Mig 4002cw, Mig 4002c Mig 5002cw, Mig 5002c Mig 6502cw, Mig
Contents
1. 61 FAULT TRACING ere 62 ORDERING OF SPARE PARTS 62 NOTES ae 63 3 READ THIS FIRST Maintenance and repair work should be performed by an experienced person and electrical work only by 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 December 2010 Origo 4002cw Mig 4002 5002cw 5002c Mig 6502cw 6502c are designed and tested in accordance with European standard EN 60974 1 and EN 60974 10 On completion of service or repair work it is the responsibility of the person s etc performing the work to ensure that the product does not depart from the requirements of the above standard WARNING Many parts of the power unit are at mains voltage INTRODUCTION The Origo Mig 4002cw Mig 5002cw Mig 6502cw are MIG MAG welding2. The voltage input senses the welding voltage at the power source welding current terminals Y2 Y3 must be linked The signal from the arc voltage input drives the welding process controller On that basis the controller calculates in real time how much current must flow in the circuit at the next instant The controller activates deactivates the no load voltage reduction function The arc voltage signal provides data to the power source display panel 1sxx02cw 28 Sp positions a Log Dumt vel Dum ae p Fi r5 gt nb Er PG Seu 3 cr ta 2 LE EE S EK 28159 D Og p pot fl BEEBE gt z j Bs EE M EE f ggg A Bee 1sxx02cw BEE A BE 5 ACH10 Driver relays board That board co operates with CBO and realises following functions e driving transistors in chopper module e monitoring of voltage across capacitors in chopper module e driving cooling fan water pump and mains relay All function units are described below ACH10 1 Circuit diagram X1 X19 Scores chopper gatas mom capacitors battery 18
3. 51 OVEIVIGW TEST beo cet LE Eee euo bL Me 53 miei m LEE 53 Checking of output stage 54 Replacing of damaged transistors 55 High current aluminum leads 55 TOCe INSTRUCTIONS 56 SAFETY ane eee athe ee art 56 INSTALLATION Ille kena teen FER fun 57 Placing eae a 57 Assembly of components 58 Mains power Supply 59 OPERATION ore err eI xp a N 60 Connections and control 60 Overheating protection 60 Water connection 61 Water flow guard 61 MAINTENANCE 3 0 net ke ee Ree ee el ate Meee ende 61 Inspection and cleaning 61 Topping up the
4. AC 17V AC 13V Power supply unit provides two stabilized voltages 14V and 10V that supply PWM driver voltage comparator and some of relays LED diodes V19 V18 indicate presence of AC17V and AC13V 1sxx02cw 30 10 3 PWM driver Input stage CONTROL BOARD CB Control board provides PWM signal that drives transistors Q01 and Q02 in chopper module Transistors work in push pull mode Signal frequency on Q01 and Q02 gates is about 10kHz Those two transistors have common load R23 on ACH10 board In result frequency of signal that drives optocoupler V17 is 10kHz 10kHz gt 20kHz Optocoupler ensures grounds separation of CBO and ACH10 and provides signal powerful enough to drive PWM output stage Output stage connections with SEMIKRON chopper type module ui SEMIKRON TYPE CHOPPER MODULE TWISTED PAIR TWISTED PAIR chopper Output stage of PWM driver is built on transistors V12 V15 this ensures low impedance output which is necessary for fast switching of transistors in chopper module Resistors R20 R25 R27 R33 limit slew rate of output signal Transil V16 eliminates over and under shots in output signal which can never exceed 15V 1sxx02cw 31 ACH10 4 Pre charging voltage sense For softer turning on of main transformer T1 chopper module rectifier capacitors battery is pre charged before
5. Thermal cutout switch B1 is mounted under the winding of main transformer T1 and opens at a temperature of 1609C The duty cycle is valid for 409C Thermal cutout switch B2 is mounted on the heat sink beside the IGBT transistors and opens at a temperature of 759C If either of the switches operates the power source is stopped and LED D1 on the front panel lights The power source cannot be restarted until it has cooled sufficiently for the switch es to close 1sxx02cw 22 CB0 5 Current sensor OUTLETS 1sxx02cw cs nna Current sensor The current signal supplied to contact S3 on circuit board CBO is 200 mA at 400 A and is linearly proportional to the welding current Measuring the voltage between contacts 53 and 54 on circuit board CBO must show 0 195 at 100 of welding current U R x I gt 3 91 x 0 05 0 195 If circuit boards 01 or CS are replaced the machine must be recalibrated Offset potentiometer R201 is not mounted on circuit board The offset adjustment is carried out by fixed resistors At no load there must be voltage of 0 2 at input 53 of circuit board If the current sensor gives an incorrect value on no load it must be replaced The sensor must be connected to CBO when making the measurement 23 CB0 5 1 Calibrating the current sensor signal Connect the power source to a resistive load Connect a calibrated shunt in series with the load
6. 4002cw 4002c 5002cw 5002c 6502cw 6502c Service manual d for serial no 805 Xxx Xxxx READ THIS FIRST 4 INTRODUCTION TET SERRA NE SE ie 4 TECHNICAL DATA ttt ikea eee LE de aay 5 WIRING DIAGRAM 8 Component 8 4002c 5002c 6502c block diagram 9 2 230V 400 415 440 460 500 18 Burndy 23 lt gt Amphenol 19 19 DESCRIPTION OF OPERATION 20 CBO Control circuit board 20 CBO0 1 Circuit board identity 20 CBO 2 Power Suppl seed 20 CB0 3 The CAN bus ein peta pelea 21 3Terminatirig resistors ee sat BOL ie ees 22 4 Temperature monitoring 22 5 Current SENSO pee nee eae 23 CB0 5 1 Cali
7. 36 REMOTE CONTROLS iiss Soe Ree Eee 36 FAULT CODES ll dee RIP ene 37 Eault log EE 37 Fault code description power 4 38 6 2 2 41 Whatis ESD 12255 ful ee 41 Lee ded oe whee 42 ESAB Administration Tool ESAT 42 CAN supply service kit 42 Antistatic Service TR peni epa TI EBORE hee ak fi 43 Checking PWM 43 Checking thermal 46 Checking Flow guard only machines with Flow Guard 47 Checking pre charging Circuit cette eee eae 48 Checking Fan 2 48 Checking liquid pump Circuit 49 Checking the LED Indicators on board 50 Checking chopper block VO
