ESAB FeedControl - Aristo User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
Aristo®
Service manual
0740 800 202 GB 20181228
Valid for: serial no. 606-, 410-, 647-xxx-xxxx
FeedMech4804, FeedControl
TABLE OF CONTENTS
0740 800 202 © ESAB AB 2018
READ THIS FIRST.................................................................................... 3
INTRODUCTION....................................................................................... 4
TECHNICAL DATA ................................................................................... 5
WIRING DIAGRAM................................................................................... 6
FeedControl & FeedMech 4804 ............................................................. 6
Component description ......................................................................... 8
DESCRIPTION OF OPERATION.............................................................. 9
13AP1 Control board.............................................................................. 9
13AP1:1 Power supply ......................................................................... 9
13AP1:2a Start / Stop........................................................................... 10
13AP1:2b Continuous water cooling (valid for serial nos.from
647-xxx-xxxx) .......................................................................................
11
13AP1:3 Gas valve............................................................................... 11
13AP1:4 Motor driving / braking ........................................................... 12
13AP1:5 Pulse generator input ............................................................ 13
13AP1:6 Monitoring gas flow................................................................ 13
13AP1:7 The CAN bus ......................................................................... 14
Communication interruptions............................................................. 14
13AP1:8 I/O.......................................................................................... 15
13AP1:9 Arc voltage sensing ............................................................... 15
13AP1 Component positions................................................................ 16
13AP2 I/O board...................................................................................... 18
13AP2:1 Power supply ......................................................................... 18
13AP2:2 Input signals .......................................................................... 18
13AP2:3 Output signals........................................................................ 19
13AP2 Component positions................................................................ 19
FAULT CODES ......................................................................................... 20
Fault log................................................................................................... 20
Fault code description ........................................................................... 20
SERVICE INSTRUCTIONS....................................................................... 22
What is ESD? .......................................................................................... 22
Service aid .............................................................................................. 22
Reconnection for welding torch with self-cooling .............................. 23
SPARE PARTS ......................................................................................... 24
Rights reserved to alter specifications without notice.
READ THIS FIRST
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© ESAB AB 2018
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 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 "SPARE PARTS", page24.
This manual contains details of design changes that have been made up to and including
November 2016.
The manual is valid for: FeedMech 4804 and FeedControl with serial numbers 606-xxx-xxxx,
410-xxx-xxxx and 647-xxx-xxxx.
The FeedMech 4804 and FeedControl are designed and tested in accordance with
international and European standards IEC/EN 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 standard.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
INTRODUCTION
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© ESAB AB 2018
INTRODUCTION
The wire feed unit consist of a drive unit (FeedMech 4804) and a separate electronic unit
(FeedControl).
The wire feed unit is intended for MIG/MAG welding along with robotic equipment.
NOTE!
The wire feed unit utilizes the robot's safety system to obtain maximum interference
protection.
Example of a robotic welding system
TECHNICAL DATA
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© ESAB AB 2018
TECHNICAL DATA
FeedMech 4804 FeedControl
Power supply 42 V 50-60 Hz 42 V 50-60 Hz
Power requirement 378 VA 378 VA
Motor current I
max
9.0 A 9.0 A
Settings data
Wire feed speed 0.8 - 25.0 m/min
Torch connection EURO
Wire dimension
Fe 0.6 - 2.4 mm
Ss 0.6 - 2.4 mm
Al 1.0 - 1.6 mm
Cored wire 0.8 - 2.4 mm
Operating temperature -10 to +40°C -10 to +40°C
Weight 9.7 kg 4.9 kg
Dimensions (l x w x h) 383 x 161 x 287 mm 330 x 118 x 320 mm
Shielding gas Gases for MIG/MAG welding Gases for MIG/MAG welding
max pressure 5 bar 5 bar
Maximum permissible load at
60% intermittents50 500 A 500 A
100% intermittents 280 A 280 A
Enclosure class IP2X IP2X
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/104°F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP2X is intended for indoor use.
