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ESAB YardFeed 200, Service Manual

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ESAB YardFeed 200 Service Manual Download Page 15

S0740 800 148/E060619/P30

-- 15 --

cwfu2de1

13AP1:9

Gas valve

The gas valve is connected to board contacts G04 and G05. The valve is

energised via triac TC1.

13AP1:10 Activation, contactor

The start signal to the power source is connected to board contact G03. The

contactor is energised via triac TC102.

13AP1:11 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.
The gas purge and inching functions are only used by

the YardFeed 200.

Summary of Contents for YardFeed 200

Page 1: ...0740 800 148 Valid for serial no 238 xxx xxxx to 612 xxx xxxx 060619 ESABFeed 30 2 M11 YardFeed 200 Origot M13y ESAB YardFeed 200 Service manual ...

Page 2: ...1 Gas purge Inching 15 13AP1 12 Processor Starting sequence 16 13AP1 Component positions 17 13AP2 Digital display 19 13AP2 Component positions 19 13AP2 Circuit diagram 20 SERVICE INSTRUCTIONS 21 What is ESD 21 Dismantling of YardFeed 200 21 Spare parts for connection sets ESABFeed 30 2 M11 22 Spare parts for connection sets YardFeed 200 23 INSTRUCTIONS 24 SAFETY 24 Lifting instructions ESABFeed 30...

Page 3: ... YardFeed 200 and YardFeed 200 with serial no 548 xxx xxxx 612 xxx xxxx The ESABFeed 30 2 M11 YardFeed 200 and ESAB YardFeed 200 are designed and tested in accordance with international and European standard IEC EN 60974 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 ab...

Page 4: ...S0740 800 148 E060619 P30 4 cwfu2de1 ...

Page 5: ... Weight 14 3 kg 11 3 kg Dimensions l x b x h 690 x 275 x 420 mm 593 x 210 x 302 mm Shielding gas max pressure All types intended for MIG MAG welding 5 bar All types intended for MIG MAG welding 5 bar Coolant max pressure 60 water 40 glycol 5 bar 60 water 40 glycol 5 bar Maximum permissible load at 35 duty cycle 60 duty cycle 400 A 365 A Enclosure class with wire bobin 440mm IP23 IP2X IP23 Accessor...

Page 6: ... 13AP2 Circuit board with display see the description on page 19 13C1 13C4 13C5 Capacitor decoupling 13G1 13G1 Tachogenerator incorporated in motor 13M1 13M1 13M1 Motor with tachogenerator 13R1 Resistor used as heating element option 13RP1 13RP1 Potentiometer for setting the wire feed speed 13RP2 Potentiometer for setting the welding voltage 13RP3 13RP3 Potentiometer for setting the burn back time...

Page 7: ...S0740 800 148 E060619 P30 7 cwfu2de1 ESABFeed 30 2 M11 ...

Page 8: ...S0740 800 148 E060619 P30 8 cwfu2de1 YardFeed 200 ...

Page 9: ...S0740 800 148 E060619 P30 9 cwfu2de1 ...

Page 10: ...r supply ESABFeed 30 2 M11 The feeder obtains a 42 V supply from the power source Its power demand at maximum load is 3 5 A 42 V AC is used for the welding gun trigger switch and as the power supply to the gas solenoid valve and the main contactor 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 regul...

Page 11: ...g the trigger stops the motor de energises the contactor and closes the gas valve If burn back is in operation welding ceases when the burn back time has elapsed 4 stroke When the switch is closed 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 ...

Page 12: ...trol board 0486 991 880 When wire feed starts the power source generates welding voltage 13AP1 4 Current relay Creep start Normal start The new version of the control board 0487 162 880 The first version of the control board 0486 991 880 Current relay The current relay operates if the welding current exceeds 20 A Creep Start The creep start function is activated when switch 13SA2 is open Creep sta...

Page 13: ...V motor supply voltage the wire feed rollers speed is 160 r min A wire feed speed of 20 m min requires a roller speed of 217 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 Q1 When the current falls Q1 conducts again at the next gate pulse The new version of the control board 0487 1...

Page 14: ...irst version of the control board 0486 991 880 The tachometer frequency is 796 Hz for a wire feed speed of 20 metres per minute 13AP1 7 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 5 seconds by potentiometer 13RP3 13AP1 8 Wire feed speed The wire feed speed range is from 1 9 to 20 ...

Page 15: ...tivation contactor The start signal to the power source is connected to board contact G03 The contactor is energised via triac TC102 13AP1 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 The gas purge and inching functions are only used by the YardFeed 200 ...

Page 16: ...s red during 5 seconds The software is in the boot mode 2 LED1 LED2 and LED3 lights green The software has started the aplication mode 3 LED1 flashes continously with a green light The board is initiated and the wire feed unit is in the application program The starting sequence above applies to boards with software version 2 00A and later Boards with software version 0 27A have LED indication as d...

Page 17: ...S0740 800 148 E060619 P30 17 cwfu2de1 13AP1 Component positions The new version of the control board 0487 162 880 0487 162 881 ...

Page 18: ...S0740 800 148 E060619 P30 18 cwfu2de1 The first version of the control board 0486 991 880 ...

Page 19: ...500t or a LAW power source The display board has two rows of 7 segment displays with three displays in each row The upper row displays arc voltage and the lower displays the welding current Data is transmitted serially to the display board from the power source via inputs A1 A4 and A5 A smoothed 12 V DC power supply is supplied to the board via inputs A2 and A3 from the welding power source Voltag...

Page 20: ...S0740 800 148 E060619 P30 20 cwfu2de1 13AP2 Circuit diagram ...

Page 21: ...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...

Page 22: ...S0740 800 148 E060619 P30 22 cwfu2se1 Spare parts for connection sets ESABFeed 30 2 M11 ...

Page 23: ...S0740 800 148 E060619 P30 23 cwfu2se1 Spare parts for connection sets YardFeed 200 ...

Page 24: ...rdFeed 200 SAFETY WARNING Read and understand the instruction manual before installing or operating Lifting instructions ESABFeed 30 2 M11 Ordering number for the lifting eye can be found in the accessory spare parts list Note If another mounting device is used this should be insulated from the wire feed unit Lifting instructions YardFeed 200 ...

Page 25: ...ESAB Logic Pump see Water connection on next page Connections and control devices YardFeed 200 1 Connection for welding current from power source OKC 8 Safety contact switch 2 Connection for shielding gas 9 Connection for welding gun 3 Connection for control cable from power source 10 Toggle switch for gas flushing wire inching 4 Connection RED for coolant to power source cooling unit 11 Toggle sw...

Page 26: ...N accessory and welding OFF The bobbin area is heated so that the welding wire is not damp when welding Gasflow control and burnback time YardFeed 200 A Controlling gas flow B Gas flow meter C Setting burnback time Setting the wire feed pressure Start by making sure that the wire moves smoothly through the wire guide Then set the pressure of the wire feeder s pressure rollers It is important that ...

Page 27: ... torque ESABFeed 30 2 M11 1 Turn the red handle to the locked position 2 Insert a screwdriver into the springs in the hub 3 Turn the springs clockwise to reduce the braking torque Turn the springs anticlockwise to increase the braking torque NOTE Turn the springs the same amount Adjusting the braking torque YardFeed 200 There are two different brake hubs used for the Yard Feed The first version us...

Page 28: ...S0740 800 148 E060619 P30 28 notes NOTES ...

Page 29: ...S0740 800 148 E060619 P30 29 notes ...

Page 30: ...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 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 2191 4333 Fax 55 31 2191 4440 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEX...

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