8. ERROR LED 545 voltage jumper feedback from workpiece disabled Pie X02 Amphenol 18 Pole CAN Connector Burndy 12 Pole CAN Connector 15 XT1 Mig 4002c 5002c 6502c 230 500 V X10 X11 X12 X13 X14X15 X16 X17 SCONES MODULE CONNECTION P FAN N HA B1 41515178 50 209 160 C1 C2 3uF 6 208 911 T1 B3 8 em 3 s PUMP ON OFF T2 1 FAN ON OFF r 015 SI 4 4 216 MAIN TRANSFORMER 019 g 1 73 S2 POWER ON QO mu d multivoltage transforomer all types sources 575V L1 CAPACITORS VOLTAGE SENSE MTA188 HS BLACK bubs fi 388 E azo AN ON OFT 0349310979 9 58 N ri ACH1 25 HAR D PWM PWM TC2 OPTIONAL CO2 HEATER 1sxx02cw 16 BOX 81X INCLUDED IN CO2 KIT 4002c 5002c 6502c 230 500 C6 1 MAINS SUPPLY CONNECTION 230V 50 60Hz C5 10 nF CURRENT SENSOR 490 415 50Hz 440 460V 60Hz C4 100nF S V 50Hz NORMALLY CONNECTED THERMAL PROTECTION CB Control Board 0487201885 400A 9487291886 500A 0487201887 650A by jumper feedback from workpiece disabled lt pase H2 STP error Leo 946 closed voltage lt gt Prk PEPP C7 10 nF x02
9. PF20 1 Circuit diagram GND1 GND2 PF20 2 Components positions 91231587887123488789 6 1117 R3 R2 Ri 2 ci e C6 e L1 REMOTE CONTROLS Remote control can be connected to the power sources these are described in separate service manual with filename ordering Fr 1sxx02cw 36 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 55 Faults are monitored detected in two ways by test routines that are run on initiation and by functions that can detect fault when it occurs The control panel displays unit number to indicate which unit has generated the fault The following unit numbers are used UO control panel U2 power source U3 wire feed unit U4 remote control unit Fault Description Control Power Wire fe Remote code panel source ed unit control unit 6 8 High temperature 1 Lost contact with the power source X X X X X X X
10. 24 V power supply on circuit board The voltage is too high or too low it must be within the range 22 1 26 0 V 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 wire feed unit and or remote control unit are connected See also section CBO CAN bus 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 CBO The CAN bus High open circuit voltage The open circuit voltage has exceeded 113 V for more than one second The power source is turned off and cannot be restarted Turn off the mains power supply to reset the unit Action Turn off the mains power supply to reset the unit Transmitter buffer overflow The control board is unable to transmit information to the other units at a sufficiently high speed Action A break in the bus line can cause this fault Check the CAN cabling Turn off themains power supply to reset the unit 1sxx02cw 39 Fault Description code Receiver buffer overflow The control board is unable to process information from the other units at sufficiently high speed This fault is caused by abnormal loading of the microprocessor Action Turn off the mains power supply to reset the unit Program op
11. 1sxx02cw 26 1 Welding with the filler wire positive voltage sensing from the wire control cable wire feeder long welding cable power long welding cable external voltmeter load resistor This is the most common arrangement of arc voltage sensing The control panel must show the same voltage value as shown on the external voltmeter 0 6 V Adjust the display value by means of potentiometer R87 2 Welding with the filler wire negative voltage sensing from the wire control cable wire feeder long welding cable power source external voltmeter load resistor The control panel must show the same voltage value as shown on the external voltmeter 0 6 V Adjust the display value by means of potentiometer R103 1sxx02cw 27 3 with the filler wire positive or negative no external sensing from the wire or workpiece control cable wire feeder long welding cable power source long welding cable V external voltmeter load resistor The external voltmeter shows a value 0 2 1 6 V higher than the value shown on the control panel Do not adjust the value shown on the control panel this is already adjusted from 1 above CB0 7 Arc voltage input in MMA process No load voltage Ws I reducing device SE Over voltage outlet protection r ee Y2 X1
12. 2 73 lt lt Many D c52 j 20 C51 e F 1 Xx ae wn N 1 c 24 V Power supply to relay board 15 V Internal power supply 15 V Internal power supply on CBO 5 V Internal power supply 1sxx02cw 20 CB0 3 The bus 15 02 SS SS So sci 5V Can 12 Can 7 M 032 A IN fat eh 10V 4 eu EE GE TC1 w TJA ZN TI L4 0 Con Remote connection ON Can Can 12V Can CAN 12V 1 14 je rd SC3 CAN B 9 GALVANIC ISOLATED HH 02 CAN V EE or p 3 5V AT 6 D sub Can sf Ca 7 13 CAN A 3 i 6 gt TRANCIEVER m 5 ANE il E In scs BE 0 CANH R23 CAN B E i 0 ohm a ca CANAL I Unt i N D sub 9 Can i Con 82 250 5y 5V Con sce L 810 5 165 7 R26 CAN 82
13. C4 198nF THERMAL PROTECTION NORMALLY CONNECTED 2545 W MTA156 CB Control Board MTA100 0487201885 400A 9487201886 500A 0487201887 658A 945 ERROR LED 045 closed voltage by jumper feedback from workpiece disabled 1 MTA156 C7 100 02 Amphenol 19 Pole Burndy 12 Pole CAN Connector CAN Connector 15 02 Mig 4002cw 5002cw 6502cw 230 500 V WATER PUMP CAPACITORS X10 X11 X12 X13 14 15 X16 X17 VOLTAGE SENSE SCONES MODULE CONNECTION 058 1 og lt 5 5 Tm JUNCTION FAN MAX SPEED RED 812 328 me n FAN ON OFF 85 2 SI 8 4 3 MAIN TRANSFORMER ON OFF 9349310979 X40 6 5 1 932 PF28 8349 311 574 Ne TC2 PE 81X INCLUDED 2 KIT Tc2 I 1sxx02cw 14 Mig 4002cw 5002cw 6502cw 230 500 V O ET a 961 956 NORMALLY CONNECTED THERMAL PROTECTION CB Control Boord 0487201885 400A 04872018886 500A 0487201887 650A 945 closed YMTA1 156 156 C7 1 15 02 MAINS SUPPLY CONNECTION 180nF TC1 230V 50 80Hz 204 ees 4 C5 1 004 400 415V 5QHz C4 10 nF 440 460 60Hz ges eos 5 500V 5 Hz HZ
14. Set the power source to MMA mode Set welding current of 100 A Load the power source so that the voltage across the load is 24 V Measure the shunt voltage using a calibrated multimeter Using potentiometer R21 on circuit board adjust the shunt voltage to correspond to 100A 8 Check the current at low values as well 16 A at 19 22 V for which the tolerance is 1 A If the current is outside the tolerance replace current sensor CS NO TO fF OND gt Power source R21 SE a Al be iL r Position of potentiometer R21 on circuit board CBO 1sxx02cw 24 CB0 6 Arc voltage input Mig Mag G No load voltage reducing device Over voltage protection LL PWM Processor 73612 77243 1sxx02cw The arc voltage input senses the welding voltage regardless of the welding polarity or welding method If sensing via the welding filler wire is turned on the voltage present on filler wire will be used if not the voltage at the power source terminals is used instead The signal from the arc voltage input drives the welding process controller On that basis the controller calculates in real time how much current must flow in the circuit at the next instant The controller activates deactivates the no load voltage reduction function The arc voltage signal provides data to the
