ESAB WeldCloud™ Universal Connector User manual

Brand: ESAB

Model: WeldCloud™ Universal Connector

Type: User manual

ESAB WeldCloud™ Universal Connector allows you to monitor and analyze your welding data remotely. It wirelessly transmits welding parameters like current, voltage, and power to the WeldCloud™ server, offering real-time insights into your welding operations. The data can be accessed from any device with an internet connection, enabling you to track weld quality, identify trends, and make informed decisions to improve productivity and efficiency.

Service manual

0463 602 001 GB 20190502

Valid for: serial no. 849-xxx-xxxx

WeldCloud™ Universal

Connector

TABLE OF CONTENTS

0463 602 001 © ESAB AB 2019

READ THIS FIRST.................................................................................... 4

BEFORE STARTING SERVICE................................................................ 5

Service aid .............................................................................................. 5

INTRODUCTION....................................................................................... 6

Basic measuring principles................................................................... 6

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

Component description ......................................................................... 7

WeldCloud™ Universal Connector, valid from serial no.

849-xxx-xxxx ...........................................................................................

TECHNICAL DATA ................................................................................... 9

FIRMWARE UPDATE ............................................................................... 10

Firmware update using the "ESABUCMon" Android application ..... 10

System update using Microsoft Windows ........................................... 11

Download the firmware from the partner login page ............................ 11

Make a bootable image using Win32DiskImager ............................... 11

Upload the firmware to the WeldCloud™UniversalConnector............ 12

Factory reset........................................................................................... 12

TROUBLESHOOTING .............................................................................. 14

Pre power up checks ............................................................................. 14

Power up checks .................................................................................... 14

General power up check ...................................................................... 14

Detailed electrical troubleshooting ....................................................... 14

DISASSEMBLY AND REASSEMBLY ...................................................... 19

Removal and attachment of the top housing of the Electronics Box 19

Removal and attachment of the top housing of the Sensor Box....... 20

CALIBRATION .......................................................................................... 21

Definitions ............................................................................................... 21

Reference power source for calibration............................................... 22

Measurement methods and measurement tolerances ....................... 22

Equipment required................................................................................ 22

Calibration range .................................................................................... 22

Preparations for calibration .................................................................. 24

Calibration of current ............................................................................. 25

Calibration of voltage............................................................................. 26

Labeling................................................................................................... 26

REPLACEMENT INSTRUCTIONS ........................................................... 27

Replacing the lithium-ion battery (in the Electronics Box) ................ 27

Replacing the lithium coin cell battery (in the Electronics Box)........ 27

Replacing the welding cables (in the Sensor Box) ............................. 28

Replacing the connector........................................................................ 28

TABLE OF CONTENTS

0463 602 001 © ESAB AB 2019

SPARE PARTS AND ACCESSORIES ..................................................... 31

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 602 001

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READ THIS FIRST

Maintenance and repair work must 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.

The circuit boards are divided into numbered blocks. 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 the "SPARE PARTS" chapter

in this manual.

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

November 2018.

The manual is valid for: WeldCloud™ Universal Connector with serial number 849-xxx-xxxx.

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

The WeldCloud™UniversalConnector is designed and tested in accordance with the

standards stated in the instruction manual. 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 involved standards.

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.

BEFORE STARTING SERVICE

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BEFORE STARTING SERVICE

Service aid

ESAB 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 sensitive

components from electrostatic discharge.

Contents:

• A conductive mat (size 610×610mm /

24×24in)

• A 1.5m (3.28ft) long ground cable with

a crocodile clip

• An adjustable wrist strap and cable with

a built-in protective resistor

Antistatic service kit

INTRODUCTION

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INTRODUCTION

WeldCloud™ Universal Connector is a device used to enable communication between any

welding power source (ESAB made or any other) and the remote WeldCloud™ server. The

welding current and welding voltage are measured and the collected data are sent to the

WeldCloud™ cloud via Wi-Fi.

Basic measuring principles

WeldCloud™ Universal Connector measures the absolute average values of the welding

current and the welding voltage with a sampling rate higher 2500Hz. The power is

calculated directly from these current and voltage values. Then all the measuring channels

are reduced to 5samples per second on the basis of the rectified arithmetic mean.

The rectified arithmetic mean value (RAMV) is used in the direct current as well as in the

alternating current range, also at square wave welding forms.

NOTE!

The accuracy of the measurement is determined based on the RAMV.

Comparative instruments with RMS at alternating current can indicate different

values!

The amount of data created and stored with each weld is dependent of:

• The welding time

• The amount of information entered into the system prior to welding

After each weld, the data is automatically sent to the WeldCloud™ server that the

WeldCloud™ Universal Connector is connected to. If the WeldCloud™ connection is lost,

the data is internally stored. A maximum of 1000 weld seams can be internally stored. If the

system is reconnected, the internally stored data is automatically sent to the WeldCloud™

server.

