ESAB | Warrior™ YardFeed 200 | Service manual | ESAB Warrior™ YardFeed 200 User manual

ESAB Warrior™ YardFeed 200 User manual
Warrior™ YardFeed 200
Warrior™ YardFeed 200w
Service manual
0463 394 001 GB 20180115
Valid for: serial no. 427-, 528-, 802-xxx-xxxx
TABLE OF CONTENTS
READ THIS FIRST....................................................................................
3
INTRODUCTION .......................................................................................
4
TECHNICAL DATA ...................................................................................
5
WIRING DIAGRAM ...................................................................................
7
General ....................................................................................................
7
Units with ordering numbers 0459 906 898 and 0459 906 899 ...........
8
Units with ordering numbers 0459 906 900 and 0459 906 901 ...........
10
Component description .........................................................................
12
DESCRIPTION OF OPERATION..............................................................
13
13AP01 Control Board ...........................................................................
13
13AP01:1 Power supply .......................................................................
13
13AP01:2 2-stroke / 4-stroke................................................................
13
13AP01:3 Start / Stop...........................................................................
14
13AP01:4 Current relay ........................................................................
14
13AP01:5 Motor driving / braking .........................................................
15
13AP01:6 Pulse generator input ..........................................................
15
13AP01:7 Wire selection / Burnback ....................................................
16
13AP01:8 Wire feed speed ..................................................................
16
13AP01:9 Gas valve.............................................................................
16
13AP01:10 Activation, contactor ..........................................................
17
13AP01:11 Gas purge / Inching............................................................
17
13AP01:12 Display setting meter / inch ...............................................
17
13AP01:13 Processor, Starting sequence............................................
17
13AP01 Component positions ..............................................................
19
13AP02 Digital display V/A ....................................................................
20
13AP02 Component positions ..............................................................
22
13AP03 Digital display Wire feed speed...............................................
22
13AP03 Component positions ..............................................................
23
Circuit diagram .....................................................................................
24
SERVICE INSTRUCTIONS.......................................................................
25
What is ESD? ..........................................................................................
25
Removing the cover of the Warrior YardFeed .....................................
26
Tigthening torques................................................................................
27
Maintenance............................................................................................
29
SPARE PARTS .........................................................................................
30
Rights reserved to alter specifications without notice.
0463 394 001
© ESAB AB 2018
READ THIS FIRST
READ THIS FIRST
Maintenance and repair work should 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.
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
January 2018.
The manual is valid for:
•
•
Warrior™ YardFeed 200
Warrior™ YardFeed 200w
The Warrior™ YardFeed 200 and Warrior™ YardFeed 200w are designed and tested in
accordance with international and European standards IEC/EN 60974-5 and IEC/EN
60974-10, Canadian standard CAN/CSA-E60974-5 and US standard ANSI/IEC 60974-5.
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 above standards.
0463 394 001
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© ESAB AB 2018
INTRODUCTION
INTRODUCTION
The wire feed units Warrior™ YardFeed 200 and Warrior™ YardFeed 200w are intended for
MIG/MAG (GMAW) welding together with welding power sources:
•
•
Warrior 400i CC/CV
Warrior 500i CC/CV
They come in different variants, see chapter "ORDERING NUMBERS" in the instruction
manual.
The wire feed units are sealed and contains a four-wheel drive wire feed mechanism as well
as control electronics.
They can be used together with wire from ESAB, standard Ø S200 mm / Ø 8 inch,
7.5 kg / 15 lbs.
Design structure of the wire feeding unit
The wire feeding unit consists of a drive unit and an electronic unit. The drive unit is the
mechanical unit that actually feeds the wire and the electronic unit is communicating with the
power source and controlling the drive unit.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
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© ESAB AB 2018
TECHNICAL DATA
TECHNICAL DATA
For serial number 427-xxx-xxxx
Warrior™ YardFeed 200
Mains voltage
42 V, 50-60 Hz
Power requirement
252 VA
Rated supply current I1
6A
Settings data
Wire feed speed
1.9 - 25.0 m/min (75 - 985 in/min)
2/4 stroke
2 stroke or 4 stroke
Wire selection / Burnback
Solid or Cored
Creep start
Always on
Gas purging
Yes
Wire inching
Yes
Torch connection
EURO
Wire bobbin: Type, Max. diameter, Max
weight
S200, 200 mm (8 in.), 5kg (10 lb)
Wire dimension
Fe
0.6 - 1.2 mm (0.02 - 3/64 in.)