15. Amphenol 10 Pole Burndy 12 Pole CAN Connector CAN Connector 1sxx02cw z177 230V 400 415 440 460 500V MAINS SUPPLY CONNECTION 230V 50 60Hz 400 415V 50Hz 440 460V 60Hz 500V 50Hz 1sxx02cw 18 Burndy 23 lt gt Amphenol 19 00 5 lt gt 3 5 o 0 peo xe NENNEN ll 2 2 1 1sxx02cw 19 DESCRIPTION OF OPERATION Control circuit board The processor on the control board monitors and controls the various functions of the power source It obtains information on welding data and welding processes from the welding data board in the MMC control panel CB0 1 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 The machine ID defines which type of power source 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 the machines e Origo 4002c cw 38 e Origo M Mig 5002c cw 39 e Origo Mig 6502c cw 40 2 Power supply CBO 047 TC1 031 CH2 mm e 7 030 H1 umi H5 H3 24 2
16. In MIG Mag process without pressing the switch the torch PWM signal is not generated output signal should be about 9V which means that chopper transistors are off eee eee eee ee 10 0 25 Feb 08 10 16 Pos 6 400 05 JE eee Cee E 10 0 25 8 10 15 Checking thermal cutout Thermal cutouts are normally closed and form loop When either of the thermal cutouts opens fault must be indicated If overheating error is indicated all the time H2 led on check connections between thermal cutouts switches resistance of switches should be near 0 Ohm when temperature is below limit NOTE Not mounted connector also causes an error message 15 02 46 E D1 L R Over temp LED AA EA R175 2 046 d SA Nero Thermal switch 2 chopper transistors heatsink D A 060 8 B1 Thermal switch 0V p Main trafo Check that voltage distribution R32 R44 R54 and R172 is correct by measuring the voltage between C1 C4 U 9 4 0 5 Check that processor input P9 4 is high and the error message is displayed when C1 C4 is open Led 2 is on If direct junction between C1 and C4 don t remove an error message then problem is in hardware Check that processor input P9 4 is low when C1 C4 are shorted directly Status of thermal cutout input can be read using ESAT software Service func
17. OU Can ON E HAN 2 e vu 5 3 Cor MOSES Pov Me ee CAN OV Can A standardised communication CAN Controller Area Network bus is used for communication between the units of the machine Communication speed is 400 kbit s The CAN bus is connected in parallel to the connectors CAN A and CAN B The 12V Can and OV Can power supply is unregulated and is galvanically isolated from other parts of the control board The shell of the CAN connectors is connected to Can GND in the diagram below is connected to the power source chassis The CAN A connector is connected to remote control unit connector X02 Connector CAN is used for internal communication e g with the control panel See the machine connection diagram Voltage regulator supplies 5 power supply to the CAN circuits on If the CAN bus fails the control panel will normally generate a fault message Check the following points in the event of problems with CAN communications terminating resistor The CAN bus resistance must lie in the range of 50 130 ohm the optimum value is 60 ohm To check the resistance turn off the power source and measure the resistance between pins which represents CAN H and CAN L signals in socket X02 on the back of the machine connection cable between units Check that the correct type of cable is being used Check that each signa
18. 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 1sxx02cw 41 Service aid We can offer number of service tools that will simplify the service ESAB Administration Tool ESAT Ordering no 0458 847 880 ESAB Administration Tool ESAT is software that provides possibility of updating the software in power source ESAT contains also service functions by which it is possible to control change or read the different func
19. power sources which can also be used for MMA welding There are two variants of the power sources xx02c without cooling unit Origo M xx02cw with cooling unit The power sources are intended for use with the Aristo Feed 3004 or Aristo Feed 4804 wire feed units All the settings are made from the wire feed unit 1sxx02cw 4 TECHNICAL DATA go Mig Mains voltage Permissible load at 60 duty cycle 100 duty cycle Setting range DC MIG MAG MMA Open circuit voltage Open circuit power with cooling unit in energy saving mode 15 min after last welding Power factor at maximum current Efficiency at maximum current Control voltage Dimensions Ixwxh Weight with cooling unit Operating temperature Enclosure class Application classification Mains voltage Permissible load at 60 duty cycle 100 duty cycle Setting range DC MIG MAG MMA Open circuit voltage Open circuit power with cooling unit in energy saving mode 15 min after last welding Power factor at maximum current Efficiency at maximum current Control voltage Dimensions Ixwxh Weight with cooling unit Operating temperature 1sxx02cw 230 400 415 500 3 50 Hz 230 440 460 V 3 60 Hz Mig Mag 400 34 V 400 36 V Mig Mag 310 30 MMA 310 33 Mig Mag 16A 8V 400 A 34 V 16A 8V 400 36 Mig Mag 62V MMA 68V 5
20. the coolant must not exceed 70 C AN CAUTION The coolant must be handled as chemical waste FAULT TRACING Try these recommended checks and inspections before sending for an authorised service technican No arc e Check that the mains power supply switch is turned on e Check that the welding current supply and return cables are correctly connected e Check that the correct current value is set Welding current is interrupted e Check whether the thermal overload trip has operated during welding indicated by the orange lamp on the front e Check the main power supply fuses The thermal overload trips e Check to see whether the air filters are clogged operate frequently e sure that you not exceeding the rated data for the power source i e that the unit is not being overloaded Poor welding performance e Check that the welding current supply and return cables are correctly connected e Check that the correct current value is set e Check that the correct welding wires are being used e Check the main power supply fuses ORDERING OF SPARE PARTS Spare parts may be ordered through your nearest ESAB dealer see the last page of this publication 2sxx02cw 62 NOTES notes 63 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
