RA2, RA3 and RA4 are used by the LED driver circuit (not

shown above) to multiplex the digits of the display. Multiplexing the displays greatly reduces

the average current draw required by the displays. Digital input RB7 of U2 is used to trigger a

“HOLD” function. When U2 sees a transition from logic High to logic Low on RB7 it will hold

the last value displayed before the transition for 10 seconds and then return to reading and

displaying the signals in real time.

DESCRIPTION OF OPERATION

0558 012 632

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DESCRIPTION OF OPERATION

0558 012 632

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Remote isolation circuit

The power source remote control circuit is designed to work with ESAB Warrior power

sources. It consists of PCB3 (isolator) and the necessary cables to connect to the Warrior

power source. Input to output circuit isolation is supplied by U2 (ISO-122) which receives its

primary power +12va, -12va and 0va from PCB1, and secondary power +12vb, and 0vb from

the power source remote receptacle. U1 (ICL7662) is a converter IC which receives +12vb

and 0vb and generates -12vb which is required by U2 and is not available from the power

source remote receptacle. The remote control signal ranges between 1.0v and 12.0vdc. It is

received by PCB3 on connector J1 pin 4, isolated by U2 and appears on connector J2 pin 2.

This signal is offset in the Warrior power source such that 1.0v = 12 arc V, and 10.0v = 44 arc

V. Calibration can be accomplished by adjustment of trim potentiometer R34 on PCB1.

FAULT INDICATIONS

0558 012 632

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FAULT INDICATIONS

Symptom Possible cause Action required

No power, nothing shown on

display.

• The power switch (S1) is

not turned on or defective.

• The cables are not

connected to the power

source or damaged.

• No output voltage

available from power

source.

• The fuse (F1) is not

installed or open.

• Check the power switch

(S1).

• Check that the cables to

the power source.

• Check the power source

for open circuit voltage

(OCV) and activate the

contactor if no OCV is

available.

• Install a fuse with a

correct value.

The display reads "000" for

wire feed speed.

• The wire feed speed

potentiometer (R1) is set

to "0" or defective.

• Adjust R1 to the desired

wire speed or replace it if

defective.

The display reads

approximately 11.0 for voltage

with no control.

• The voltage control

potentiometer (R2) is

defective.

• Replace R2.

The gas solenoid operates

but the contactor is not

activated and the wire is not

fed.

• The circuit breaker (CB1)

has tripped or is defective.

• Replace CB1.

The fuse (F1) blows when the

power switch (S1) is turned

on.

• The rectifiers BR1, BR2,

the capacitor C1 or the

varistor MOV1 is

defective.

• The circuit board PCB1 is

defective.

• Replace the defective

part.

• Replace PCB1.

The trigger lock does not lock

ON.

• The arc is not established

before the trigger is

released.

• The trigger lock switch

(S3) or the current

detector is defective.

• Set the trigger lock ON

and then release the

trigger after the arc is

established.

• Replace the defective

part.

Wire feed speed runs

approximately 180 ipm higher

than the set value.

• The tacho signal to PCB1

is missing or the circuit

board PCB1 is defective.

• Check the tacho

connections to pCB1,

P2-9 and P2-10.

• Check AC fequency of

tacho signal. It should be

approximately 1 Hz/ipm.

• Replace PCB1.

FAULT INDICATIONS

0558 012 632

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Symptom Possible cause Action required

No remote voltage control of

power source.

• The remote control cable

is not connected to the

power source or defective.

• The remote option is not

installed in the power

source or the power

source software is an

early version.

• Check the connection to

the power source and

inspect the cable for

damage.

• Check the remote option

installation, contact ESAB

service department with

the power source serial

number.

The remote voltage control

operates but the set voltage

and the actual voltage are not

the same.

• The remote voltage signal

is out of calibration.

• Adjust the trim

potentiometer R34 to

match the MobileFeed

meter with the power

source meter.

The wire feed speed does not

match the displayed speed.

• The tacho circuit is out of

calibration.

• Adjust the trim

potentiometer R39 to

match the MobileFeed

meter with the power

source meter.

The wire feed speed matches

the displayed speed but

changes while welding.

• CV/CC switch is set to CC

mode.

• Wire feed speed

increases when arc

voltage increases.

• Set CV/CC switch to CV

mode.

The display reads "000" for

the voltage while welding.

• Rectifier BR2 is defective

or there is a missing

connection to circuit board

PCB1, P2-3.

• Replace BR2 if necessary.

• Check the connections to

circuit board PCB1.

The contactor chatters rapidly

when the torch trigger is

operated.

• The torch trigger is

shorted to the welding

circuit.

• There is an issue with

power source software

• The MobileFeed is

connected to a CC power

source with a too low

current setting.

• Check if the torch trigger

switch is shorted.

• Check the operation of the

power source by turning

the power source OFF

and ON.

• Check the power source

process mode and setting.

SERVICE INSTRUCTIONS

0558 012 632

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SERVICE INSTRUCTIONS

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling

electrostaticsensitive devices.

• Use proper static-proof bags and boxes.

What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESD stands

for Electrostatic Discharge.

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to people.

ESD damage occurs when an ungrounded person or object with a static charge comes into

contact with a component or assembly that is grounded. A rapid discharge can occur,

causing damage. This damage can take the form of immediate failure, but it is more likely

that system performance will be affected and the component will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from building

up on you or on anything at your work station, then there cannot be any static discharges.

Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static

charge, so you should not bring unnecessary nonconductive items into the work area. It is

obviously difficult to avoid all such items, so various means are used to drain off any static

discharge from persons to prevent the risk of ESD damage. This is done by simple devices:

wrist straps, connected to ground, and conductive shoes.

Work surfaces, carts and containers must be conductive and grounded. Use only antistatic

packaging materials. Overall, handling of ESD-sensitive devices should be minimized to

prevent damage.

Maintenance

NOTE!

Regular maintenance is important for safe and reliable operation.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer

attempts any work to rectify any faults in the product during the warranty period.

SERVICE INSTRUCTIONS

0558 012 632

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Removing the MobileFeed 201 cover

1. Remove the spool retainer.

2. Remove the nut and the washer with a 1 1/16" (27 mm) socket wrench.

3. Remove the 4 screws with a square drive number 2 and loosen the cover.

SERVICE INSTRUCTIONS

0558 012 632

- 19 -

Removing the MobileFeed 301 cover

1. Remove the spool retainer nut.

2. Remove the screw with a M8 (5/16")Hex key and remove the hub.

3. Remove the 4 screws with a square drive number 2 and loosen the cover.

SERVICE INSTRUCTIONS

0558 012 632

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Removing the bus bar and contactor

1. Disconnect the cable lug.

2. Remove the bus bar connection with a 14 mm (9/16") wrench. The bus connections

should use 3/8 inch or M10 bolts, lockwasher, and nut.

The tightening torque is 18.3 - 19.7 Nm (13.5-14.5 ft-lb).

3. Remove the contactor connections with a 17 mm (11/16") wrench. Contactor studs are

M10.

The tightening torque is 18.3 - 19.7 Nm (13.5-14.5 ft-lb).

4. Remove the 2 screws in the contactor support bracket.

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ESAB MobileFeed 201 AVS User manual

Brand: ESAB

Model: MobileFeed 201 AVS

Category: Welding System

Type: User manual

This manual is also suitable for

MobileFeed 301 AVS

Download PDF

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ESAB MobileFeed 201 AVS User manual

This manual is also suitable for

ESAB MobileFeed 201 AVS User manual

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