ESAB | WeldCloud™ Universal Connector | Service manual | ESAB WeldCloud™ Universal Connector User manual

ESAB WeldCloud™ Universal Connector User manual
WeldCloud™ Universal
Connector
Service manual
0463 602 001 GB 20190502
Valid for: serial no. 849-xxx-xxxx
TABLE OF CONTENTS
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 ...........................................................................................
8
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
0463 602 001
© ESAB AB 2019
TABLE OF CONTENTS
SPARE PARTS AND ACCESSORIES .....................................................
31
Rights reserved to alter specifications without notice.
0463 602 001
© ESAB AB 2019
READ THIS FIRST
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.
•
•
0463 602 001
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
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© ESAB AB 2019
BEFORE STARTING SERVICE
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
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© ESAB AB 2019
INTRODUCTION
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.
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© ESAB AB 2019
WIRING DIAGRAM
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.
•
•
0463 602 001
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
-7-
© ESAB AB 2019
WIRING DIAGRAM
WeldCloud™ Universal Connector, valid from serial no.
849-xxx-xxxx
0463 602 001
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© ESAB AB 2019
TECHNICAL DATA
TECHNICAL DATA
WeldCloud™ Universal Connector, Valid from serial no. 849-xxx-xxxx
Permissible load (I2):
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
U1
10–100 V
Current and power at U1 = 30 V:
I1
0.3 A
Pmax
9W
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.
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© ESAB AB 2019
FIRMWARE UPDATE
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.
2.
3.
Find the latest firmware update file of type "UC_X.X.X-XXX_Update.tar" on ESABs
partner login web page.
Download the file and save it in the download folder of the Android device, e.g. in the
"TC75x\Internal storage\Download" folder.
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.
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© ESAB AB 2019
FIRMWARE UPDATE
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.
2.
3.
Find the latest firmware update file of type "UC_X.X.X-XXX_FW.zip" on ESABs
partner login web page.
Download the file and save it.
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.
2.
Insert the micro SD card into the PC micro SD card reader.
Select the downloaded firmware image file from your PC by clicking the folder icon.
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© ESAB AB 2019
FIRMWARE UPDATE
3.
Write the image to the micro SD card by clicking Write.
4.
The process will take approximately five minutes.
Remove the micro SD card when writing is finished.
Upload the firmware to the WeldCloud™ Universal Connector
1.
2.
3.
4.
5.
6.
Make sure the WeldCloud™ Universal Connector is powered off and disconnected
from the welding power source.
Remove the top housing of the Electronics Box (see "Removal and attachment of
the top housing of the Electronics Box", page 19).
Insert the micro SD card into the micro SD card reader found on the carrier board
(25AP1).
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.
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.
Remove the micro SD card from the micro SD card reader.
Factory reset
1.
Connect to the preferred WeldCloud™ Universal Connector unit.
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© ESAB AB 2019
FIRMWARE UPDATE
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.
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© ESAB AB 2019
TROUBLESHOOTING
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.
2.
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.
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.
2.
3.
4.
5.
6.
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.
Connect the welding cables from the welding power source to the WeldCloud™
Universal Connector and from the WeldCloud™ Universal Connector to the load.
Start the welding power source and set it to an output of 10–100 V and 15–500 A.
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.
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).
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.
2.
Connect the welding cables from the welding power source to the WeldCloud™
Universal Connector and from the WeldCloud™ Universal Connector to the load.
Start the welding power source and set it to an output of 10–120 V and 50–500 A.
0463 602 001
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© ESAB AB 2019
TROUBLESHOOTING
3.
4.
5.
6.
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.
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.
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.
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.
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© ESAB AB 2019
TROUBLESHOOTING
7.
8.
9.
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.
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.
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.
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© ESAB AB 2019
TROUBLESHOOTING
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.
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© ESAB AB 2019
TROUBLESHOOTING
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.
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© ESAB AB 2019
DISASSEMBLY AND REASSEMBLY
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.
0463 602 001
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© ESAB AB 2019
DISASSEMBLY AND REASSEMBLY
Removal and attachment of the top housing of the Sensor Box
Equipment required
•
1.
