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Service manual

0740 801 028 GB 20171110

Valid for: serial no. 921-, 943-, 049-, 327-, 628-xxx-xxxx

A2, A6 PEK Control Unit

Содержание A2-A6 PEK

Страница 1: ...Service manual 0740 801 028 GB 20171110 Valid for serial no 921 943 049 327 628 xxx xxxx A2 A6 PEK Control Unit...

Страница 2: ...y 28 1AP1 5 Encoder monitoring 29 1AP1 6 Ethernet interface from serial no 628 xxx xxxx 30 1AP1 7 USB host B internal from serial no 628 xxx xxxx 31 1AP1 Component positions 32 26 Motor control motor...

Страница 3: ...de description 48 SERVICE INSTRUCTIONS 55 What is ESD 55 Service aid 55 Replacing the battery 56 SOFTWARE UPDATE 57 Motor control 26AP1 57 Welding data unit 1AP1 57 Updating software 60 Reset with res...

Страница 4: ...ist as a guide to where the components are located in the equipment The spare parts list is published as a separate document see Spare Parts section This manual contains details of design changes that...

Страница 5: ...wer source emergency stop CAN bus USB memory From serial no 628 xxx xxxx the unit is equipped with a second USB connector located inside the unit on the MMC Welding data board motors control of flux g...

Страница 6: ...ard except for the CAN circuits supplied with 12 V via the CAN connection The board can supply 5 V to a laser lamp and 5 15 or 24 VDC for the motor encoder 26AP2 Motor driver board The motor driver bo...

Страница 7: ...top X1 Terminal block XP1 Connector XS1 24AP1 CANbus connection XS2 USB connector XS3 Ethernet connector from serial no 628 xxx xxxx 200 Wire 14 2 14 4 14 5 Wire from CN14 1 CN14 4 and CN14 5 18 2 Wir...

Страница 8: ...RAM 0740 801 028 8 ESAB AB 2017 A2 A6 PEK Control Unit Serial no 921 943 049 327 xxx xxxx Updates From serial no 921 010 XXXX Cable 18 1 removed From serial no 921 010 XXXX Wire jumper X1 12 to X1 15...

Страница 9: ...WIRING DIAGRAM 0740 801 028 9 ESAB AB 2017...

Страница 10: ...WIRING DIAGRAM 0740 801 028 10 ESAB AB 2017 A2 A6 PEK Control Unit Serial no 628 xxx xxxx...

Страница 11: ...WIRING DIAGRAM 0740 801 028 11 ESAB AB 2017...

Страница 12: ...nsions l w h 246 235 273 mm Weight 6 6 kg Enclosure class IP23 Travel speed 0 200 cm min See separate instruction manual for automatic welding machines Max manual travel speed 2 0 m min Wire feed spee...

Страница 13: ...ce 6 Inlet for cable travel motion pulse encoder 2 USB connection 7 Inlet for cable arc voltage feedback 3 Connection CAN for remote control unit or service tool 8 Outlet for motor cable travel motion...

Страница 14: ...ote control unit or service tool 3 Two CANbus connections 500 kbit s for external equipment remote control or the ESAT servicetool Termination of CANbus Inside the unit there are CANbus terminations a...

Страница 15: ...k for connection of limit switches flux gas 42VAC arc voltage and emergency stop 4 CN16 Connection for travel motion pulse encoder 2 CN19 CN20 Voltage selection for encoders 5 CN7 Connection for motor...

Страница 16: ...urce if it is engaged The circuit can be extended to other external emergency stop buttons according to the right figure above At terminal block X1 remove the link between 1 and 2 At terminal block X1...

Страница 17: ...nal equipment or ON OFF of the laserlamp The internal relay is rated for max 8A 250 VAC Named Relay 2 in the menues Connect optional equipment to terminal block X1 at 15 and 16 Manufactured after seri...

Страница 18: ...t to terminal block X1 at 14 24 V Connect to terminal block X1 at 20 0 V With ON OFF function Manufactured before serial no 921 010 xxxx With this configuration ON OFF of the light is handled via the...

Страница 19: ...o terminal block X1 at 13 and 14 Connection for limit switches Motor drive and field supply Power connection to motor 1 and 2 There are outputs to drive two motors The motors are connected directly to...

Страница 20: ...ectly to the 26AP1 motor control board with an ESAB accessory cable Connect encoder for motor 1 wire feed to CN17 motor 2 travel to CN16 Installation At the back of the unit remove the plug s from the...

Страница 21: ...r Arc voltage Inside the unit there is a connection to the arc voltage measurement circuit in the welding power source At the back of the unit remove the plug from the hole Insert a cable fitting with...

Страница 22: ...upply external units Max output current depends on the connected welding power source At the back at the unit remove the plug from the hole Insert a cable fitting with strain relief into the hole Inse...

Страница 23: ...election and parameter settings The welding data board monitors the function of the entire welding system It stores welding data and handle the MMC and communicates over the CAN bus with the welding p...

Страница 24: ...e program memory of the welding data unit is checked by a check sum test If the test detects a fault fault code E1 will be logged 3 The external RAM memory is checked by a read write test of each memo...