21. 0 Fan off Argument 2 OxFF Fan full speed If fan is on the voltage between X7 4 X7 2 should be about 24 Be Careful High Mains Voltage is on X8 connector When fan is off voltage between X8 A X8 B should be about 230V When on High speed is on when temperature sensor B3 closes working of that circuit can be checked by shorting X7 2 X7 1 then K4 closes and fan operates on high speed When 48 1sxx02cw speed is low temperature sensor is open voltage between X7 2 X7 1 should be about 13V Fan On Off 25 Fan control Max Half speed temperature sensor 80 056 Checking liquid pump circuit Check if relay K2 on ACH10 closes when ELP switch on wire feeder is up When K2 on 10 is closed voltage on diode V11 should be about 24V Be Careful High Mains Voltage is on X6 connector When pump is off voltage between X8 A X8 C should be about 230V When on OV CB CONTROL BOARD S14K275V MICROCONTROLLER 230V AC WATER PUMP 1sxx02cw 49 Checking the LED Indicators on board The indications are two coloured LED indicators red and green One indicator can have three indication states off red on and green on Three indicators are used which means that 9 states can be indicated The following events will be indicated Event Indicator Indicator Indicator Power on and boot program execution started off off Boot program has establish
22. 00 W 700 W 60W 0 88 70 96 42 V 50 60 Hz 830 x 640 x 835 mm 149 kg 163 kg 10 to 40 C IP 23 5 go Mig 230 400 415 500 3 50 Hz 230 440 460 V 3 60 Hz Mig Mag 500 39 500 40 V Mig Mag 400 A 34 V MMA 400 A 36 V Mig Mag 16A 8V 500 39 16A 8V 500 40 V Mig Mag 62V MMA 68V 72 42 V 50 60 Hz 830 x 640 x 835 mm 185 kg 199 kg 10 to 40 C Enclosure class IP 23 Application classification s ig og Mains voltage Permissible load at 60 duty cycle 100 duty cycle Setting range DC MIG MAG MMA Open circuit voltage Open circuit power with cooling unit in energy saving mode 15 min after last welding Power factor at maximum current Efficiency at maximum current Control voltage Dimensions Ixwxh Weight with cooling unit Operating temperature Enclosure class Application classification 230 400 415 500 3 50 Hz 230 440 460 V 3 60 Hz Mig Mag 650 A 44 V 650 44 V Mig Mag 500 39 500 40 V Mig Mag 16A 8V 650 A 44 V MMA 16A 8V 650 A 44 V Mig Mag 62V MMA 68V 670 W 870 W 60W 0 90 76 42 V 50 60 Hz 830 x 640 x 835 mm 222 kg 236 kg 10 to 40 C IP 23 S Cooling unit Cooling power Coolant Coolant quantity Maximum water flow Duty cycle 2500 W at40 C temp difference and flow 1 50 96 water 50 gl
23. 11 85 BELGIUM S A 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 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 4351 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 Ib rica S A Alcal 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
24. 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 amp 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 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 E
25. 7 Connection for weldng current cable Indicating lamp overheating fault 8 Connection BLUE for cooling water to the wire feed unit 4 Connection for weldng current cable 9 Connection RED for cooling water from the wire feed unit 5 Connection for weldng current cable 10 A24 panel accessory Overheating protection The power source has one thermal overload trip which operates if the internal temperature becomes too high interrupting the welding current and lighting the orange indicating lamp on the front of the unit It resets automatically when the temperature has fallen and the indicating lamp will go out 2sxx02cw 60 Water connection The Aristo Feed has sensor ELP ESAB Logic Pump that senses if the water hoses of the welding gun are connected When water cooled welding gun is connected the water pump starts When connecting the cooling water hoses to from the Feed wire feed unit the mains ON OFF switch of the Mig must be in the OFF position Note if a water cooled welding gun is used when the pump is inactive the welding gun might be damaged therefore it is not recommended to use wire feeders not equipped with ELP Water flow guard The water flow guard interrupts the welding current in the event of loss of coolant and an orange indicating lamp on the front of the power source lights up The water flow guard is an accessory Ordering number see in user manual MAINTENANCE
26. 9 temperature sensor B3 is opened and fan is operating on low speed When temperature reaches 80 C limit sensor closes contactor on 10 is powered capacitor C1 is shorted by K4 contact and fan starts operating at full speed 1sxx02cw 33 ACH10 7 Cooling liquid pump CB CONTROL BOARD MICROCONTROLLER 230V WATER PUMP Water pump is controlled by microcontroller on board via transistors 047 036 relay K2 on ACH10 board ACH10 8 Flow guard CB CONTROL BOARD 10 FLOW GUARD SENSOR 19 x 5 10 23 26 X5 23 26 la X40 When liquid cooled torch is connected to wire feeder board CBO senses voltage on pin B10 that pin is pulled up by R34 on board ACH10 Contact in the flow guard closes when the liquid flow rate exceeds 0 7 minute If liquid is not flowing or the flow rate is smaller than 0 7 l minute an error is displayed and welding process is stopped Machines without a flow guard behave as there was always proper flow rate of cooling liquid All machines without a flow guard even without liquid cooling system have connection between X4 1 X4 2 15 02 34 ACH10 Components positions GSX 8 18 11 12 13 14 15 0000000000000 0000000000000 2 LJ LO EP MONTH 11215 5 7 18 11 12 35 15 02 PF20 Suppression circuit board
27. GYPT 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 www esab com ESAB AB 695 81 LAX SWEDEN Phone 46 584 81 000 www esab com 081016
28. Regular maintenance is important for safe reliable operation Maintenance must be executed by professional Only those persons who have appropriate electrical knowledge authorised personnel may remove the safety plates Note All guarantee undertakings from the supplier cease to apply if the customer himself attempts any work in the product during the guarantee period in order to rectify any faults Inspection and cleaning Check regularly that the power source is free from dirt The power source should be regularly blown clean using dry compressed air at reduced pressure More frequently in dirty environments Otherwise the air inlet outlet may become blocked and cause overheating To avoid this you can use an airfilter The airfilter is an accessory Ordering number in user manual Topping up the coolant ESAB ready mixed coolant is recommended for use See accessories in user manual e Fill with coolant The fluid level must not exceed the upper marking but neither must it be below the lower marking 2sxx02cw 61 e Disconnect the coolant hose for outgoing water welding torch blue connection in order for any trapped air to disappear e Connect the coolant hose again Note Coolant must be topped up if connecting a welding torch or connection cables that are 5 meters in length or longer When adjusting the water level by topping up the coolant hose does not need to be disconnected The temperature of
