ESAB | Feed 30w | Service manual | ESAB Feed 30w User manual

ESAB Feed 30w User manual
Origo™
Feed 30
Feed 30w
Service manual
0349 300 069
120618
Valid for serial no. 638-xxx-xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OrigoTM Feed 30w, Feed 30* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1 Control board 0349 304 491 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:1a
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:2a
Activation, contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:3a
Wire feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:4a
Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:5a
Mode selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:6a
Creep start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:7a
Current relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:8a
Burn-back time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:9a
Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1:10a
Motor driving / braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
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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 design changes that have been made up to and including
June 2007.
The OrigoTM Feed 30 and Feed 30w are designed and tested in accordance with
international and European standards IEC-/EN 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
standard.
CAUTION
Read and understand the instruction manual before
installing or operating.
INTRODUCTION
Feed 30, Feed 30w wire feed unit is intended for MIG/MAG welding together with
step controlled welding power sources, with solid steel, stainless steel, aluminium
wire and flux-cored wires.
-3cm56_00
S0349 300 069/E120618/P16
© ESAB AB 2007
TECHNICAL DATA
Power supply
Power requirement
Welding current at 60% duty cycle
Feed 30, Feed 30w
42V, 1∼50/60 Hz
420 VA
500 A
Settings data
Wire feed speed
1,5-25 m/min
Burnback time
0,0-0,7 sec
Spot welding time
0,2-5,0 sec
Welding gun connection
EURO
Wire dimension range
0,8-1,6 (Fe,SS);
1,0-1,6 ( Al);
1,0-1,6 (FCW)
Shielding gas
All types for MIG/MAG - max 5 bar
Max diam. / weight of wire bobin
300 mm / 18kg
Dimensions lxwxh
700x255x420
Weight
14,8 kg (Feed 30)
with cooling liquid system
15,0 kg (Feed 30w)
Operating temperature
-10 to +40oC
Transportation temperature
-20 to +55oC
Enclosure class
IP 23 (wire bobbin - IP 2X)
Application classification
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.
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 designed for indoor and outdoor use.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Apparatus marked IP2X are intended for indoor use.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
-4cm56_00
S0349 300 069/E120618/P16
© ESAB AB 2007
WIRING DIAGRAM
Component description
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostaticsensitive devices.
S
Use proper static-proof bags and boxes.
This component description refers to the wiring diagram.
A1
Main circuit board with control electronics.
M1
Motor.
R1
Potentiometer, 2.2 kΩ, for setting the wire feed speed.
R2
Potentiometer, 100 kΩ, for setting the burn-back time.
R3
Potentiometer, 100 kΩ, for setting the spot welding time.
S1
2/4-stroke, spot welding, inching and gas purging change-over switch.
S2
Switch, creep start ON/OFF.
XS1
28-pole panel socket, for connection to the welding power source.
K1
Gas valve.
H1
LED lamp 42V AC.
-5cm56_00
S0349 300 069/E120618/P16
© ESAB AB 2007
OrigoTM Feed 30w, Feed 30*
* S4 (ELP) not applied for Feed 30
-6cm56_00
S0349 300 069/E120618/P16
© ESAB AB 2007
DESCRIPTION OF OPERATION
A1 Control board 0349 304 491
This description is valid for control board 0349 304 491, which is fitted in Feed 30, Feed 30w.
A1:1a
Power supply
The feeder obtains a 42 V supply from the control power supply transformer in
the power source.
42 V AC is used for power supply to the gas solenoid valve and the main
contactor. It is also used for the motor drive circuits.
The 42 V is rectified and then reduced to +15 V by resistors R65 - R67 and
zener diodes V30 and V31.
A1:2a
Activation, contactor
The start signal to the power source is connected to board contact X3.9. The
contactor is energised via triac V22.
-7cm56_01
A1:3a
Wire feed speed
The wire feed speed range is from 1.5 to 22 meters per minute.
Potentiometer R8 is used to adjust the maximum wire feed speed and
potentiometer R1 sets the minimum speed. Adjust R8 first and then R1.
A1:4a
Start / Stop
The wire feed unit starts when the welding gun switch closes.
A1:5a
Mode selector switch
2-stroke
When switch 13SA1 is in position 1, all input terminals are open, and the unit
operates in 2-stroke mode. Operating the trigger on the welding gun starts the
motor, opens the gas valve and energises the power unit contactor.
Releasing the trigger stops the motor, de-energises the contactor and closes
the gas valve. If burn-back mode is in operation, welding ceases when the
burn-back time has elapsed.
4-stroke
When switch 13SA1 is in position 2, input terminal X1.8 is connected to +15 V,
and the unit operates in 4-stroke mode. Operating the trigger on the welding
gun opens the gas valve: releasing the trigger then starts the motor and
energises the power source contactor.
Operating the trigger switch for a second time stops the motor and
de-energises the contactor in the power source: releasing the switch then
closes the gas solenoid valve. If burn-back mode is in operation, welding
ceases when the burn-back time has elapsed.
-8cm56_01
Spot welding
The start sequence is the same as for the 2-stroke mode.
When the spot welding time has elapsed, the motor stops, the contactor
de-energises and the gas valve closes. If burn-back mode is in operation,
welding ceases when the burn-back time has elapsed.
The welding time can be adjusted by potentiometer 13RP3.
Inching
Pressing the trigger switch, starts the wire feed. The gas valve and contactor
are not activated.
Gas purging
Pressing the trigger switch, opens the gas valve. The wire feed and contactor
are not activated.
A1:6a
Creep start
Creep start means that the motor runs at 50% of the set speed until the current
relay operates, after which the speed increases to the set speed.
Selector switch 13SA2 selects creep start On/Off. Closing the switch on to the
+15 V supply engages creep start.
The creep start function is disabled during inching.
-9cm56_01
A1:7a
Current relay
The current relay is activated when the welding current exceeds 20 A.
A1:8a
Burn-back time
The burn-back time is the time from when motor braking starts until the main
contactor in the power source opens. It can be adjusted between 0 and 0.7
seconds by potentiometer 13RP2.
A1:9a
Gas valve
The gas valve is connected to board contacts X3.7 and X3.8. The valve is
energised via triac V23.
- 10 cm56_01
A1:10a
Motor driving / braking
Driving
The motor is powered from the 42 V AC supply, which is rectified and
thyristor-controlled. The motor speed is controlled by thyristors V19 and V20.
The voltage across resistor R64 is proportional to the motor current. This is
used as the actual value signal for the wire feed speed.
Braking
When the motor is to brake, thyristor V16 is activated by transistor V13. The
thyristor conducts and short-circuits the motor voltage through resistor R52.
- 11 cm56_01
A1
Component positions
Control board 0349 304 491
- 12 cm56_01
SERVICE INSTRUCTIONS
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostaticsensitive devices.
S
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.
- 13 cm56f2
S0349 300 069/E120618/P16
© ESAB AB 2007
NOTES
- 14 notes
S0349 300 069/E120618/P16
© ESAB AB 2007
- 15 notes
S0349 300 069/E120618/P16
© ESAB AB 2007
ESAB subsidiaries and representative offices
Europe
AUSTRIA
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Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
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Tel: +32 2 745 11 00
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AS ESAB
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Tel: +27 (0)21 975 8924
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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Archerfield BC QLD 4108
Tel: +61 1300 372 228
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www.esab.com
© ESAB AB
110915
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