Torx screwdriver T25
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 AB 2019
CALIBRATION
CALIBRATION
According to standard IEC 60974-14: Welding equipment which measures and displays
current, voltage and/or wire feed speed (displayed values) shall be calibrated.
WeldCloud™ Universal Connector measures the welding values with internal instruments
and the values are displayed in the ESAB UCMon app and the WeldCloud as "display
values".
On the basis of this consideration, calibration must be carried out in accordance with IEC
60974-14.
The calibration of WeldCloud™ Universal Connector can therefore be carried out according
to for instance IEC 60974-14. The necessary equipment largely corresponds to the
equipment for the calibration of welding power sources. In addition, it is assumed that the
WeldCloud™ Universal Connector together with the power source form a unit and is used
for the documentation of welds.
On this basis, the calibration of WeldCloud™ Universal Connector can largely be taken from
IEC 60974-14. In the later course, the special features of the calibration of the WeldCloud™
Universal Connector will be dealt with.
NOTE!
Welding equipment shall be tested by an expert with suitable qualifications,
corresponding experience and sufficient training in welding and measurement
technology, with knowledge of electrical hazards that may occur and the required
protective measures.
Definitions
Adjustment:
Setting or adjusting a measuring device. The offset and gain are adjusted so that the device
displays the real measured values. It is always necessary to calibrate after an adjustment
and repair.
Calibration:
Measuring without adjustments of the settings within the device. The accuracy of the device
is checked. Calibration can only be performed with reference measuring instruments of
known accuracy (e.g. WeldValidator).
An annual calibration of the WeldCloud™ Universal Connector is recommended according
to the IEC 60974-14 standard. After every repair or after every operation that could have
disturbed the measurement accuracy (e.g. severe overload of the inputs or external
damage) a new calibration should be carried out. The compliance with the measuring
accuracy of 2%, in relation to the full-scale value, of the measured variables welding current
(500 A) and welding voltage (100 V) is checked. The standard IEC 60974-14 is applied.
WeldCloud™ Universal Connector is regarded as an additional display of a current source.
The calibration of current and voltage is carried out independently of each other.
If the accuracy class / measuring accuracy of one or both measured variables is not
achieved after completion of the calibration, contact your authorized ESAB distributor
and service centre for readjustment or repair.
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© ESAB AB 2019
CALIBRATION
Reference power source for calibration
The calibration should be performed using a direct current source or a welding current
source equipped with a load resistor. There is a risk that the reference power source can
"colour" the measured reference value. Influences of weld dynamic and arc-force can be an
issue. Make sure what the properties are so that you are aware of this. The reference
measuring instrument and the WeldCloud™ Universal Connector being tested, must use the
same measuring method.
Measurement methods and measurement tolerances
The WeldCloud™ Universal Connector determines the measured values as rectified
arithmetic mean values. The reference measuring instrument must use the same measuring
method (averaging and rectification of the measured values) in the DC range.
For alternating current, various measurement methods are used for reference instruments
(TRMS, RMS, rectified arithmetic mean). The WeldCloud™ Universal Connector uses the
rectified arithmetic mean for alternating current. The different measuring methods result in
different measured values for the same alternating current. Therefore, calibration in the AC
range is strongly discouraged.
In the field application it will occur that a welding device and a WeldCloud™ Universal
Connector may display different values even though both systems are calibrated. This is
due to the measurement tolerances and the method of measurement value formation of
both different measurement systems. The measurement tolerances can result in deviations
up to the sum of both measurement tolerances. If the measurement methods differ (TRMS,
RMS, rectified arithmetic mean), significantly larger deviations are to be expected. ESAB
welding power sources usually work with the rectified arithmetic mean and should therefore
not show any significant differences from the WeldCloud™ Universal Connector due to the
measurement method. A maximum deviation up to the sum of the two measurement
tolerances is expected.