29. T ICLUDED 2 1sxx02cw 10 MAIN TRANSFORMER ON OFF d Ns CAPACITORS ACH1 5 5 X40 GREET C3 1 nF 11 X12 13 X14X15 X16 X17 8 SCOMES MODULE CONNECTION oi NTA 8 0349310979 CONNECTION MTA156 wr SEMIKRON MODULE MTA156 L1 VOLTAGE SENSE 4002cw 5002cw 6502cw 400 415 C6 19 nF C5 10 nF CURRENT SENSOR 961 C4 1 nF NORMALLY CONNECTED THERMAL PROTECTION CB Control Board 0487201885 400A 0487201886 500A 0487201887 650A e4sg H2 ERROR LED 046 closed voltage by jumper feedback from workpiece disabled 1 MTA156 C7 108nF x02 Amphenol 18 Pole Burndy 12 Pole CAN Connector Connector 1sxx02cw 11 4002c 5002c 6502c 400 415 L1 ae omm 5250 961 CAPACITORS 1 X11 X12 X13 14 15 X16 X17 VOLTAGE SENSE 8 SCONES MODULE CONNECTION 5 958 MTAI 0 ng lt 8 5 5 5 BLACK gu 5 g G RED 8 z 8 zx 5 8256 6 054 AN ON OFF a5 T2 0349310979 95 multivoltge Ne FEET transforomer in all types 032 x100 B X 81X INCLUDED IN CO2 KIT OPTIONAL CO2 HEATER 1sxx02cw 12 4002c 5002c 6502c 400 415 C6 19 nF CURRENT SENSOR 3 SC 061
30. X X X X X X X X X X X X X X X X X X X X X X 1sxx02cw 37 Fault Description Control Power Wire fe Remote code panel source ed unit control unit 19 Memory error in data memory 2 Memory allocation error x 22 Transmitter buffer overflow 23 Receiver buffer overflow X 9 2 0 i X X i X X Fault code description power source The fault codes for the control panel wire feed unit and the remote control unit are described in the manuals for these units This manual describes the fault codes for the power source Fault Description code 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 load new software via ESAT If the fault still persists replace circuit board CBO which carries the memory chip Microprocessor RAM error The microprocessor is unable to read write from to a particular memory address in its internal memory This test is preformed only on initiation after power up This fault does not disable any functions Action Restart the machine If the fault persists replace circuit board CBO which carries the microprocessor chip Memory error external RAM The microprocessor is unable to read write from to a pa
31. able areas 5092 4002cw 4002c Mig 5002cw 5002c Mig 6502cw 6502c Mains voltage 230 400 415 500 V 230 400 415 500 V 230 400 415 500 V Primary current 60 duty cycle 56 32 43 26 75 43 50 34 103 59 65 47 100 duty cycle 43 25 20 57 33 26 80 46 37 Mains cable area 4 10 4 4 mm 16 6 6 mm 25 10 10 mm Fuse anti surge 35 25 50 20 63 35 50 35 80 50 63 50 Hz 4002cw 4002c Mig 5002cw 5002c Mig 6502cw 6502c Mains voltage 230 440 460 V 230 440 460 V 230 440 460 V Primary current 60 duty cycle 56 32 43 26 75 43 50 34 103 59 65 47 100 duty cycle 43 25 20 57 33 26 80 46 37 Mains cable area 4 10 4 4 mm 16 6 6 mm 25 10 10 mm Fuse anti surge 35 25 50 20 A 63 35 50 35 A 80 50 63 50 A AAG Arc Air Gouging NB The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations They may not be applicable in other countries make sure that the cable area and fuse sizes comply with the relevant national regulations 2sxx02cw 59 General safety regulations for the handling of the equipment appear from page 56 Read through before you start using the equipment AN WARNING TIPPING RISK Fasten the equipment particularly if the ground is uneven or sloping Connections and control devices Mains supply switch 6 Control cable socket from to wire feeder 2 Indicating lamp power supply ON
32. brating the current sensor 24 6 Arc voltage input Mig Mag 25 CB0 6 1 Calibration of the arc voltage feedback 26 7 Arc voltage input in MMA process 28 CBO Components positions 29 10 Driver relays board 30 ACH10 1 Circuit diagram 30 ACH10 2 Power 30 ACH10 3 PWM driver ccc mrs 31 ACH10 4 Pre charging voltage sense 32 ACH10 5 Mains contactor circuit energy saving 33 AGH10 6 Cooling fan xis ka n baad Vac reni hen ioe dia ee awe 33 ACH10 7 Cooling liquid pump 34 AGH 10 8 Fow guarde stengt acit sts 34 10 Components positions 35 PF20 Suppression circuit board 36 PE20 1 Circuit diagram alee bead gaben us 36 PF20 2 Components positions
33. ch should be detected as conducting between output minus and battery minus outputs Battery minus is available on second heatsink and DC capacitors link and as additional washer with connector on capacitors side 1sxx02cw 54 Replacing of damaged transistors In order to replace damaged transistor following items have to be disassembled e diode rectifiers e output terminal DC link terminals unconnected from modules Important note IGBT module is symmetrical except two plastic pins for positioning PCB During replacement check if marked side of module is placed on capacitors side and ant the end is connected to DC link terminals Before placing new module its base plate has to be covered by thin layer of thermal conducing silicon paste Fixing torques e module to heatsink screw M5x18 T 3 5Nm e terminal screw M6x16 T 3 5Nm NOTE Always replace all modules High current aluminum leads maintenance NOTE In case of disconnecting the high current aluminum leads of main transformer or rectifier bridge the service technician must perform following actions prior to re connecting e mechanically remove the oxides from the contact surfaces e cover the contact surfaces with thin layer of electro conducting paste EL 5 846 140g tube Ordering No 0349 312 885 re connect the lead and tighten with torque 10Nm 1sxx02cw 55 INSTRUCTIONS This chapter is an extract from the instructions f
34. ected securely Work on high voltage equipment may only be carried out by a qualified electrician Appropriate fire extinquishing equipment must be clearly marked and close at hand Lubrication and maintenance must not be carried out on the equipment during operation WARNING Read and understand the instruction manual before installing or operating 2sxx02cw 56 INSTALLATION The installation must be executed by professional WARNING This product is intended for industrial use In domestic environment this product may cause radio interference It is the user s responsibility to take adequate precautions Lifting instructions The power supply should be lifted by means of its lifting eye The handle is only intended for pulling it along the ground Placing Position the welding power source such way that its cooling air inlets and outlets are not obstructed 2sxx02cw 57 Assembly components A WARNING During transport the rear wheels of the power source are in their forward position Before use place the wheels in their rear position 2sxx02cw 58 Mains power supply 400 415V 3 50 Check that the unit is connected to the correct mains power supply voltage and that it is protected by the correct fuse size protective earth connection must be made in accordance with regulations Rating plate with supply connection data Recommended fuse sizes and minimum c