WIRING DIAGRAM

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WIRING DIAGRAM

The WeldCloud™UniversalConnector is function module 25. The names of the circuit

boards and components included in the WeldCloud™UniversalConnector contains the

number 25 to indicate that they belong to the WeldCloud™ UniversalConnector. The circuit

boards and components are listed in the component description below.

Wires/cables within modules are marked 100 - 6999.

Wires/cables between modules are marked 7000 - 7999.

Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors

XS1 - XS99 (S = socket), XT1 - XT99 (T = terminal).

Circuit boards within each module have names such as 20AP1 - 20AP99.

20 = module association, 1-69

AP = circuit board

1 = individual identification number, 0-99

Transistors within particular modules have identification numbers such as 15Q1 - 15Q99.

15 = module association, 1-69

Q = transistor

1 = individual identification number, 0-99

Component description

Component Description

25 Gateway module (The WeldCloud™ Universal Connector) Wire

numbers 2500–2599

25AP1 Carrier board

25AP2 Battery holder board

25AP3 Sensor board

25AP4 Current sensor board

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

WIRING DIAGRAM

0463 602 001

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WeldCloud™ Universal Connector, valid from serial no.

849-xxx-xxxx

TECHNICAL DATA

0463 602 001

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TECHNICAL DATA

WeldCloud™UniversalConnector, Valid from serial no. 849-xxx-xxxx

Permissible load (I

60% duty cycle 500 A

100% duty cycle 400 A

MIG 15A/14.8V to 500A/39V

TIGHF 15A/10.6V to 500A/30V

10–100 V

Current and power at U

=30 V:

0.3 A

max

9 W

Measurement accuracy (regarding measured

current and voltage)

±2%

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

Battery data:

Technology Lithium-ion battery

Nominal voltage 3.7V(±0.1V)

Rated Capacity 2200mAh

Storage temperature -20 to +60°C (-4 to +140°F)

Charging temperature +5to+40°C (+41 to +104°F)

Dimensions (l × w × h):

Sensor box 318 × 234 × 74 mm (12.5 × 9.2 × 2.9 in.)

Electronics box 238 × 147 × 40 mm (9.4 × 5.8 × 1.6 in.)

Weight:

Sensor box 2.0 kg (4.4 lb)

Electronics box 0.7 kg (1.5 lb)

Totally including cables 7 kg (15.4 lb)

Enclosure class IP43

Application class

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP43 is intended for indoor and outdoor use; however, should not be

operated in precipitation unless sheltered.

FIRMWARE UPDATE

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FIRMWARE UPDATE

Firmware update using the "ESABUCMon" Android application

NOTE!

To perform a complete system update, see "System update using Microsoft

Windows", page11.

1. Find the latest firmware update file of type "UC_X.X.X-XXX_Update.tar" on ESABs

partner login web page.

2. Download the file and save it in the download folder of the Android device, e.g. in the

"TC75x\Internal storage\Download" folder.

3. Connect to the preferred WeldCloud™ Universal Connector unit.

4. Switch to the Config tab and enter your password to access the configuration menu.

The default password is Esab.

5. In the Firmware section of the screen, click File.

6. Select the downloaded firmware update file from the list and click Accept.

FIRMWARE UPDATE

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7. Upload the selected firmware update file to the WeldCloud™UniversalConnector, by

clicking the Update.

The WeldCloud™UniversalConnector will apply the update and reboot the system.

The update takes approximately three minutes to finalize. It is not possible to connect

to the unit during this time. The new firmware version is presented in the Config tab

next to Software version.

System update using Microsoft Windows

Equipment required

• APC with a microSD card reader

• AmicroSD card, minimum size 4GB

• Installed software to create a bootable image on the SDcard, for instance "Win32 Disk

Imager"

Download the firmware from the partner login page

1. Find the latest firmware update file of type "UC_X.X.X-XXX_FW.zip" on ESABs

partner login web page.

2. Download the file and save it.

3. Unzip the downloaded file.

The name of the unzipped file should be "UC_X.X.X-XXX_FW.img".

Make a bootable image using Win32DiskImager

1. Insert the micro SD card into the PC micro SD card reader.

2. Select the downloaded firmware image file from your PC by clicking the folder icon.

FIRMWARE UPDATE

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3. Write the image to the micro SD card by clicking Write.

The process will take approximately five minutes.

4. Remove the micro SD card when writing is finished.

Upload the firmware to the WeldCloud™UniversalConnector

1. Make sure the WeldCloud™ Universal Connector is powered off and disconnected

from the welding power source.

