ESAB Aristo RoboFeed 30-4 Service Manual Download Page 34

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Summary of Contents for Aristo RoboFeed 30-4

Page 1: ...Aristo Service manual 0740 800 169 GB 20140710 Valid for serial no 501 620 745 310 xxx xxxx RoboFeed 3004w ...

Page 2: ...3 Gas valve 14 13AP1 4 Motor driving braking 14 13AP1 5 Pulse generator input 15 13AP1 6 Monitoring gas pressure 16 13AP1 7 The CAN bus 16 13AP1 8 I O 17 13AP1 9 Arc voltage sensing 17 13AP1 Component positions 18 13AP2 I O board 20 13AP2 1 Power supply 20 13AP2 2 Input signals 20 13AP2 3 Output signals 21 13AP2 Component positions 22 FAULT CODES 23 Fault log 23 Fault code description 23 SERVICE I...

Page 3: ...s 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 all design changes that have been made up to and including May 2013 The manual is valid for Aristo RoboFeed 30 4 with serial no 501 xxx xxxx RoboFeed 3004w with serial no 620 745 310 xxx xxxx The Aristo Ro...

Page 4: ...m Shielding gas max pressure All types intended for MIG MAG welding 5 bar Coolant max pressure ESAB s ready mixed coolant 5 bar Permissible load at 60 duty cycle 100 duty cycle 500 A 280 A Enclosure class IP2X 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 Encl...

Page 5: ...ics see the description in Section 13AP1 Control board page 12 13AP2 I O circuit board see the description in Section 13AP2 I O board page 20 13C1 13C3 Capacitor 0 1 uF 13G1 Pulse generator incorporated in motor 13M1 13HL1 Lamp indicating power supply on 13L1 Ferrite ring core 13M1 Wire feed motor 13RE1 Relay for activation of reversed wire feed 13RE2 Relay for deactivation of touch sensing From s...

Page 6: ...WIRING DIAGRAM 0740 800 169 6 ESAB AB 2014 RoboFeed 3004w Aristo RoboFeed 30 4 valid for serial no 501 xxx xxxx 620 xxx xxxx ...

Page 7: ...WIRING DIAGRAM 0740 800 169 7 ESAB AB 2014 ...

Page 8: ...WIRING DIAGRAM 0740 800 169 8 ESAB AB 2014 RoboFeed 3004w valid for serial no 745 xxx xxxx ...

Page 9: ...WIRING DIAGRAM 0740 800 169 9 ESAB AB 2014 ...

Page 10: ...WIRING DIAGRAM 0740 800 169 10 ESAB AB 2014 RoboFeed 3004w valid for serial no 310 xxx xxxx ...

Page 11: ...WIRING DIAGRAM 0740 800 169 11 ESAB AB 2014 ...

Page 12: ...can bus The ID numbers of the wire feeders are Aristo RoboFeed 30 4 Machine ID 8 Hardware ID 6 Unit type 3 wire feeder unit RoboFeed 3004w Machine ID 8 13AP1 1 Power supply The wire feed unit is supplied at 42 V from the control current power supply transformer in the welding power source The feed unit can briefly draw up to about 8 A when accelerating the wire DC supplies The diodes D13 D16 recti...

Page 13: ...for test purposes Closing the switch input activates optocoupler IC7 pulling C47 low this generates a Start command Gas pre flow starts then wire feed also starts and 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 switch is ...

Page 14: ...ving braking Schematic diagram of the motor drive stage The print numbers refer to different board prints See component positions 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 97 of the pulse period Freewheel diode D27 provides current path during t...

Page 15: ...fallen below the current limit Speed monitoring Wire feed speed is monitored by the microprocessor on the circuit board Wire feed is stopped if the feed speed deviates from the set speed by more than 1 5 m min for more than 5 1 seconds The U8 displays fault code 11 Braking Capacitor C67 is charged via diode D31 when the motor starts Zener diodes D33 and D34 limit the voltage to 15 V When optocoupl...

Page 16: ...ies a 12 V power supply to the U8 this is not used on circuit board 13AP1 0 V on the circuit board is connected to 0 V in the U8 Starting sequence On power up the board s CAN controller reads in the bus speed from the micro processor 400 kbit s The circuit board displays the starting sequence from power up LED1 lights red Then LED1 LED2 and LED3 lights green When the board has been initiated and t...

