Related Manuals for ESAB AristoFeed 30 4 Series
Summary of Contents for ESAB AristoFeed 30 4 Series
- Page 1 Feed 3004 Feed 4804 Aristo AristoFeed 30- 4, AristoFeed 48- 4 Service manual 0740 800 132 060707 Valid for serial no. 038- -xxx- -xxxx to 620- -xxx- -xxxx...
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Page 2: Table Of Contents
READ THIS FIRST ..............INTRODUCTION . -
Page 3: Read This First
Water connection ............. . . Remote control unit . -
Page 4: Technical Data
TECHNICAL DATA Feed 3004 Feed 4804 Power supply 42 V 50 -- 60 Hz 42 V 50 -- 60 Hz Power requirement 336 VA 378 VA Motor current Wire feed speed 0.8 -- 25 m/min 0.8 -- 25 m/min EURO EURO Welding gun connection Max. -
Page 5: Wiring Diagram
WIRING DIAGRAM Component description WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic- - sensitive devices. Use proper static- -proof bags and boxes. This component description should be read in conjunction with the wiring diagram. The description of operation contains a more detailed description of the functions of the components. -
Page 6: Aristofeed 30- -4, Aristofeed 48- -4
AristoFeed 30- -4, AristoFeed 48- -4 valid for serial no. 038- -, 105- -, 136- -, 214- -, 233- -, 249- -, 445- -xxx- -xxxx S0740 800 132/E060707/P40 - - 6 - - cmel1d_1... - Page 7 S0740 800 132/E060707/P40 - - 7 - - cmel1d_1...
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Page 8: Feed 3004, Feed 4804, Aristofeed 30- -4, Aristofeed 48- -4
Feed 3004, Feed 4804, AristoFeed 30--4, AristoFeed 48 valid from serial no. 451- -xxx- -xxxx S0740 800 132/E060707/P40 - - 8 - - cmel1d_1... - Page 9 S0740 800 132/E060707/P40 - - 9 - - cmel1d_1...
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Page 10: Description Of Operation
DESCRIPTION OF OPERATION 1 MMC panel The MMC panel consists of a control panel and a welding data board. The power source, the wire feed unit and control panel each have their own microprocessor for control. The control panel is the central unit in the system: in addition to setting and controlling welding data, it also has overall control of the entire system. -
Page 11: 13Ap1 Control Board, Valid For Serial No. 038- - To 445- -Xxx- -Xxxx
Valid for serial no. 038- , 105- , 136- , 214- , 233- , 249- , 445- xxx- xxxx 13AP1 Control board, valid for serial no. 038- - to 445- -xxx- -xxxx This description is valid for control board 0486 384 894, which is fitted in the AristoFeed up to and including serial no. -
Page 12: 13Ap1:2 Start / Stop
Valid for serial no. 038- , 105- , 136- , 214- , 233- , 249- , 445- xxx- xxxx 13AP1:2 Start / Stop The welding gun switch contact is supplied at 17 V AC from transformer TR1. Closing the switch contact activates optocoupler IC7, pulling C47 low. When gas pre--flow starts, wire feed also starts and the power source generates welding voltage. - Page 13 Valid for serial no. 038- , 105- , 136- , 214- , 233- , 249- , 445- xxx- xxxx Wire feeders with serial number prior to 136--xxx--xxx, with software version prior to 2.81A: The current limit is 15 A on starting. After one second, this is reduced to 8 A in the AristoFeed 30 and 9 A in the AristoFeed 48.
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Page 14: 13Ap1:5 Pulse Generator Input
Valid for serial no. 038- , 105- , 136- , 214- , 233- , 249- , 445- xxx- xxxx 13AP1:5 Pulse generator input Pulse generator and tachometer inputs The pulse generator, 13G1, is fitted to drive motor 13M1 (AristoFeed 30), or 13M2 (AristoFeed 48). -
Page 15: 13Ap1:7 Monitoring Wire And Gas
Valid for serial no. 038- , 105- , 136- , 214- , 233- , 249- , 445- xxx- xxxx 13AP1:7 Monitoring wire and gas Circuit board 13AP1 is prepared for future monitoring of wire and gas supply. The MMC panel displays a fault code if either of the inputs is closed. Fault code 27 = out of wire. -
Page 16: 13Ap1:9 Arc Voltage Sensing
Valid for serial no. 038- , 105- , 136- , 214- , 233- , 249- , 445- xxx- xxxx Starting sequence Circuit board 13AP1 carries an EEPROM, IC16, which forms the heart of operation of the board. On power--up, the board’s CAN controller reads in the bus speed from IC16: 400 kbit/s. -
Page 17: Ap1 Component Positions
Valid for serial no. 038- , 105- , 136- , 214- , 233- , 249- , 445- xxx- xxxx 13 AP1 Component positions Control board 0486 384 894 S0740 800 132/E060707/P40 - - 17 - - cmel1d_13ap1a... -
Page 18: 13Ap1 Control Board, Valid From Serial No. 451- -Xxx- -Xxxx
Valid from serial no. 451- xxx- xxxx 13AP1 Control board , valid from serial no. 451- -xxx- -xxxx This description of operation is valid for control board 0487 187 88x, which is fitted in the wire feeders from serial no. 451--xxx--xxxx. This board can also be used as spare part for earlier versions of the wire feeders. -
Page 19: 13Ap1:12 Start / Stop
Valid from serial no. 451- xxx- xxxx Voltage monitoring If the +60 V supply drops below 42 V or exceeds 78 V, the MMC panel displays fault code 9. This fault does not disable any functions. The +24 V is monitored by IC12 and potential divider R129, R130, R180. If the voltage drops to 18 V or less, IC12 generates a warning signal to the processor, which responds by stopping the wire feed and then all communication on the bus. -
Page 20: 13Ap1:14 Motor Driving / Braking
Valid from serial no. 451- xxx- xxxx 13AP1:14 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 99 % of the pulse period. -
Page 21: 13Ap1:15 Pulse Generator Input