Ss
0.6 - 1.2 mm (0.02 - 3/64 in.)
Al
1.0 - 1.2 mm (0.04 - 3/64 in.)
Cored wire
0.8 - 1.2 mm (1/32 - 3/64 in.)
Weight
WYF 200
11.6 kg (25.6 lb)
WYF 200w
11.8 kg (26.0 lb)
Dimensions (l × w × h)
593 × 210 × 302 mm (23,3 × 8,3 × 11,9 in.)
Operating temperature
-10 to +40 °C (+14 to +104 °F)
Transport and storage temperature
-20 to +55 °C (-4 to +131 °F)
Shielding gas
All types intended for MIG/MAG welding
max pressure
0.5 MPA (5 bar / 72.5 psi)
Maximum permissible load at
60% duty cycle
365 A
100% duty cycle
280 A
Enclosure class
IP23
From serial number 528-xxx-xxxx
Warrior™ YardFeed 200
Mains voltage
42 V, 50-60 Hz
Power requirement
252 VA
Rated supply current I1
6A
Settings data
0463 394 001
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© ESAB AB 2018
TECHNICAL DATA
Warrior™ YardFeed 200
Wire feed speed
1.9 - 25.0 m/min (75 - 985 in/min)
2/4 stroke
2 stroke or 4 stroke
Wire selection / Burnback
Solid or Cored
Creep start
Always on
Gas purging
Yes
Wire inching
Yes
Torch connection
EURO
Wire bobbin: Type, Max. diameter
S200, 200 mm (8 in.)
Wire dimension
Fe
0.6 - 1.2 mm (0.023 - 0.045 in.)
Ss
0.6 - 1.2 mm (0.023 - 0.045 in.)
Al
1.0 - 1.2 mm (0.040 - 0.045 in.)
Cored wire
0.8 - 1.6 mm (0.030 - 1/16 in.)
Weight
WYF 200
12 kg (26.5 lb)
WYF 200w
12.2 kg (26.9 lb)
Dimensions (l × w × h)
593 × 210 × 312 mm
(23.3 × 8.3 × 12.28 in.)
Operating temperature
-10 to +40 °C (+14 to +104 °F)
Transport and storage temperature
-20 to +55 °C (-4 to +131 °F)
Shielding gas
All types intended for MIG/MAG welding
max pressure
0.5 MPA (5 bar / 72.5 psi)
Maximum permissible load at
60% duty cycle
365 A
100% duty cycle
280 A
Enclosure class
IP23
Standard factory settings
Standard factory settings for Warrior™ YardFeed 200 are in/min and fully open gas valve.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40 °C (104 °F).
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.
0463 394 001
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© ESAB AB 2018
WIRING DIAGRAM
WIRING DIAGRAM
General
The wire feed unit is a function module and is described in the component descriptions on
the following pages. Wire numbers and component names in the wiring diagram show to
which modules the components belong.
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), XP1–XP99 (P = plug), XT1–XT99 (T = terminal).
Circuit boards within each module have names such as 13AP1–13AP99.
13 = module association, 1–69
AP = circuit board
1 = individual identification number, 0–99
Capacitors within particular modules have identification numbers such as 13C1–13C99.
13 = module association, 1–69
C = transistor
1 = individual identification number, 0–99
0463 394 001
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© ESAB AB 2018
WIRING DIAGRAM
Units with ordering numbers 0459 906 898 and 0459 906 899
0463 394 001
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© ESAB AB 2018
WIRING DIAGRAM
0463 394 001
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© ESAB AB 2018
WIRING DIAGRAM
Units with ordering numbers 0459 906 900 and 0459 906 901
0463 394 001
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© ESAB AB 2018
WIRING DIAGRAM
0463 394 001
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© ESAB AB 2018
WIRING DIAGRAM
Component description
Component Description
13AP01
Main circuit board with control electronics, see the description in “13AP01
Control Board”, page 13.