Page 17: ... that there is good contact at the connections to capacitor 13C3 see the relevant wiring diagram in Section WIRING DIAGRAM page 5 Power source Check that there is good contact with the chassis connection to the control circuit board the interference suppression board and the interference suppression capacitors Check the power supply voltages on circuit board 13AP1 If there are no faults in any of ...

Page 18: ...DESCRIPTION OF OPERATION 0740 800 169 18 ESAB AB 2014 13AP1 Component positions ...

Page 19: ...DESCRIPTION OF OPERATION 0740 800 169 19 ESAB AB 2014 ...

Page 20: ...urce is not activated Reverse When switch 13SB1 is pressed the wire is fed backwards with the latest used wire feed speed The welding power source is not activated Gas purge When switch 13SB2 is pressed the gas valve 13YV1 opens The gas valve is controlled by the control board The welding power source is not activated Anti collision The anti collision input is intended for an opening switch contac...

Page 21: ...ot 13AP2 3 Output signals Reverse When the reverse switch on the front of the wire feeder is depressed the processor activates relay 13RE1 and the wire is fed backwards with the latest used wire feed speed The revers function can also be activated by a command to the processor from an external control system Spatter removal This function is controlled by the robot The relay can also be activated b...

Page 22: ...DESCRIPTION OF OPERATION 0740 800 169 22 ESAB AB 2014 13AP2 Component positions Circuit board 13AP2 version 0487 307 882 Circuit board 13AP2 version 0487 083 880 ...

Page 23: ...ror Check sum test of the program memory which is run only when initiating the unit after power up This fault does not disable any functions The program memory is damaged This is a serious fault that can have unforeseen effects Action Restart the machine If the fault persists load new software via ESAT If the fault still persists replace circuit board 13AP1 which carries the memory chip 2 Micropro...

Page 24: ...lt Check the CAN cabling Turn off the mains power supply to reset the unit 23 Receiver buffer overflow The control board is unable to process information from the other units at a sufficiently high speed This fault is caused by abnormal loading of the microprocessor Action Turn off the mains power supply to reset the unit 27 Out of wire The wire feed unit is not feeding any wire The current weldin...

Page 25: ...ty 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 f...

Page 26: ...ich it is possible to control change or read the different functions of the equipment For the installation and use of the ESAT you need a PC with operating system Windows The ESAT service kit contents CAN adapter with connection cables CD with software Instruction manual for ESAT USB2CAN for connection to the USB port of the PC ordering no 0458 847 881 Replacing the old gas flow guard This instruc...

Page 27: ...SERVICE INSTRUCTIONS 0740 800 169 27 ESAB AB 2014 3 Unscrew and remove the Control circuit board 13AP1 and the I O circuit board 13AP2 4 Drill four holes in the centre of the central mounting plate ...

Page 28: ...4 5 Attach the new pressure guard using cable straps connect the hoses to the guard and connect the guard s socket connector 13XS13 to connector K on Control circuit board 13AP1 6 Refit the Control circuit board 13AP1 and the I O circuit board 13AP2 ...

Page 29: ...dering no 0155 716 880 in series with the welding torch 2 Open the gas to the preferred flow 3 Connect a multimeter over the pressure guard 4 Turn the adjusting screw on the pressure guard until you reach the break point 5 Repeat the test if needed 6 After having set the correct pre set value fasten the adjusting screw using thread locker Loctite 243 or equivalent Replacing rubber dampers with bak...

Page 30: ...IONS 0740 800 169 30 ESAB AB 2014 2 Remove the four rubber dampers 3 Insert the hexagonal screws a into the oval holes in the bakelit bars and attach the bakelit bars to the bottom plate using screws b washers and nuts ...

Page 31: ...SERVICE INSTRUCTIONS 0740 800 169 31 ESAB AB 2014 4 Re attach the wire feeder cover ...

Page 32: ...40 800 169 32 ESAB AB 2014 SPARE PARTS The spare parts list is published in a separate document that can be downloaded from the Internet www esab com Filename Product 0461 030 990 RoboFeed 3004w Aristo RoboFeed 30 4 ...

Page 33: ...SPARE PARTS 0740 800 169 33 ESAB AB 2014 ...

Page 34: ...ID Tel 34 91 878 3600 Fax 34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB International AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 UKRAINE ESAB Ukraine LLC Kiev Tel 38 044 501 23 24 Fax 38 044 575 21 88 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 F...

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