Equipment required
Number Device
Variant a
Variant b
1
Device under test
WeldCloud™ Universal Connector
2
Reference instrument
3
Current source
Welding power source or current source with 500 A,
e.g. Warrior™ 500i
4
Load resistor
500 A load
HKS load resistor
5
Voltage source
6
Display for the values
7
Voltage source
WeldValidator
Voltage meter and current meter
according to ESAB specification
Checkmaster 9000
Output 100 V / 9 W between 20 V and 100 V
Android device with ESAB UCMon application installed
24 V / 12 W DC
Calibration range
The calibration should be carried out over the entire measuring range. Calibration must be
carried out over the negative and positive measuring ranges.
The table below shows recommended values for calibration of current and voltage
respectively.
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© ESAB AB 2019
CALIBRATION
Note that the table refers to two independent operations, calibration of current from –475 A to
475 A on one hand and calibration of voltage from –95 V to 95 V on the other!
Measurement point
Current
Voltage
1
0.0 A
0.0 V
2
100 A
20 V
3
200 A
40 V
4
300 A
60 V
5
400 A
80 V
6
475 A
95 V
7
0.0 A
0.0 V
8
–100 A
–20 V
9
–200 A
–40 V
10
–300 A
–60 V
11
–400 A
–80 V
12
–475 A
–95 V
Measurement values greater than 500 A or 100 V are automatically limited to 500 A or 100 V
respectively. For this reason, the WeldCloud™ Universal Connector only calibrates up to
maximum 95% of the measuring range.
The calibration is carried out according to IEC 60974-14. The mean values from the
reference instrument and from the WeldCloud™ Universal Connector must have a deviation
smaller than the permissible deviation (see IEC 60974-14).
Permissible deviations are:
Current:
500 A × 2% = ±10 A
Voltage:
100 V × 2% = ±2 V
The accuracy of the calibration thus corresponds to the standard class according to
IEC 60974-14 (measurement error ≤ 2.5%).
The measured values are only displayed positively by the internal rectification. The
prescribed polarity reversal for WeldCloud™ Universal Connector results from the reversal
of the polarity of the connections at the WeldCloud™ Universal Connector.
The calibration grade is standard grade. The mains voltage is the external supply voltage
(24 V DC) from the WeldCloud™ Universal Connector.
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© ESAB AB 2019
CALIBRATION
Preparations for calibration
1.
2.
3.
Remove the top housing of the Sensor Box according to "Removal and attachment
of the top housing of the Sensor Box", page 20.
Connect the 24 V DC voltage source between CN11_1 and CN11_2 on the sensor
board (25AP3).
Connect the ESAB UCMon application to WeldCloud™ Universal Connector via
Bluetooth.
The ESAB UCMon application will serve as a display of the measured values
during the calibration.
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© ESAB AB 2019
CALIBRATION
Calibration of current
Set up the equipment according to the diagram below:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Set the welding power source output to MMA.
Connect an Android device, with the ESAB UCMon application installed, via
Bluetooth to the WeldCloud™ Universal Connector.
Display the measured values in the ESAB UCMon application.
Capture the measured value after a stabilization time of 10 seconds.
Measure at measurement points 1 up to and including 6 (see "Calibration range",
page 22), from down to up. The voltage drop on the load resistor should be
minimum 12 V.
Change the polarity by shifting the plug connectors from plus to minus and from
minus to plus.
Measure at the remaining measurement points, from 7 up to and including 12 (see
"Calibration range", page 22), from down to up.
Take notes of the measured values, from the reference instrument and the values
displayed in the ESAB UCMon application.
Insert the measurement results into the ESAB calibration certificate for the involved
WeldCloud™ Universal Connector.
0463 602 001
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© ESAB AB 2019
CALIBRATION
Calibration of voltage
Set up the equipment according to the diagram below:
WARNING!
Take relevant safety precautions when performing measurements using high
voltage!
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove the resistor and connect the voltage source with a maximum output of
100 V / 9 W between 20 V and 100 V.
Connect an Android device, with the ESAB UCMon application installed, via
Bluetooth to the WeldCloud™ Universal Connector.
Display the measured values in the ESAB UCMon application.
Capture the measured value after a stabilization time of 10 seconds.
Measure at measurement points 1 up to and including 6 (see "Calibration range",
page 22), from down to up.