2. Remove the top housing of the Electronics Box (see "Removal and attachment of

the top housing of the Electronics Box", page19).

3. Insert the micro SD card into the micro SD card reader found on the carrier board

(25AP1).

4. Attach the top housing of the Electronics Box (see "Removal and attachment of

the top housing of the Electronics Box", page19) and connect the welding

cables.

5. Power up the welding power source and the WeldCloud™ Universal Connector.

Update of the firmware will start automatically when the WeldCloud™ Universal

Connector is energized. When the update is completed, the unit will power down

and the micro SD card can be removed.

6. Remove the micro SD card from the micro SD card reader.

Factory reset

1. Connect to the preferred WeldCloud™ Universal Connector unit.

FIRMWARE UPDATE

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2. Switch to the Config tab and enter your password to access the configuration menu.

The default password is Esab.

3. In the Information section of the screen, click Factory and then click Yes to start the

factory reset.

The WeldCloud™ Universal Connector will reset and reboot the system.

TROUBLESHOOTING

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TROUBLESHOOTING

Pre power up checks

WARNING!

Disconnect the welding cables from the welding power source and the welding torch.

Open the battery lid and remove the lithium-ion battery. Wait for at least 2minutes to

allow the capacitors to discharge before continuing troubleshooting!

1. Visually inspect the WeldCloud™ Universal Connector and its included parts (the

Sensor Box, the Electronics Box, the cables and the connectors) for any signs of

damage.

Remove the top housings from the Sensor Box and the Electronics Box and check the

printed circuit boards for burned varistors or other components.

2. Using a multimeter set to resistance test setting, measure the resistance between the

welding cables. The resistance should be = 20kΩ±10%.

If the measurement specification is not met, contact an authorized ESAB distributor or

service centre for further assistance.

Power up checks

General power up check

1. Insert the lithium-ion battery into the battery compartment of the Electronics Box and

measure the battery voltage. The voltage should be in the interval 3.2–4.2V.

If the measurement specification is not met, charge or replace the battery. Then

reattach the battery lid.

2. Connect the welding cables from the welding power source to the WeldCloud™

Universal Connector and from the WeldCloud™ Universal Connector to the load.

3. Start the welding power source and set it to an output of 10–100V and 15–500A.

4. Check that the processor LED on the electronics box is on with green fixed or flashing

light.

If the processor LED is off, continue troubleshooting according to "Detailed electrical

troubleshooting", page14.

5. Wait until the Bluetooth LED on the Electronics Box flashes in blue light (which means

that the Bluetooth functionality is "On" and connection is possible).

6. Connect the WeldCloud™ Universal Connector to the ESABUCMon application and

check the welding voltage and current readings presented in the application.

If there is no voltage or current reading presented in the ESABUCMon application,

continue troubleshooting according to "Detailed electrical troubleshooting", page14.

If the welding voltage and current readings presented in the ESABUCMon

application, deviates more than 2% from the values indicated by the welding power

source, calibrate the external sensor in the WeldCloud™ Universal Connector

according to "Calibration", page21. If the readings still deviates more than 2% after

calibration has been performed, continue troubleshooting according to "Detailed

electrical troubleshooting", page14.

Detailed electrical troubleshooting

1. Connect the welding cables from the welding power source to the WeldCloud™

Universal Connector and from the WeldCloud™ Universal Connector to the load.

2. Start the welding power source and set it to an output of 10–120 V and 50–500 A.

TROUBLESHOOTING

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3. Using a multimeter set to voltage test setting, with the negative test probe on CN7_1

and the positive test probe on CN7_2 on the sensor board (25AP3), measure the

voltage. The voltage should be in the interval 4.5–5.5V.

If the measurement specification is not met, contact an authorized ESAB distributor or

service centre for further assistance.

4. Using a multimeter set to voltage test setting, with the negative test probe on X12_1

and the positive test probe on X12_2 on the carrier board (25AP1), measure the

voltage. The voltage should be in the interval 4.5–5.5V.

If the measurement specification is not met, replace the signal cable between the

Sensor Box and the Electronics Box.

5. Check that the processor LED on the Electronics Box is on with green fixed or flashing

light.

If the processor LED is off, contact an authorized ESAB distributor or service centre

for further assistance.

6. Using a multimeter set to voltage test setting, measure the voltage between CN5_1

and CN5_2 on the sensor board (25AP3). The voltage should be =the welding

voltage multiplied by 0.0175±10%.

If the measurement specification is not met, contact an authorized ESAB distributor or

service centre for further assistance.