WIRING DIAGRAM
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© ESAB AB 2018
WIRING DIAGRAM
FeedControl & FeedMech 4804
WIRING DIAGRAM
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© ESAB AB 2018
WIRING DIAGRAM
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© ESAB AB 2018
Component description
Component Description
13AP1 Main circuit board, with control electronics. See the description in "13AP1
Control board", page9.
13AP2 I/0 circuit board. see the description in "13AP2 I/O board", page18.
13C1 - 13C3 Capacitor, 0.1 μF
13G1 Pulse generator. Incorporated in motor 13M2.
13HL1 Lamp, indicating power supply on.
13M2 Wire feed motor with pulse generator.
13M3 Wire feed motor.
13RE1 Contactor for activation of reversed wire feed.
13SB1 Push-button, reversed wire feed.
13SB2 Push-button, gas purging.
13SB3 Push-button, inching.
13SL1 Micro-switch, gas flow guard.
13XP . . Plug connectors.
13XS . . Socket connectors.
13YV1 Solenoid valve for welding gas.
13YV2 Solenoid valve for air.
DESCRIPTION OF OPERATION
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© ESAB AB 2018
DESCRIPTION OF OPERATION
13AP1 Control board
Spare part boards
CAUTION!
This circuit board looks identical to the control board used in other wire feed units, but
there may be differences both in hardware and software. If wrong board is used, it
might be damaged. Make sure that the replacement board has correct article number,
see the spare parts list.
Circuit board identity
The control board has a machine ID, a hardware ID and a unit type number. To read this you
need the ESAT service kit, see "Service aid", page22.
• The machine ID determines which type of wire feed unit the board is intended for.
• The hardware ID shows design and type of circuit board.
• The unit type is used for identification on the can bus.
The ID numbers of this board are:
Machine ID = 9
Hardware ID = 6
Unit type = 3
13AP1:1 Power supply
The wire feed unit is supplied at 42 V from the control current power supply transformer in
the welding power source. The feed unit can briefly draw up to about 8 A when accelerating
the wire.
DC supplies
The diodes D13 - D16 rectify the 42 V AC supply. The rectified voltage is used to power the
wire feed motor(s). It also powers the switched voltage regulator.
DESCRIPTION OF OPERATION
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IC21, IC8, Q12, L1 and D37 forms a switched voltage regulator. The +24 V output voltage of
the regulator supplies the +15 V and +5 V regulators, VR2 and VR1. It also supplies the
reference circuit IC22, which generates +2.5 V reference voltage, this is used by the
analogue inputs of the processor.
Voltage monitoring
If the +60 V supply drops below 42 V or exceeds 78 V, the control panel displays fault
code9. This fault does not disable any functions.
The +24 V is monitored by IC12 and potential divider R129IR130. If the voltage drops to
19.5V or less, IC12 generates a warning signal to the processor, which responds by
stopping the wire feed and then all communication on the bus. The control panel displays
fault code 4.
The +15 V is monitored by the processor and potential divider R152IR153. If the 15 V supply
drops below 13 V or exceeds 17 V, the control panel panel displays fault code 8. This fault
does not disable any functions.
13AP1:2a Start / Stop
The Start and Stop commands come from the robot, via the CAN bus.
Terminals E1 and E2 are intended for Start / Stop signal from a manual welding torch, this is
not used by the FeedControl.
DESCRIPTION OF OPERATION
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© ESAB AB 2018
13AP1:2b Continuous water cooling (valid for serial nos.from 647-xxx-xxxx)
To attain continuous water cooling when welding, connector 13XS80 is connected to
terminal E in FeedControl units with serial numbers from 647-xxx-xxxx. The connector
contains a jumper between terminals E3 and E4, which results in continuous operation of
the water pump when welding.
NOTE!
If the control board is replaced, connector 13XS80 must be removed from
the old board and connected to the new board. Otherwise the welding
torch will have no cooling!
NOTE!