13AP02
Digital display V/A, see the description in “13AP02 Digital display V/A”, page
20.
13AP03
Digital display Wire feed speed, see the description in “13AP03 Digital display
Wire feed speed”, page 22.
13C4, 13C5 Capacitor, decoupling.
13G1
Pulse generator (encoder) built into motor 13M1, see the description in
“13AP01:6 Pulse generator input”, page 15.
13M1
Motor, rated voltage 42 V.
13R1
Resistor, used as a heating element (option).
13R2
Resistor, 2.2 kΩ for adaptation of the start signal between the feeder and the
power source.
13RP1
Potentiometer, 10 kΩ for setting the wire feed speed.
13RP2
Potentiometer, 10 kΩ for setting the welding voltage.
13S2
Safety contact switch, 3 position switch.
13S3
Switch, 2/4-stroke. When the switch is closed, 4-stroke control mode is
selected.
13S4
Switch, three way returning to middle. Gas purge is activated in one direction
and Inching (cold wire feed) in the other.
13S6
Switch, selection of unit for wire speed shown on display, m/min or inch/min.
13S7
Trigger switch on welding torch.
13S8
Switch, wire selection. When the switch is closed, a fixed burnback time is
selected to adapt to welding with cored wire. When the switch is open, Short
Circuit Termination (SCT) behavior is selected to adapt to welding with solid
wire.
13XP . .
Plug connectors.
13XS . .
Socket connectors.
13YV1
Gas valve.
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© ESAB AB 2018
DESCRIPTION OF OPERATION
DESCRIPTION OF OPERATION
13AP01 Control Board
The sections 13AP01:1 to 13AP01:13 refers to the wiring diagram in the chapter "WIRING
DIAGRAM".
13AP01:1 Power supply
The power source supplies the wire feeder with 42 V AC. The wire feeder's power demand at
maximum load is 6.0 A.
42 V AC is used for the welding torch trigger switch, the power supply to the gas valve and
for the current relay.
Rectifier BR1 rectifies the 42 V supply to 60 V. Capacitor C28 smooths the voltage, which
then supplies the wire feeder motor.
Transistor Q8 is a pre-regulator which reduces the voltage from 60 V to 20 V. Q8 is
current-limited to about 200 mA. If the 20 V supply drops below 13 V, the wire feed unit
stops.
VR1 and VR2 are 5 V and 15 V voltage regulators respectively.
13AP01:2 2-stroke / 4-stroke
2-stroke
When the switch 13S3 is open, 2-stroke control mode is selected. This means that closing
the welding torch trigger switch starts the wire feed motor, opens the gas valve and closes
the power source contactor. Releasing the switch stops the motor, releases the contactor and
closes the gas valve.
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© ESAB AB 2018
DESCRIPTION OF OPERATION
4-stroke
When switch 13S3 is closed, 4-stroke control mode is selected. This means that first closure
of the trigger switch operates the gas valve, with the wire feed motor starting, and the power
source contactor operating, when the trigger switch is released.
Closing the trigger switch for the second time stops the motor and de-energises the contactor
in the power source. Releasing the switch closes the gas valve.
13AP01:3 Start / Stop
The welding torch trigger switch is supplied with 42 V AC. Closing the switch activates
optocoupler IC1, causing the voltage across C35 to go low.
When the wire feed starts, the power source generates welding voltage. If this is not followed
by a flow of welding current within three seconds, the power source shuts down the welding
power supply, although wire feed continues until the welding torch trigger switch is released.
13AP01:4 Current relay
Current relay
The current relay operates if the welding current exceeds 20 A.
Creep start
The creeps start function is always activated.
