ESAB RA 12 User manual

0740 800 201 Valid for serial no. 506-xxx-xxxx to 719-xxx-xxxx081118

MTA1 CAN, M1 10Prog CAN,

AT1 CAN, AT1 CoarseFine CAN,

RA 12, RA 23, RA T1,

MechT1 CAN, FS002 CAN,

T1 Foot CAN

Service manual

S0740 800 201/E081118/P20

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Rights reserved to alter specifications without notice.

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

INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminating resistors 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote controls 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MTA1 CAN 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M1 10Prog CAN 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AT1 CAN 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AT1 CourseFine CAN 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FS 002 CAN 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T1 Foot CAN 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MechT1 CAN 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control adapters 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RA 12 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RA 23 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RA T1 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAN adapter board, position of terminal J1 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT CODES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault log 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault code description 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is ESD? 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service aid 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S0740 800 201/E081118/P20

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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.

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

October 2008.

The manual is valid for:

Remote controls MTA1 CAN, M1 10Prog CAN, AT1 CAN, AT1 CoarseFine CAN, FS 002

CAN with serial number 506-xxx-xxxx.

Remote adapters RA 12 and RA 23 with serial number 506-xxx-xxxx.

Remote control MechT1 CAN with serial number 652-xxx-xxxx.

Remote adapter RA T1 with serial number 719-xxx-xxxx.

Remote control T1 Foot CAN with serial number 719-xxx-xxxx.

CAUTION!

Read and understand the instruction manual before

installing or operating.

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

INTRODUCTION

The remote controls and adapters are designed for ESAB's welding equipment with CAN

bus communication.

When the remote control or adapter is connected to the welding equipment, the control

panel is in remote control mode, the buttons and knobs are blocked. The functions can only

be adjusted via the remote control unit.

If the remote control unit is not to be used, it must be disconnected from the welding

equipment, otherwise the equipment will remain in remote control mode.

For more information about the operation of the remote control unit, see the operating

instructions for the control panels.

Only one remote control or adapter may be connected to the welding equipment.

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DESCRIPTION OF OPERATION

Terminating resistors

In order to avoid communication interference, the ends of the CAN bus must be terminated

by resistive loads.

The CAN remote controls and CAN adapters have a built-in terminating resistor. This

resistor can be disconnected by removing the jumper from terminal J1 on the CAN adapter

board. See the component positions diagram on page 16.

To check if the terminating resistor of the CAN remote control or CAN adapter is connected:

measure the resistance between pin 3 and 4 of the 4 pole panel plug, or the corresponding

pins of the 12 pole or 10 pole cable plug. The resistor is connected if the resistance is about

120 ohm.

Principal diagram of the CAN bus and connecting up of the terminating resistors

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cf08_mta1

Remote controls

The remote controls have a software identity, machine ID. The ID defines how the welding

equipment reacts on the commands from the remote control. When starting up the

equipment the MMC unit sends a request for the ID.

The remote controls are delivered with the correct machine ID. Spare part boards are

delivered without machine ID. To read or change the machine ID you need the ESAT

service kit, see page 19.

The welding data unit of the equipment must have correct software version in order for the

remote control to operate correctly.

The remote controls have a built-in terminating resistor. This resistor can be disconnected

by removing a jumper from terminal J1 on the CAN adapter board. See the component

positions diagram on page 16.

MTA1 CAN

Remote control for MIG/MAG, TIG and MMA

welding.

MIG/MAG: Setting wire feed speed

TIG: Setting current

TIG pulse: Setting pulse current

MMA: Setting current

MIG/MAG: Setting voltage or voltage deviation

+/- from the synergic line

TIG: No function

TIG pulse: Setting background current

MMA: Setting arc force

Locking knobs

Specifications

S Machine ID = 4

S Bus speed 400 kbit/s

S Termination resistor connected

S Connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specification.

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cf08_m110p

M1 10Prog CAN

Remote control for MIG/MAG, TIG and MMA

welding.

Choice of one of 10 program selections

MIG/MAG: Voltage deviation +/- from selected

program

TIG and MMA: Setting welding current +/- from

selected program

TIG pulse: Setting pulse current +/- from

selected program

Locking knob

Specifications

S Machine ID = 6

S Bus speed 400 kbit/s

S Termination resistor connected

S Connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specifications.

S0740 800 201/E081118/P20

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cf08_at1

AT1 CAN

Remote control for MMA and TIG welding.

MMA and TIG: Setting welding current

TIG pulse: Setting pulse current

MIG/MAG: Setting wire feed speed

Locking knob

Specifications

S Machine ID = 3

S Bus speed 400 kbit/s

S Termination resistor connected

S Connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specifications.