Change the polarity by shifting the plug connectors from plus to minus and from
minus to plus.
Measure at the remaining measurement points, from 7 up to and including 12 (see
"Calibration range", page 22), from down to up.
Take notes of the measured values, from the reference instrument and the values
displayed in the ESAB UCMon application.
Insert the measurement results into the ESAB calibration certificate for the involved
WeldCloud™ Universal Connector.
Labeling
The documentation of the calibration must comply with IEC 60974-14.
Some special values are given in the table below.
Specifications
Typical value
Mains voltage
24 V
Calibration method
Load resistor with meter
Calibration grade
Standard
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© ESAB AB 2019
REPLACEMENT INSTRUCTIONS
REPLACEMENT INSTRUCTIONS
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!
Replacing the lithium-ion battery (in the Electronics Box)
Equipment required
•
•
Torx screwdriver T10
Small flat screwdriver
1.
2.
Loosen the two screws and remove the battery lid.
Remove the battery, using for instance a flat screwdriver.
3.
Insert the new battery and attach the lid and the screws in the reverse order, using
the correct tightening torque according to the illustration.
Replacing the lithium coin cell battery (in the Electronics Box)
1.
2.
3.
Remove the top housing of the Electronics Box according to "Removal and
attachment of the top housing of the Electronics Box", page 19.
Replace the battery.
Reattach the top housing according to "Removal and attachment of the top
housing of the Electronics Box", page 19.
0463 602 001
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© ESAB AB 2019
REPLACEMENT INSTRUCTIONS
Replacing the welding cables (in the Sensor Box)
Equipment required
•
•
Torx screwdriver T20
Open end wrench 42 mm
NOTE!
The connectors can be of OKC type or Tweco type, depending on the
WeldCloud™ Universal Connector variant.
1.
2.
3.
4.
5.
6.
7.
Remove the top housing of the Sensor Box according to "Removal and attachment
of the top housing of the Sensor Box", page 20.
Remove the screw attaching the cable clamp to the spacing screw for the welding
cable to be replaced.
Unfasten the two cable glands for the welding cable to be replaced.
Remove the male or female connector on the welding cable to be replaced.
Hold the welding cable in that end on which you have not removed the connector
and pull the cable out of the Sensor Box.
Insert the new welding cable by pulling it through the Sensor Box and reinstall in
the reverse order.
Shift over the connectors from the old cable to the new one or, if needed, attach
new connectors.
Tighten all screw joints, using the correct tightening torques according to the
illustration.
Reattach the top housing according to "Removal and attachment of the top
housing of the Sensor Box", page 20.
Replacing the connector
It is required to replace the non-ESAB cable connectors with the provided connectors if any
of the following conditions occur:
0463 602 001
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© ESAB AB 2019
REPLACEMENT INSTRUCTIONS
•
•
•
The connections to the welding output terminals on the power source are not secure.
The connector is damaged.
The rubber surface of the connector is very hot.
1.
2.
3.
4.
Pull the rubber housing (1) off the brass connector.
Remove the Allen screws from the brass connector (2).
Remove the brass connector from cable wiring (3).
If the cable wire shroud (4) is damaged or missing, add the provided cable wire
shroud. Insert the cable wire with the cable wire shroud into the provided brass
connector (5).
Tighten the Allen screws to fasten the cable wire in the brass connector (6). Tigthen
the Allen screws to be aligned with or below the surface of the brass connector.
Pull the rubber housing back (7) until it completely covers the brass connector (5).
5.
6.
0463 602 001
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© ESAB AB 2019
REPLACEMENT INSTRUCTIONS
0463 602 001
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© ESAB AB 2019
SPARE PARTS AND ACCESSORIES
SPARE PARTS AND ACCESSORIES
For spare parts, see the spare parts list for the product. For accessories, see the instruction
manual for the product. These documents can be downloaded from the Internet:
www.esab.com
Document type
File name
Spare parts list
0463 603 001 WeldCloud™ Universal Connector
Instruction manual 0463 601 *
0463 602 001
Product
Note
WeldCloud™ Universal Connector
- 31 -
© ESAB AB 2019
For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
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