If the wire feeder is used together with a self-cooled welding torch,
connector 13XS80 must be removed. Otherwise the water pump will
operate continuously and will ultimately break down! For details, see section
"Reconnection for welding torch with self-cooling", page23.
13AP1:3 Gas valve
The gas valve is controlled by the microprocessor. In normal operation the gas valve opens
when the start signal is activated by the robot. The gas valve can also be opened by a
separate signal from the robot.
DESCRIPTION OF OPERATION
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13AP1:4 Motor driving / braking
Schematic diagram of the motor drive stage
Driving
The motor is powered from the smoothed +60 V supply. Pulse-width modulation of transistor
Q4 varies the effective motor voltage. Pulse frequency is 39 kHz, and the maximum
conduction period is 97 % of the pulse period. Freewheel diode D27 provides current path
during the pulse off periods.
The feed roller speed at the maximum wire feed speed of 25 m/min is 167 r/min.
Current monitoring
Resistor R114 generates a voltage signal proportional to the motor current.
This voltage is applied to potential divider R105/R106 and the output is compared with a
reference voltage at voltage comparator IC14:11. The reference voltage is provided by the
microprocessor via R104.
The current limit is between 15 and 18 A on starting. After one second, this is reduced to a
lower value. The current limit is related to the pulse peak current.
If the current exceeds the current limit, IC14:2 interrupts the gate pulse to Q4.
The current falls, and Q4 conducts on the next gate pulse, which is again interrupted if the
current is still too high. This sequence continues until the motor current has fallen below the
current limit.
Speed monitoring
Wire feed speed is monitored by the microprocessor on the circuit board.
Wire feed is stopped if the feed speed deviates from the set speed by more than 1.5 m/min
for more than 5.1 seconds. The control panel displays fault code 11.
DESCRIPTION OF OPERATION
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© ESAB AB 2018
Braking
Capacitor C67 is charged via diode D31 when the motor starts. Zener diodes D33 and D34
limit the voltage to 15 V.
When optocoupler IC11 is energised, its output transistor conducts and connects capacitor
C67 to the gate of transistor Q2, which conducts and short-circuits the motor supply via
dynamic braking resistors R71 and R79. The resistors limit the current to about 20 A.
Reversed feed
Activation of contactor 13RE1 reverses the feed direction, see "13AP2:3 Output signals",
page19.
13AP1:5 Pulse generator input
The pulse generator, 13G1, is fitted to drive motor 13M2. It generates 60 pulses per
revolution, which means that, at a wire feed speed of 25 m/min, the pulse frequency is
8192Hz.
13AP1:6 Monitoring gas flow
The FeedControl is prepared for monitoring gas supply.
The control panel displays fault code 32 if the inputs is open.
DESCRIPTION OF OPERATION
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13AP1:7 The CAN bus
The circuit board includes a driver for the CAN bus, IC2, which looks after communication
with the control panel and with other units in the system.
Although the welding power source supplies a +12 V power supply to the control panel, this
is not used on circuit board 13AP1. 0 V on the circuit board is connected to 0 V in the control
panel.
Starting sequence
0n power-up, the board's CAN controller reads in the bus
speed from the microprocessor: 400 kbit/s.
The circuit board displays the starting sequence from
power-up.
LED1 lights red. Then LED1, LED2 and LED3 lights green.
LEDs on circuit board 13AP1
When the board has been initiated, and the wire feed unit is in the application program, LED1
flashes continuously with a green light.
There is more information about the operation of the CAN bus in the service manual for the
power source.
Communication interruptions
The control panel displays fault codes 12 and/or 14 if communication between the control
panel and the FeedControl or power source fails.
Check the following points in the event of problems with CAN communication:
• That a terminating resistor is fitted.
• The control cable:
Check that the correct type of cable is being used, i.e. the same as that between the
power source and the wire feed unit when the equipment was delivered.
Check that the cores are correctly connected. CAN H and CAN L must be carried by
the twinned pair.
• Check that all screen connections are sound.
• FeedControl: Check that there is good contact at the connections to capacitor 13C3.
See the main wiring diagram in "FeedControl & FeedMech 4804", page6.