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cf08_at1cf

AT1 CourseFine CAN

Remote control for MMA and TIG welding.

Rough setting

Fine setting

Locking knobs

MMA and TIG: Setting of welding current

TIG pulse: Setting of pulse current

MIG/MAG: Setting of wire feed speed

Specifications

S Machine ID = 3

S Bus speed 400 kbit/s

S Termination resistor connected

S Connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specifications.

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ct08_fs002

FS 002 CAN

Remote control for TIG welding.

Potentiometer for setting of welding current,

positions 1 - 10

Foot pedal for weld start and setting of welding

current.

If potentiometer (1) is set at position 10, the

current is set, from min. to max. with the foot

pedal.

If potentiometer (1) is set at position 5, the

current is set, from .min. to 50% of max. current

with the foot pedal.

TIG pulse: Setting of pulse current

Specifications

S Machine ID = 5

S Bus speed 400 kbit/s

S Termination resistor connected

S Connection cable 5 metres with 4 pole

socket to 12 pole plug, included.

S Optional connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specifications.

S0740 800 201/E081118/P20

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ct08_t1f

T1 Foot CAN

Remote control for TIG welding. Controls welding

start and current.

Specifications

S Machine ID = 11

S Bus speed 400 kbit/s

S Termination resistor connected

S Connection cables, 5 metres:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

S0740 800 201/E081118/P20

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ct08_mecht1

MechT1 CAN

Remote control for MechTig.

Quick stop

Display

Indication of selected function

Pushbuttons for selection of function

Increase (+) the parameter value

Decrease (-) the parameter value

Selected function indication

Specifications

S Machine ID = 9

S Bus speed 500 kbit/s

S Termination resistor connected

S Connection cables:

4 pole socket to 12 pole plug

See the spare parts list for length

specifications.

S0740 800 201/E081118/P20

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cf08_ra12

Remote control adapters

The remote control adapters have a software identity, machine ID. The ID defines how the

welding equipment reacts on the commands from the remote control. Spare part boards are

delivered without machine ID. To read or change the machine ID you need the ESAT

service kit, see page 19.

The control panel of the equipment must have correct software version in order for the

remote control adapter to function correctly.

The adapters have a built-in terminating resistor. This resistor is disconnected on delivery.

It can be connected by short-circuiting the two pins of terminal J1 on the CAN adapter

board. See the component positions diagram on page NO TAG.

RA 12

Specifications

Remote control adapter RA 12 up to and

including serial number 506-640-4574.

S Remote control adapter with 12 pole

socket. Used for connecting analogue

remote controls to CAN-based

equipment.

S Two analogue inputs.

S Machine ID = 1

S Bus speed 400 kbit/s

S Termination resistor disconnected

S Connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specifications.

Specifications

Remote control adapter RA 12 from

serial number 506-640-4575.

S Remote control adapter with 12 pole

socket. Used for connecting analogue

remote controls to CAN-based

equipment.

S Two analogue inputs and start signal.

S Machine ID = 2

S Bus speed 400 kbit/s

S Termination resistor disconnected

S Connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specifications.

S0740 800 201/E081118/P20

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cf08_ra12

RA 12 up to and including serial number

506-640-4574

RA 12 from serial number 506-640-4575

S0740 800 201/E081118/P20

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cf08_ra23

RA 23

Specifications

S Remote control adapter with 23 pole socket.

Used for connecting analogue remote

controls to CAN-based equipment.

S Two analogue and seven digital inputs.

S Machine ID = 1

S Bus speed 400 kbit/ s

S Termination resistor disconnected

S Connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specifications.

S0740 800 201/E081118/P20

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cf08_rat1

RA T1

Remote control adapter, used for connection

of TIG torches with +/- function to CAN-based

equipment.

Specifications

S Machine ID = 10

S Bus speed 400 kbit/ s

S Termination resistor disconnected

S Connection cables:

4 pole socket to 12 pole plug or

4 pole socket to 10 pole plug.

See the spare parts list for length

specifications.

S0740 800 201/E081118/P20

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cf08_pos

CAN adapter board, position of terminal J1

View of the CAN adapter board

View of the CAN adapter and display board for the MechT1 CAN

S0740 800 201/E081118/P20

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cf08_f1

FAULT CODES

Fault codes are used in order to indicate and identify a fault in the equipment.

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 erase when

the next fault occurs.

Only the most recent fault message is displayed on the control panel. To read the entire

fault log, the machine must be connected to the ESAT: see service tools on page 19.

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

unit numbers are described in the service manual for the power source.

Fault code description

This manual describes the fault codes for the remote control. The fault codes for the other

units are described in the manuals for these units.

Code Description

1 EPROM check sum error - program memory error

Check sum test of the program memory, which is run only when initiating the power source

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.

