Related Manuals for ESAB MEK 4
Summary of Contents for ESAB MEK 4
- Page 1 MEK 4 cmek0p00 Service manual 0740 800 085 040426 Valid for serial no. 431- -xxx- -xxxx to 826- -xxx- -xxxx...
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Page 2: Table Of Contents
LIST OF CONTENTS Page READ THIS FIRST ........COMPONENT DESCRIPTION . - Page 3 The MEK 4 wire feed unit is designed and tested in accordance with European standard EN 60974- -1 and EN 50199. 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.
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Page 4: Component Description
Not mounted, from machine number 514- - 615- - xxxx XS13 12- - pole connector: MEK 4 with serial number 431- - xxx- -xxxx 23- - pole connector: MEK 4 from serial number 514- - xxx- - xxxx and above. YV01 Solenoid valve - - 4 - - cmek0de1... -
Page 5: Wiring Diagram
WIRING DIAGRAM Valid for serial no. 431--xxx--xxxx MEK 4 See page 17 cmek0e01 - - 5 - - cmek0de1... -
Page 6: Wiring Diagram
WIRING DIAGRAM Valid for serial no. 514--xxx--xxxx to 826--xxx--xxxx MEK 4 See page 17 - - 6 - - cmek0de1... -
Page 7: Description Of Operation
Description. A new circuit board (486 205- -882) replaces circuit board 486 205- - 880. It can be used as a replacement part in all MEK 4 units. The following changes have been introduced on the new board: a. New program version, with modified creep start characteristics. - Page 8 cmek0e04 Circuit board 0486 205 880 is supplied with capacitor C35, on circuit board 0486 205 882 capacitor C35 is replaced by diode D35. See the description of operation, items 4a and 4b. Component positions, circuit board AP01 - - 8 - - cmek0de1...
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Page 9: Power Supply
The wire feed unit receives 42 V from the control power supply transformer in the welding power unit via connector XP01. LAW 400 and 500 welding power units can supply a maximum of 6 A to the MEK 4. The wire feed unit’s own power requirement at maximum load is 5 A. -
Page 10: Crater Filling
Crater filling The crater fill function can be used when the MEK 4 is working with a LAW power unit. The crater fill function comprises the following modules : An input for selecting crater fill function On/Off. cmek0e07 Closing switch SA02 activates the function. - Page 11 Phase 2 Phase 2 starts when phase 1 finishes. The wire feed unit further reduces the wire speed to 84% of the value during phase 1. Optocoupler IC10 turns off, giving the power unit a signal further to reduce the voltage. Phase 2 continues also for a maximum of 1.27 seconds.
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Page 12: Voltage Adjustment
Voltage adjustment Applies to MEK 4 with serial number 431 ..cmek0e10 Voltage adjustment, circuit board AP01 with article number 0486 205 880 When the MEK 4 is connected to a power unit with steplessly variable output voltage, potentiometer RP02 on the front of the unit can be used to control the power unit output voltage. - Page 13 Voltage adjustment Applies to MEK 4 with serial number 514 ..and above. cmek0e23 Voltage adjustment, circuit board AP01 with article number 0486 205 882 When the MEK 4 is connected to a power unit with steplessly variable output voltage, potentiometer RP02 on the front of the unit can be used to control the power unit output voltage.
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Page 14: Gas Valve
K and J in the remote control connector (XS13). Gas valve Applies to MEK 4 with serial number 514 ..and above. cmek0e24 The gas valve is connected to connectors F04 and F05. If an intermediate wire feed unit is being used, its gas valve is connected via pins V and U in the remote control connector (XS13). -
Page 15: 2--Stroke / 4--Stroke
2- - stroke / 4- - stroke cmek0e12 2--stroke When switch SA01 is open, 2- -stroke control mode is selected. This means that closing the welding gun trigger switch starts the wire feed motor, opens the gas valve and closes the power unit contactor. Releasing the switch stops the motor, releases the contactor and closes the gas valve. -
Page 16: Wire Feed Speed
E11 cannot drop below about 0.6 V. Wire feed speed Applies to MEK 4 with serial number 514 ..and above. ADJUSTMENT ON THE FRONT PANEL OF THE FEEDER UNIT The function is the same as described in item 8a above. -
Page 17: Creep Start / Normal Start
MEK 4 with circuit board 0486 205 880 will start at a speed of 3 m/minute when the creep start is activated. If the set speed is less than 3 m/minute, wire feed starts at the set speed. -
Page 18: Motor Driving / Braking
Motor driving / braking cmek0e17 The motor is powered by the smoothed +60 V supply. Pulse width modulation, controlled by transistor Q3, is used to vary the motor voltage. The pulse frequency is 12 kHz, and the maximum conducting time of the pulses is 97% of the pulse cycle time. -
Page 19: Tachometer Input
Pins XP01;R and XP01;S are used if there is a separate display unit for showing wire feed speed. The digital displays in the MEK 4 and the LAW power units cannot show the wire feed speed. Connections D01 - - D02 are used only if there is an external instrument for displaying the wire feed speed. -
Page 20: Start / Stop
Start / Stop cmek0e20 The trigger switch in the welding gun is supplied at 42 V AC. Closing the switch energises optocoupler IC10, pulling down the voltage across C46. Processor The processor stores the machine program. It monitors the power supply voltages: if the voltages drop to too low a level, wire feed is stopped, as described in section 1 above. -
Page 21: Remote Control Input
Applies to MEK 4 with serial number 431 ..cmek0e21 Remote control input, MEK 4 with serial number 431 ..The following items can be connected to the remote control input : Wire feed speed remote control unit: pins A, B and C in XS13. -
Page 22: Digital Display
Digital display The digital display unit is standard in the - - 881 and - - 883 variants of MEK 4. It is available as an accessory for other wire feeder units: see the list on page 27. The instrument can be connected either to the wire feeder unit or to the LAW power unit. - Page 23 Circuit diagram, display board AP02 - - 23 - - cmek0de1...
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Page 24: Technical Data
TECHNICAL DATA The MEK 4 wire feed units is of enclosed construction with four- - wheel drive to the wire. Power supply 42 V 50 -- 60 Hz Power requirement 300 VA Feed speed 1.9 -- 25 m/min Welding gun connection EURO Max. -
Page 25: Setting The Wire Feed Pressure
SETTING THE WIRE FEED PRESSURE Start by checking that the wire can run freely through the wire liner, and then adjust the pressure of the wire feed rollers. It is important that the pressure is not too high. Figure 1 Figure 2 To check for correct feed pressure, feed the wire out against a piece of insulating material, such as a piece of wood. -
Page 26: Control Panel And Connections
CONTROL PANEL AND CONNECTIONS 1. Cooling water connections (only - -882 and - - 883 models). 2. Gas connection. 3. Connector for control cable from the power unit. 4. Connector for welding current cable from the power unit. 5. Switch, crater filling On/Off. Crater filling operates only with the LAW power units. -
Page 27: Accessories
ACCESSORIES Ordering no. Ordering no. Ordering no. Ordering no. Item when used with when used with when used with when used with Denomination LAW 400 LAW 410W LAW 510 LAW 510W 0469 789 880 0469 789 880 0469 789 880 0469 789 880 Lifting eye 0469 836 880... -
Page 28: Spare Parts
SPARE PARTS The spare parts list for the MEK 4 is published in a separate document with filename / ordering no. 0469 952 990 NOTES - - 28 - - notes... - Page 29 - - 29 - - notes...
- Page 30 ESAB subsidiaries and representative offices Europe NORWAY Asia/Pacific Representative offices 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...
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