35. ed contact received red red Id message Application start green green green Application initiated operationable green off off Flashing 0 25 4 2 flashing Watchdog timeout red Non recoverable communication error CAN bus off Program Loading started off green Program Loading in Progress green off Flashing every 20th CANmessage flashing Program Loading OK green green Program Loading Failure red green Default value set Attribute memory reset red green n the boot master the program load timeout will produce this indication 1sxx02cw 50 Checking chopper block VO Chopper is assembled form three main blocks input rectifier capacitors bank and output IGBT stage Chopper module schematic diagram There are three types chopper modules each one for particular power source 4 OrigoMig 4002c 4002cw 5 5002c 5002cw 6 OrigoMig 6502c 6502cw Differences lay within heatsinks dimensions type and number of power IGBT modules capacitance of capacitors type of rectifier diodes All of types have similar structure Assembled module view 1sxx02cw 51 1sxx02cw Overview test Each block consist of at least two serviceable parts The first step of control is taking overview and checking if any parts are looking abnormal Broken parts can have marks of thermal damage change of colors or shape If after that checking nothing was find out next step is
36. electrical testing Rectifier test The first part for test is input rectifier consisted of diodes and two heatsinks details no 15 One heatsink is on positive potential and second on negative one For checking diodes following steps can be achieved 1 Use measuring instrument with semiconductor conduction test possibility Connect one terminal to one phase AC input detail no 9 and second to front opposite side to AC terminals heatsink detail no 15 If diode is conducting from AC to heatsink replace measuring terminals and check if diode is blocked If so diode is working properly this phase 2 Next check second diode this phase by opposite side conduction test Diode conduct from heatsink to AC terminal If so diode in this phase is working properly 3 If diode is short circuited or non conducted in both sides it means diode is broken and its replace is necessary Diode is screwed into aluminum heatsink and has to be carefully removed and new one screwed with torque 10Nm 90lb in 4 Repeat that test in other phases Important note in case of damage of any diode replace both in each broken switch 1sxx02cw 53 For easy disassembly unscrew both rectifier heatsinks from capacitors side and plastic shelf with AC terminals and disassemble two M6 screws down the heatsink on opposite side Important note all diode threads have to be covered with very thin layer of No 2 Electro Joint Compound before replaci
37. energising contactor K1 Voltage on capacitors is sensed by comparator A 3A and optocoupler V6 is turned on when sensed voltage is more than 44V this is signalized by LED diode V4 Voltage across C10 is turning down by optocoupler this is sensed by microcontroller on CBO trough input G 2 Pre charging circuit Chopper module capacitors battery is pre charged by additional wounding on TC1 transformer Resistor R1 limits charging current to safe value and protects TC1 against overloading during welding 1sxx02cw 32 ACH10 5 Mains contactor circuit energy saving CB CONTROL 8 8 Mains is controlled microcontroller on board via transistors 042 Q31 relay 1 on ACH10 board RC snubber element 9 suppress over voltages transients during turning off the K1 Energy saving If welding source 1 not used process longer than 15 minutes the microcontroller turns off the contactor K1 and source is in energy saving mode Pressing switch on torch enables source for welding K1 closed again ACH10 6 Cooling fan CONTROL 2 Fan On Off Fan control speed Cooling fan is controlled in ON OFF principle by microcontroller on board CBO via transistors Q38 Q37 and relay K3 on board ACH10 Fan has two speeds hardware controlled Until temperature on chopper transistor heatsink is below 80
38. erating fault Something has prevented the processor from performing its normal program duties The program restarts automatically The current welding process will be stopped This fault does not disable any functions This fault should never occur Action Contact ESAB if the fault does occur Stack overflow The stack memory is full This fault should never occur the fault code is intended as an aid during development work Action Contact ESAB if the fault does occur No cooling liquid flow The flow monitor switch has operated The current welding process will be stopped and cannot be restarted Action Check the cooling water circuit and pump Water flow monitoring is an option No gas flow Gas flow is less than 6 l min Action Check the gas valve hoses and connectors Gas monitoring is fitted only to special versions of the TIG and MIG machines 1sxx02cw 40 SERVICE INSTRUCTIONS WARNING STATIC ELECTRICITY can damage circuit boards and electronic components e Observe precautions for handling electrostatic sensitive devices e 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
39. l is being carried by the correct core CAN H and CAN L must be carried by the twinned pair e All screen connections must be solid e Good contact with the chassis connections from to the control board suppressor board and suppressor capacitors See the main circuit diagram 21 Terminating resistors MMC panel Power source Wire feeder Remote control Unit no 0 Unit no 2 Unit Unit no 4 120 ohm CAN high 120 where low Principal diagram of the CAN bus and connecting up of the terminating resistors In order to avoid communication interference the ends of the CAN bus must be terminated by resistive loads One end of the CAN bus is at the control panel which incorporates terminating resistor The other end is in the power source and it must be fitted with terminating resistor If CAN remote control with terminating resistor is connected to the power source the terminating resistor must be removed from the power source The CAN remote controls and CAN adapters have a built in terminating resistor This resistor can be disconnected or connected by moving a jumper See the service manual for the CAN based remote controls filename 0740 800 170 CB0 4 Temperature monitoring D1 Over temp LED AA E T m 2 046 061 Thermal switch chopper transistors heatsink 62 B2 La 060 B1 Thermal switch Main trafo