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© ESAB AB 2018
DESCRIPTION OF OPERATION
13AP01:5 Motor driving / braking
Driving
The motor is powered from the smoothed +60 V supply. Motor speed is controlled by pulse
width modulation of transistor Qd. The pulse frequency is 39 kHz. The maximum conducting
time of the pulses is 99% of the pulse cycle time. During the pulse spaces, the motor current
freewheels through diode D8.
At 24 V motor supply voltage, the wire feed rollers' speed is 175 r/min. A wire feed speed of
25 m/min. requires a roller speed of 265 r/min.
Current limit
Resistor R19 produces a voltage drop proportional to the motor current. If the current
exceeds the current limit, IC5 turns off the gate pulses to Qd. When the current falls, Qd
conducts again at the next gate pulse.
The control board has a dynamic current limit controlled by the processor. The current limit is
11 A on starting. When the set speed is achieved, this is reduced to 7 A.
Braking
When the motor starts, capacitor C43 charges up via diode D28: the voltage is limited to
15 V by zener diodes D10 and D21. When the motor is to brake, the LED in optocoupler IC8
lights, causing the transistor in IC8 to conduct and discharge capacitor C43 (15 V) to the gate
of transistor Qb. The transistor conducts and short-circuits the motor voltage through
resistors R51 and R64, which limit the current to about 20 A.
13AP01:6 Pulse generator input
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© ESAB AB 2018
DESCRIPTION OF OPERATION
The pulse generator (encoder), 13G1, is fitted to drive motor 13M1. It generates 60 pulses
per revolution.
At a wire feed speed of 20 m/min, the pulse generator produces a pulse frequency of 5093
Hz.
13AP01:7 Wire selection / Burnback
Wire selection – Solid wire
Short Circuit Termination (SCT) behavior is selected when the trigger is released to adapt to
welding with solid wire.
SCT is a way to stop the welding with some small short circuits to reduce the end crater and
oxidation. It also gives the advantage of a good start performance with solid wire.
Wire selection – Cored wire
A constant burnback time is selected when the trigger is released to adapt to welding with
cored wire.
Burnback
The burn-back time is the time from when motor braking starts until the main contactor in the
power source opens.
13AP01:8 Wire feed speed
The wire feed speed range is from 1.9 to 25 m/min for the YardFeed.
A 5 V reference voltage signal at connection A02 represents a speed of 25 m/min.
The processor monitors the wire feed speed. If the wire speed deviates from the set value by
more than 1.5 m/min for more than five seconds, wire feed will be stopped.
13AP01:9 Gas valve
The gas valve is connected to board contacts G04 and G05. The valve is energised via triac
TC1.
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© ESAB AB 2018
DESCRIPTION OF OPERATION
13AP01:10 Activation, contactor
The start signal to the power source is connected to board contact G03. The contactor is
energised via triac TC102.
13AP01:11 Gas purge / Inching
Gas purging, flushes gas without voltage or wire feed starting.
Wire inching is used to feed wire without welding voltage being applied.
13AP01:12 Display setting meter / inch
The setting of wire speed units, meter or inch, shown on the digital display is done with the
switch 13S6. When the switch is open, meter is shown. When the switch is closed, inch is
shown.
13AP01:13 Processor, Starting sequence
Processor
The processor stores the feeder program. It monitors the power supply voltages: if the
voltages drop to too low a level, wire feed is stopped, as described in section "13AP01:1
Power supply".
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© ESAB AB 2018
DESCRIPTION OF OPERATION
Starting sequence
The circuit board displays the starting sequence from power-up.
1.
2.
3.
LED1 lights red during 5 seconds. The software is in the boot mode.
LED1, LED2 and LED3 lights green. The software has started the application mode.
LED1 flashes continously with a green light. The board is initiated, and the wire feed
unit is in the application program.
The software version is indicated by a label on the processor, IC6.
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© ESAB AB 2018
DESCRIPTION OF OPERATION
13AP01 Component positions
0463 394 001
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© ESAB AB 2018
DESCRIPTION OF OPERATION
13AP02 Digital display V/A
The display board is intended for use in Warrior YardFeed 200 and Warrior YardFeed 200w
connected to power sources Warrior 500i CC/CV or Warrior 400i CC/CV.