13AP1:16 Monitoring the cooling water connection The wire feed unit with water connection is equipped with a detection system ELP (ESAB Logic Pump) which checks that the water hoses are connected. When connecting a water--cooled welding gun, the water pump starts. -
Page 22: 13Ap1:17 Monitoring Wire And Gas
Valid from serial no. 451- xxx- xxxx 13AP1:17 Monitoring wire and gas Circuit board 13AP1 is prepared for future monitoring of wire and gas supply. The MMC panel displays a fault code if either of the inputs is closed. Fault code 27 = out of wire. Fault code 32 = no gas flow. 13AP1:18 The CAN bus The circuit board includes a driver for the CAN bus, IC2, which looks after communication with the MMC panel and with other units in the system. -
Page 23: 13Ap1:19 Arc Voltage Sensing
Valid from serial no. 451- xxx- xxxx When the board has been initiated, and the wire feed unit is in the application program, LED1 flashes continously with a green light. There is more information about the operation of the CAN bus in the service manual for the power source. -
Page 24: 13Ap1 Component Positions
Valid from serial no. 451- xxx- xxxx 13AP1 Component positions Control board 0487 187 88x S0740 800 132/E060707/P40 - - 24 - - cmel1d_13ap1b... -
Page 25: Can Adapter Option
Valid from serial no. 451- xxx- xxxx CAN adapter option The CAN adapter option is used when MiggyTrac, RailTrac or a welding gun with pull motor is connected to the wire feeder. Connection instructions for the option are included in the delivery. There is a copy of the instructions on page 27. -
Page 26: Welding Gun With Pull Motor
Valid from serial no. 451- xxx- xxxx Welding gun with pull motor Can adapter board, filter board and cable set connected to the control board of the wire feeder Adapter option for welding gun with pull motor 0459 681 881 The adapter board is delivered with machine ID 7. -
Page 27: Connection Instructions
Valid from serial no. 451- xxx- xxxx Connection instructions Wire feeder with built- -in control panel Wire feeder controlled by U8, NOTE: the switch must be in position B. S0740 800 132/E060707/P40 - - 27 - - cmel1d_mtrt_pp... -
Page 28: Remote Controls
REMOTE CONTROLS A number of remote control units can be connected to the Aristo, these are described in a separate service manual with filename / ordering no. 0740 800 170. 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: up to 99 error messages can be saved. -
Page 29: Fault Code Description
Fault Description Control Power Wire feed Remote code panel source unit control unit Memory allocation error Transmitter buffer overflow Receiver buffer overflow Program operating fault Out of wire Stack overflow No cooling water flow No reply from the display unit No gas flow Incompatible units Fault code description... - Page 30 Stack overflow The program execution does not work. This fault should never occur in reality: the fault code is intended as an aid during development work. Contact ESAB if the fault does occur. No gas flow Gas flow is too low.
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Page 31: Service Instructions
SERVICE INSTRUCTIONS WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic- - sensitive devices. Use proper static- -proof bags and boxes. What is ESD? A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electrostatic Discharge. -
Page 32: Service Aid
The software update is made from a PC, it has to be managed by a trained serviceman. For this a computer program called Esat, ESAB software administration tool, is needed. The PC is connected to the welding equipment by a cable connector and a CAN reader. From the Esat it is possible to update the software in power source, wire feeder and control panel. -
Page 33: Spare Parts For Connection Sets
Spare parts for connection sets S0740 800 132/E060707/P40 - - 33 - - cmel1s1... -
Page 34: Instructions
This chapter is an extract from the instructions for the Feed 3004 and Feed 4804. 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. -
Page 35: Installation
(M0) and with control box AristoPendant U8. Two feed units are to be connected according to the picture. When connecting more than two feed units, an authorised ESAB service technican must perform the installation. S0740 800 132/E060707/P40 - - 35 - - cmel1ins... -
Page 36: Operation
(cooling unit) -- BLUE Connection for the welding gun Connection for protection gas NOTE! Cooling water connections only available on certain models. * ELP = ESAB Logic Pump, see Water connection on next page. S0740 800 132/E060707/P40 - - 36 - - cmel1ins... -
Page 37: Water Connection
Water connection The wire feed unit with water connection is equipped with a detection system ELP (ESAB Logic Pump) which checks that the water hoses are connected. AristoMig 400 and 500 The power unit On/Off switch must be in the “0” position (Off) when connecting a water--cooled welding gun. -
Page 38: Maintenance
SPARE PARTS The spare parts list for the Feed 3004 and Feed 4804 is published in a separate document with filename 0458 716 990. This can be downloaded from the Internet: www.esab.com S0740 800 132/E060707/P40 - - 38 - -... -
Page 39: Notes
NOTES S0740 800 132/E060707/P40 - - 39 - - notes... - Page 40 ESAB subsidiaries and representative offices Europe Asia/Pacific Representative offices NORWAY AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna- -Liesing Sofia Shanghai Fax: +47 33 11 52 03...