40. ler wire positive voltage sensing from the wire and workpiece Y1 and Y2 must be linked This method allows for the voltage drop on both the supply and return conductors The input signal is measured between X1 and Amplifier 14 is active Note If the voltage signal connection to X3 is lost the power source loses control of the arc voltage CB0 6 1 Calibration of the arc voltage feedback R93 RIO4 Cl Positions of potentiometers 87 R103 circuit board The arc voltage input can be calibrated using trimming potentiometers R87 and R103 on circuit board The board has been calibrated in the factory further adjustment should not normally be necessary Check that there is short circuiting link across connectors Y2 Y3 see the circuit diagram above Connect wire feed unit to the power source Connect long welding current cables to give an appreciable voltage drop in the cables Connect a wire to the feed rollers and connect an external voltmeter as shown in the diagrams on next page Set the power source to MIG short arc welding mode and apply resistive load to give current of 100 A at 25 30 V Start the power source from the welding gun trigger contact and adjust the current by changing the wire feed speed setting Adjust the voltage by varying the load resistor Use properly calibrated external voltmeter to measure the output voltage of the machine
41. ng Also heatsink side which is connected to DC link has to be covered with No 2 EJC Checking of output stage Output stage is made of IGBT modules assembled on main heatsink Each module is equipped with PCB containing gate resistors and protection diodes For detection of transistors go in following order 1 Check transistors gate resistance and if is lower than 800W it means transistor s gate is broken For this test use measuring instrument and measure resistance between red and black cables in pairs into control plug If resistance of at least one pair is lower than limit value both transistors must be replaced 2 Modules operate in parallel but electrically they act as single switches one diode and one transistor 3 Check chopper diode using diode conduction tester check if between output minus terminal and output plus terminal diode is conducting After passing this test check if diode is blocked non conducting in opposite direction If test is positive diodes are working properly 4 Checking chopper transistor a First measure resistance between output minus and battery minus terminals If it is short circuited at least one transistor is broken Both transistors should be replaced b If transistor gates are properly working and no short circuit is detected use 15V DC 100mA supply source and connect positive potential to red control cable and negative to black control cable After supplying gate transistor swit
42. or the Origo M 4002c 4002cw 5002c 5002cw and 6502c 6502cw SAFETY Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions Safety precautions must meet the requirements that apply to this type of welding equipment The following recommen dations should be observed in addition to the standard regulations that apply to the workplace All work must be carried out by trained personnel well acquainted with the operation of the welding equipment Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment 1 Anyone who uses the welding equipment must be familiar with its operation location of emergency stops e its function relevant safety precautions welding 2 The operator must ensure that nounauthorised person is stationed within the working area of the equipment when it is started up no one is unprotected when the arc is struck 3 The workplace must be suitable for the purpose e be free from draughts 4 Personal safety equipment Always wear recommended personal safety equipment such as safety glasses flame proof clothing safety gloves Do not wear loose fitting items such as scarves bracelets rings etc which could become trapped or cause burns 5 General precautions Make sure the return cable is conn
43. ories listed in user manual Rectifier Thermal switch Protects the main transformer against excessive temperature Thermal switch Protects the chopper block against excessive temperature Thermal switch Controls the speed of fan motor M1 Current sensor Resistor pre charging Inductor Control circuit board ACH10 X02 Driver relays circuit board Chopper module Connector r Amphenol 10 pole or Burndy 12 pole obsolete For connection to from the wire feed unit Origo M Mig 4002c 5002c 6502c block diagram 1sxx02cw switch POWER ON VO chopper block mains transformer ann rectifier il vf 10 GE driver relay board control board current sensor Bi thermal LL sensor pre charging overheat sense voltage feedback ERROR LED fan speed control FAN optional B3 i thermal 88 sensor HENG MMC panel True ARC voltage flow sensor wire feeder connector 4002cw 5002cw 6502cw 400 415 WATER PUMP x30 CHOPPER MODULE 8 804 Ei PUMP T2 1 907 012 JUNCTION FAN MAX SPEED FAN ON OFF 015 SI 818 3 multivoltage transforomer in all types sources TC1 PE 092 FRONT FAN 0000 PUMP 00022 TC1 00000 2 X 81X INCLUDED IN CO2 KI
44. power source display panel No load voltage reduction No load overvoltage protection This circuits normally shouldn t operate Voltage levels were matched to double forward converter and are much higher as in chopper topology voltages can be maximum is rectifier voltage 70V Methods of measuring the arc voltage Various methods of measurement are available by transferring a link among contacts Y1 Y2 and When delivered the link is fitted between Y2 The link must be connected between Y2 and for and TIG welding Welding with the filler wire positive voltage sensing from the wire This is the most common arrangement for welding Y2 must be linked This method of measurement allows for the voltage drop in the supply conductor to the welding gun The input signal is measured between inputs X1 and W2 Amplifier IC8 14 is active Welding with the filler wire negative voltage sensing from the wire Y2 Y3 must be linked This method of measurement allows for the voltage drop in the supply conductor The input signal is measured between inputs X1 and W5 Amplifier 8 is active 25 Welding with the filler wire positive or negative without external sensing from the wire or workpiece Y2 Y3 must be linked The input signal is measured between inputs W5 and W2 the voltage at the power source terminals as there 1 no connection to X1 Amplifier 14 is active Welding with the fil