Action: Restart the machine. If the fault persists, replace the adapter circuit board, 43AP1.

8 5 V power supply on adapter circuit board 43AP1

The voltage is too high or too low. This fault does not disable any functions.

Action: Restart the machine. If the fault persists, check the +12 V supply to the remote

control. If the fault still persists, replace the adapter circuit board, 43AP1.

9 10 V power supply on adapter circuit board 43AP1

The voltage is too high or too low. This fault does not disable any functions.

Action: Restart the machine. If the fault persists, check the +12 V supply to the remote

control. If the fault still persists, replace the adapter circuit board, 43AP1.

12 Communication error (warning)

The load on the system CAN bus is temporarily too high, or there is electric noise on the

bus.

Action: Check the equipment to ensure that only one remote control unit is connected.

See also section “The CAN bus” in the service manual for the power source.

15 Lost messages

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

by this fault.

Action: Check that all units are correct connected to the CAN bus. See also section “The

CAN bus” in the service manual for the power source.

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cf08_f1

SERVICE INSTRUCTIONS

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.

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

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cf08_f1

Service aid

We 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 sensitve

components from electrostatic discharge.

Contents:

S A conductive mat (size 610 x 610 mm)

S A 1.5 metre long ground cable with a

crocodile clip

S An adjustable wrist strap and cable with

an inbuilt protective resistor

Antistatic service kit

ESAT service kit

The software update is made from a PC, it has to be managed by a trained serviceman. For

this a PC program called ESAT, ESAB Software Administration Tool, is needed. The PC is

connected to the welding equipment by a cable connector and a CAN reader. From the

ESAT it is possible to update the software. ESAT also contains service functions by which it

is possible to control, change or read the different functions of the equipment.

For the installation and use of the ESAT you need a PC with operating system Windows.

The ESAT service kit contents:

S CAN adapter with connection cables

S CD with software

S Instruction manual for ESAT

Ordering no:

0458 847 880 PPCAN for connection to the print port of the PC

0458 847 881 USB2CAN for connection to the USB port of the PC

SPARE PARTS

The spare parts lists are published in separate documents that can be downloaded from

the internet: www.esab.com

Filename Product

0459 576 990 MTA1 CAN, M1 10Prog CAN, AT1 CAN, AT1 CoarseFine CAN, RA 12,

RA 23, RA T1, FS 002 CAN, T1 Foot CAN

0459 839 011 MechT1 CAN

ESAB AB

SE-695 81 LAXÅ

SWEDEN

Phone +46 584 81 000

www.esab.com

081016

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H

Vienna-Liesing

Tel: +43 1 888 25 11

Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.

Brussels

Tel: +32 2 745 11 00

Fax: +32 2 745 11 28

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.

Vamberk

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Herlev

Tel: +45 36 30 01 11

Fax: +45 36 30 40 03

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel: +33 1 30 75 55 00

Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

Andover

Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft

Budapest

Tel: +36 1 20 44 182

Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A.

Mesero (Mi)

Tel: +39 02 97 96 81

Fax: +39 02 97 28 91 81

THE NETHERLANDS

ESAB Nederland B.V.

Amersfoort

Tel: +31 33 422 35 55

Fax: +31 33 422 35 44

NORWAY

AS ESAB

Larvik

Tel: +47 33 12 10 00

Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o.

Katowice

Tel: +48 32 351 11 00

Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 8 310 960

Fax: +351 1 859 1277

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel: +421 7 44 88 24 26

Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A.

Alcalá de Henares (MADRID)

Tel: +34 91 878 3600

Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB

Gothenburg

Tel: +46 31 50 95 00

Fax: +46 31 50 92 22

ESAB international AB

Gothenburg

Tel: +46 31 50 90 00

Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem-MG

Tel: +55 31 2191 4333

Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 02 20

Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products

Florence, SC

Tel: +1 843 669 44 11

Fax: +1 843 664 57 48

Asia/Pacific

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 2326 3000

Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 45 670 7073

Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd

USJ

Tel: +603 8023 7835

Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 6861 43 22

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Representative offices

BULGARIA

ESAB Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

EGYPT

ESAB Egypt

Dokki-Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

ROMANIA

ESAB Representative Office

Bucharest

Tel/Fax: +40 1 322 36 74

RUSSIA

LLC ESAB

Moscow

Tel: +7 095 543 9281

Fax: +7 095 543 9280

LLC ESAB

St Petersburg

Tel: +7 812 336 7080

Fax: +7 812 336 7060

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

ESAB RA 12, AT1 CAN, AT1 CF CAN, FS 002 CAN, M1 10P CAN, MechT1 CAN, MTA1 CAN, RA 23, RA T1 - Remote controls, T1 Foot CAN User manual

Related papers

Other documents