The display unit has two groups of three digits. The left group (DY1–DY3) is used for
displaying set or actual arc voltage and the right group (DY4–DY6) is used to display the
measured welding current.
Data is transmitted to the display board from the power source using a three line serial
interface through the inputs:
0463 394 001
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© ESAB AB 2018
DESCRIPTION OF OPERATION
•
•
•
CN1:01 Clock
CN1:04 Load
CN1:05 Data
The signal amplitude at CN1:01/04/05 is 15 V and all signals are active low.
The board is power supplied with 24 V DC from the power source at CN1:02.
0 V for power and signals is at CN1:03.
The internal switch-mode power supply converts 24 V to the internal voltage +5V. The actual
voltage on +5V is about 4.6 V to minimize the power losses in the three display drivers
IC1–IC3.
The voltage +5V may be measured at CN2:02.
0463 394 001
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© ESAB AB 2018
DESCRIPTION OF OPERATION
13AP02 Component positions
13AP03 Digital display Wire feed speed
The display unit board has one group of three digit seven segment LED-displays to present
wire feed speed. The board is suplied with 42 V AC from the power supply. A rectifier and a
DC/DC converter supplies the logic circuit and the LED modules with +5 V.
NOTE!
The display for the wire feed speed is activated a few seconds after the safety
contact switch is set to "Welding ON" (1), that is when the control board has
reached application mode.
The data to the display unit board is received from the control board in the wire feeder over a
two line serial interface. The data is converted from serial input and thereafter shown on the
LED indicators.
Serial data are read by the microcontroller unit on the display unit board. The microcontroller
unit translate the data and drive the segments of the display modules. There is one discrete
input on the display unit board to change the unit of the data (m/min or inch/min) shown on
the display.
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© ESAB AB 2018
DESCRIPTION OF OPERATION
13AP03 Component positions
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© ESAB AB 2018
DESCRIPTION OF OPERATION
Circuit diagram
0463 394 001
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© ESAB AB 2018
SERVICE INSTRUCTIONS
SERVICE INSTRUCTIONS
CAUTION!
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.
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
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.
0463 394 001
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© ESAB AB 2018
SERVICE INSTRUCTIONS
Removing the cover of the Warrior YardFeed
0463 394 001
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© ESAB AB 2018
SERVICE INSTRUCTIONS
Tigthening torques
CAUTION!
Use the correct torque when tightening the screws.
0463 394 001
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© ESAB AB 2018
SERVICE INSTRUCTIONS
0463 394 001
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© ESAB AB 2018
SERVICE INSTRUCTIONS
Maintenance
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt. Clean and replace worn parts
of the wire feed mechanism at regular intervals. Note that if pre-tensioning is set too hard,
this can result in abnormal wear on the pressure roller, feed roller and wire guide.
The brake hub
The hub is adjusted when delivered, if readjustment is required, follow the instructions
below. Adjust the brake hub so that the wire is slightly slack when wire feed stops.
Brake hub in units with ordering numbers
0459 906 898 and 0459 906 899
0463 394 001
Brake hub in units with ordering numbers
0459 906 900 and 0459 906 901
- 29 -
© ESAB AB 2018
SPARE PARTS
SPARE PARTS
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
Filename
Product
Spare parts list
0463 390 001
Warrior™ YardFeed 200 / 200w
Instruction manual
0463 387
Warrior™ YardFeed 200 / 200w (CE)
Instruction manual
0463 387
Warrior™ YardFeed 200 / 200w (NA)
0463 394 001
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© ESAB AB 2018
SPARE PARTS
0463 394 001
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© ESAB AB 2018
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 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 15 25 79 30
Fax: +32 15 25 79 44
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: +359 2 974 42 88
Fax: +359 2 974 42 88
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
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
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AS ESAB
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Fax: +47 33 11 52 03
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Ltd
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Products
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Gothenburg
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Langenfeld
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Baar
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www.esab.com
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Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 0220
Fax: +1 905 670 4879
SPAIN
ESAB Ibérica S.A.
San Fernando de Henares
(MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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