45. rticular memory address in its external memory This test is preformed only on initiation after power up This fault does not disable any functions Action Restart the machine If the fault persists replace circuit board CBO which carriesthe microprocessor chip 1sxx02cw 38 Fault Description code 5 V power supply too low The unregulated power supply voltage is too low the smoothing capacitors cannot keep the voltage up enough for the processor to continue to operate The processor stops all normal activities expecting to be shut down Action Turn off the mains power supply to reset the unit If the fault persists check the power supply to circuit board CBO Chopper s module rectifier DC voltage to low The DC voltage on rectifier to low to weak power supply high inductance of the supply Action See also pre charging circuit High temperature Thermal overload cutout B1 or B2 The power source is stopped and cannot be restarted until the cutout has reset Possible causes Overloading fan not working properly cooling air inlets or outlets blocked or obstructed or dirt on the heat exchanger 15 V power supply on circuit board CBO The voltage is too high or too low it must be within the range 14 1 15 9 V This fault does not disable any functions 15 V power supply on circuit board CBO The voltage is too high or too low it must be within the range 14 2 16 4 V This fault does not disable any functions
46. tion no 16 Read thermal cutout input Argument 2 0 Argument 0 Response One argument byte long Value 0 means not active Value Oxff means active Checking Flow guard only machines with Flow Guard sensor Esab Logic Pump switch on feeder must be on in Mig Mag process Turn of the plug from X4 1 X4 2 on ACH10 When switch on torch is pressed an error message should be displayed welding process is stopped The following description refers to cooling units with a flow guard machines without a flow guard behave as if cooling water is always flowing All machines without flow guard even without water cooling have connection between X4 1 X4 2 1sxx02cw 47 Checking pre charging circuit After few second from turning the power on led diode V4 should light up and contactor K1 should switch on 9 m ommo 10 came OLRE i 13 VA li 56698 V anton 4 C22 C9 E oll a If not an error message should be displayed error nr 5 Check the pre charging circuit If voltage on chopper capacitors is more than 45V V4 should light on Check voltage on pin A3 A in reference to GND should be more than 7 5V If V4 led light on but error is still displayed check voltage between X2 5 X2 6 should be less than 1V 0000 Checking Fan Circuit Fan should operates during all processes Turning on also can be done by ESAT software Service function 13 Argument 2
47. tions in the equipment For the installation and use of ESAT computer with operating system Windows 9 2000 or XP is needed Contents e CAN adapter MECEL PPCAN e Connection Cable between CAN adapter and power source e CAN adapter software e ESAT software e Instruction manual for Esat CAN supply service kit Ordering no 0349 310 369 As the Origo Mig 400t 500t don t have external CAN connector and the CAN interface is not internally supplied the CAN supply service kit is needed Contents e transformer 230V 9V cable 9 DSUB male female To make an update of the system you will also need an application program upgrade This program will be sent to registered ESAT users by e mail or be downloaded from ESAB web site ESAT has it s own instruction manual 0458 885 174 Assuming previous installation of ESAT software in the computer disconnect the machine from mains and remove the left side cover to achieve connectors on the PC boards see drawing Connect the CAN supplying transformer to W socket and connect the 9 9 DSUB cable to CAN_A or CAN_B DSUB connector Connect the other side of cable to the parallel port of the PC via PPCAN adapter 1sxx02cw 42 CABLE 9 9 DSUB TRANSFORMER 230 9V CAN connection Antistatic service kit Ordering no 0740 511 001 The kit makes it easier to protect sensitve components from electrostatic discharge Contents Conductive mat si
48. ycol 5 51 2 0 l min The duty cycle refers to the time as a percentage of a ten minute period that you can weld at a cer tain load without overloading 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 23 is designed for indoor and outdoor use Application class The symbol S indicates that the power source is designed for use in areas with increased electrical hazard 1sxx02cw This page is left blank intentionally 15 02 WIRING DIAGRAM WARNING STATIC ELECTRICITY can damage circuit boards and electronic components e Observe precautions for handling electrostatic sensitive devices e Use proper static proof bags and boxes Component description XT1 PF20 Q01 K1 M1 M2 C1 C2 C3 C7 C8 H2 H4 T1 TC1 TC2 VB1 B1 B2 B3 CS R1 L1 CBO 1sxx02cw 9 pole terminal block Suppression circuit board Main ON OFF switch Main contactor Fan 230V 50Hz Pump motor 230V 50Hz 0 2kW Only machines with water cooler Capacitor GuF 250V for reducing the speed of fan motor M1 Capacitor 3uF 400V Start and run capacitor for fan motor M1 Suppression capacitors 0 1uF 250V Snubber for K1 coil Orange indicating lamp Error overheating White indicating lamp power supply ON Main transformer Control power transformer Transformer for CO2 heater an accessory see an access
49. ze 610 x 610 mm 1 5 metre long ground cable with a crocodile clip Adjustable wrist strap and cable with inbuilt protective resistor Antistatic service kit Checking PWM signal PWM signal can be checked booth on CBO and ACH10 boards Output signal form CBO comes to ACH10 and can be measured on R23 If MMA process is chose measured signal without load on outlet should looks similar as on below scope screen Amplitude should be about 15V frequency 20kHz 0 5kHz 1sxx02cw 43 Without load MMA process duty cycle 15 about 90 g ol Ie e K rs Jo 0 o o of o 0 Sg R20 LS 6000 vi2 X19 X18X17X16 X15X14X13X12X11X10 al KA OLRE O og 8 2M HE X20 15 porong BEI E E EE 15 02 44 Output PWM signal from ACH10 can be checked V16 condition load on output Amplitudes should be about 14V 9 frequency 20kHz 0 5kHz duty cycle about 90 ALL 2v lsi st ir 9 16 9 1 st 196 C8 gt V3 C18 Soo Ws 2 o0 x oto 200 x 98 19 Pos 6 400 05 BE E E E E E EE EE E E E E EE E EM EE EE 10 0 25 Feb 05 10 03 1sxx02cw 45
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