TROUBLESHOOTING

0463 602 001

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7. Using a multimeter set to voltage test setting, measure the voltage between X10_1

and X10_2 on the carrier board (25AP1). The voltage should be =the welding

voltage multiplied by 0.0175±10%.

If the measurement specification is not met, replace the signal cable between the

Sensor Box and the Electronics Box.

8. Connect the WeldCloud™ Universal Connector to the ESABUCMon application and

check the welding voltage reading presented in the application.

If the welding voltage reading presented in the ESABUCMon application, deviates

more than 2V (2% of the measuring range) from the welding power source, contact

an authorized ESAB distributor or service centre for further assistance.

9. Using a multimeter set to voltage test setting, with the positive test probe on CN4_1

and the negative test probe on CN4_2 on the sensor board (25AP3), measure the

voltage. The voltage should be in the interval 4.5–5.5V.

If the measurement specification is not met, contact an authorized ESAB distributor or

service centre for further assistance.

10. Using a multimeter set to voltage test setting, with the positive test probe on CN1_1

and the negative test probe on CN1_2 on the current sensor board (25AP4), measure

the voltage. The voltage should be in the interval 4.5–5.5V.

If the measurement specification is not met, contact an authorized ESAB distributor or

service centre for further assistance.

TROUBLESHOOTING

0463 602 001

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11. Using a multimeter set to voltage test setting, measure the voltage between CN1_3

and CN1_4 on the current sensor board (25AP4). The voltage should be = the

welding current multiplied by 0.0015625 ±30%.

If the measurement specification is not met, contact an authorized ESAB distributor or

service centre for further assistance.

12. Using a multimeter set to voltage test setting, measure the voltage between CN4_3

and CN4_4 on the sensor board (25AP3). The voltage should be = the welding

current multiplied by 0.0015625 ±30%.

If the measurement specification is not met, contact an authorized ESAB distributor or

service centre for further assistance.

13. Using a multimeter set to voltage test setting, measure the voltage between CN5_3

and CN5_4 on the sensor board (25AP3). The voltage should be = the welding

current multiplied by 0.0015625 ±30%.

If the measurement specification is not met, contact an authorized ESAB distributor or

service centre for further assistance.

14. Using a multimeter set to voltage test setting, measure the voltage between X10_3

and X10_4 on the carrier board (25AP1). The voltage should be = the welding

current multiplied by 0.0015625 ±30%.

If the measurement specification is not met, replace the signal cable between the

Sensor Box and the Electronics Box.

TROUBLESHOOTING

0463 602 001

- 18 -

15. Connect the WeldCloud™ Universal Connector to the ESABUCMon application and

check the welding current reading presented in the application.

If the welding current reading presented in the ESABUCMon application, deviates

more than 2V (2% of the measuring range) from the welding power source, contact

an authorized ESAB distributor or service centre for further assistance.

16. Using a multimeter set to voltage test setting and measure the voltage between

CN6_2 and CN7_1 on the sensor board (25AP3). The voltage should be 5.0 V ± 0.3 V.

If the measurement specification is not met, replace the signal cable between the

Sensor Box and the Electronics Box. If this does not solve the issue, contact an

authorized ESAB distributor or service centre for further assistance.

17. Using a multimeter set to voltage test setting and measure the voltage between X11_1

and X12_1 on the carrier board (25AP1). The voltage should be < 1 V. If the

measurement specification is not met, replace the signal cable between the Sensor

Box and the Electronics Box. If this does not solve the issue, contact an authorized

ESAB distributor or service centre for further assistance.

DISASSEMBLY AND REASSEMBLY

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DISASSEMBLY AND REASSEMBLY

WARNING!

Always disconnect the welding cables from the welding power source and the welding

torch and wait for at least 2 minutes to allow the capacitors to discharge, before

disassembling the Electronics Box or the Sensor Box!

Removal and attachment of the top housing of the Electronics Box

Equipment required

• Torx screwdriver T20

1. Unscrew the six screws located at the bottom of the Electronics Box and remove

the top housing.

2. After having finished the required service work, attach the top housing and tighten

the screws using the correct tightening torque according to the illustration.

DISASSEMBLY AND REASSEMBLY

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Removal and attachment of the top housing of the Sensor Box

Equipment required

• Torx screwdriver T25

1. Unscrew the eight screws located at the bottom of the Sensor Box and lift off the

top housing.

NOTE!

Make sure the sealing for the top housing is not lost.

2. After having finished the required service work, attach the top housing and tighten

the screws using the correct tightening torque according to the illustration.

NOTE!

Make sure the current sensor harness does not get squeezed between

the screw pillars in the top and bottom housings!

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ESAB WeldCloud™ Universal Connector User manual

ESAB WeldCloud™ Universal Connector User manual

ESAB WeldCloud™ Universal Connector User manual

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