DESCRIPTION OF OPERATION
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© ESAB AB 2018
• Power source: Check that there is good contact with the chassis connection to the
control circuit board, the interference suppression board and the interference
suppression capacitors.
• Check the power supply voltages on circuit board 13AP1.
• If there are no faults in any of the above, replace circuit board 13AP1.
13AP1:8 I/O
Terminal BA is the interface connection to the I/0 board.
See "13AP2:2 Input signals", page18.
13AP1:9 Arc voltage sensing
In order to avoid spurious voltage drops when measuring the welding arc voltage, the power
source senses the arc voltage via the filler wire and the feeder unit motor.
DESCRIPTION OF OPERATION
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© ESAB AB 2018
13AP1 Component positions
DESCRIPTION OF OPERATION
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DESCRIPTION OF OPERATION
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© ESAB AB 2018
13AP2 I/O board
13AP2:1 Power supply
The I/0 board is voltage supplied by the control board.
13AP2:2 Input signals
Inching
When switch 13SB3 is pressed, the wire is fed forward with the latest used wire feed speed.
The welding power source is not activated.
Reverse
When switch 13SB1 is pressed, the wire is fed backwards with the latest used wire feed
speed. The welding power source is not activated.
Gas purge
When switch 13SB2 is pressed, the gas valve, 13YV1, opens. The gas valve is controlled by
the control board. The welding power source is not activated.
Anti collision
The anti collision input is intended for an opening switch contact. When the input opens, the
control board sends a fault message to the robot via the CAN bus. If no Anti collision is
connected, the inputs (S and T or C and D in 13XS16) should be bridged to avoid fault
messages. See circuit diagram.
External activation
Inching, reverse, gas purge and spatter removal (air purge) may also be activated by the soft
buttons on the control panel, or by a command from an external control system (robot).
DESCRIPTION OF OPERATION
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© ESAB AB 2018
13AP2:3 Output signals
Reverse
When the reverse switch on the front of the wire feeder is depressed, the processor activates
relay 13RE1 and the wire is fed backwards with the latest used wire feed speed. The reverse
function can also be activated by a command to the processor from an external control
system.
Spatter removal
This function is controlled by the robot. The relay can also be activated by a soft button
function on the control panel.
13AP2 Component positions
FAULT CODES
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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 in the control panel. To read the entire fault
log, the equipment must be connected to the ESAT (see section "Service aid", page22.
Faults are monitored/detected in two ways: by test routines that are run on initiation and by
functions that can detect a fault when it occurs.
The control panel displays a unit number to indicate which unit has generated the fault. The
following unit numbers are used:
U0 = welding data unit U2 = power source U3 = wire feed unit
Fault code description
This manual describes the fault codes for the wire feed unit. The fault codes for 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 unit
after power-up. This fault does not disable any functions.
The program memory is damaged. This is a serious fault, that can have unforeseen
effects.
Action: Restart the equipment. If the fault persists, load new software via ESAT. If
the fault still persists, replace circuit board 13AP1, which carries the memory chip.
2 Microprocessor RAM error
The microprocessor is unable to read/write fromIto a particular memory address in its
internal memory. This test is preformed only as part of initiation after power-up. This
fault does not disable any functions.
Action: Restart the equipment. If the fault persists, replace circuit board 13AP1,
which carries the microprocessor chip.
8 +15 V power supply on circuit board 13AP1
The voltage is too high or too low: it must be within the range 12.8 - 16.8 V. This fault
does not disable any functions.
9 +60 V unregulated power supply on circuit board 13AP1
The voltage is too high or too low: it must be within the range 42.3 - 78.6 V. This fault
does not disable any functions.
11 Wire feed speed
The wire feed speed differs from the set value by more than 1.5 m/min for more than
3 seconds. This fault stops the wire feed. After a period of 5 seconds, restart is
permitted.
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ESAB FeedControl - Aristo User manual
- Category
- Welding System
- Type
- User manual
- This manual is also suitable for
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