ESAB MobileFeed 301 AVS User manual

Category
Welding System
Type
User manual

This manual is also suitable for

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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© ESAB AB 2016
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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© ESAB AB 2016
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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© ESAB AB 2016
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
1
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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© ESAB AB 2016
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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© ESAB AB 2016
WIRING DIAGRAM
MobileFeed 201, MobileFeed 301
WIRING DIAGRAM
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© ESAB AB 2016
DESCRIPTION OF OPERATION
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© ESAB AB 2016
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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© ESAB AB 2016
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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© ESAB AB 2016
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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© ESAB AB 2016
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
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© ESAB AB 2016
DESCRIPTION OF OPERATION
0558 012 632
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© ESAB AB 2016
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
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© ESAB AB 2016
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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© ESAB AB 2016
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
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© ESAB AB 2016
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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© ESAB AB 2016
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
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© ESAB AB 2016
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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© ESAB AB 2016
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 301 AVS User manual

Category
Welding System
Type
User manual
This manual is also suitable for

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