Страница 25: ...red in order to be able to save data to RAM and interrupt or terminate processes in progress in a controlled manner Circuit diagram for power supply from battery The RAM and clock circuits need a main...

Страница 26: ...be loaded with 2 5 kohm from resistors R86 R89 R98 and R99 Read more about the CAN bus in the service manual for the power source Circuit diagram for the CAN bus Starting sequence At power up the boar...

Страница 27: ...cannot be adjusted Circuit diagram for backlight illumination of the display The processor controls via transistor Q1 and Q2 the background illumination ON OFF To increase the lifetime of the display...

Страница 28: ...1AP1 1AP1 4 USB memory Programs and settings can be exported to imported from a USB memory Error and quality function logs can be exported to a USB memory See the instruction manual for Export Import...

Страница 29: ...t 2 0 V to contacts 1 and 3 but with a slight time difference between them This generates pulses that are displaced by about 90 relative to each other One square wave pulse is used as clock frequency...

Страница 30: ...DESCRIPTION OF OPERATION 0740 801 028 30 ESAB AB 2017 1AP1 6 Ethernet interface from serial no 628 xxx xxxx Circuit diagram for Ethernet interface...

Страница 31: ...nication status Off No activity On Activity 1AP1 7 USB host B internal from serial no 628 xxx xxxx From serial no 628 xxx xxxx the PEK control unit is equipped with a second USB connector This connect...

Страница 32: ...DESCRIPTION OF OPERATION 0740 801 028 32 ESAB AB 2017 1AP1 Component positions Component positions for the welding data board up to and including serial no 327 xxx xxxx...

Страница 33: ...DESCRIPTION OF OPERATION 0740 801 028 33 ESAB AB 2017 Component positions for the welding data board from serial no 628 xxx xxxx...

Страница 34: ...circuits It handles the communication and generates control signals to the motor drive board Circuit board identity Using the Unit information menu on the control panel you can decipher The machine I...

Страница 35: ...he CAN is supplied from the welding power source The shell of the CAN connectors is connected to 0V_CAN Voltage regulator VR4 supplies a 5 V power supply to the CAN circuits Starting sequence On power...

Страница 36: ...green light 3 Turn the power off and remove the jumper When the power is turned on again the hardware is reset 26AP1 3 Encoder for wire feed motor The external encoder is supplied with 5 15 or 24 V d...

Страница 37: ...and 6 of terminal CN19 selects 24 V During rotation there are pulses at terminals CN16 3 and 4 The pulse frequency is a measure of the speed The phase relation between the two pulse trains gives the...

Страница 38: ...CN3 and the relay on 26AP2 A lamp connected to X1 16 can then have ON and OFF controlled by the software The current from the lamp is connected to 0V at 26AP1 via CN18 2 Before serial no 921 010 xxxx...

Страница 39: ...DESCRIPTION OF OPERATION 0740 801 028 39 ESAB AB 2017 26AP1 Component positions...

Страница 40: ...the control board 26AP1 26AP2 1 Power supply The motor drive board is supplied with power from the welding power source The 42 VAC is rectified by BR1 and supplied to CN5 1 and CN5 5 On the board it g...

Страница 41: ...DESCRIPTION OF OPERATION 0740 801 028 41 ESAB AB 2017 26AP2 2 Motor 1 drive Wire feed at CN7...

Страница 42: ...signal at IC5 4 turns off the motor in case of overvoltage at the 60 V bus Voltages above 85 V are defined as overvoltage Terminal CN2 15 is always high this means that the current limit is low 1 A H...

Страница 43: ...DESCRIPTION OF OPERATION 0740 801 028 43 ESAB AB 2017 26AP2 3 Motor 2 drive Travel motion at CN6...

Страница 44: ...rrent limit is low 1 A High signal level as mentioned above is about 5 V Low signal level as mentioned above is about 0 V All control signals comes from the processor on the motor control board 26AP1...

Страница 45: ...aded to a higher capacitance Reason for upgrading in some applications there have not been enough time to download important dynamic parameters at power off The spare parts list is updated with orderi...

Страница 46: ...DESCRIPTION OF OPERATION 0740 801 028 46 ESAB AB 2017 26AP2 Component positions...

Страница 47: ...the most recent fault message is displayed on the control panel Faults are monitored detected in two ways by test routines that are run on initiation and by functions that can detect a fault when it o...

Страница 48: ...place the welding data board 1AP1 3 Error in the external RAM Read write test of the processor s external RAM This test is performed only on initiation after power up The microprocessor is unable to r...

Страница 49: ...tion error bus off The system s internal CAN bus has temporarily ceased to work due to excessive load The current welding process is stopped Action Check that there are no faulty units connected to th...

Страница 50: ...microprocessor has no contact with the display board Action Check the cabling and connectors between the 1AP1 welding data board and the 1AP2 display board 32 No gas flow External equipment indicates...

Страница 51: ...ed CAN system Nodes from Aristo 1000 and LAF TAF systems are connected in the same system Action Check if the motor card is correctly configured for the system 67 Primary frequency voltage is outside...

Страница 52: ...power source to improve the airflow 4204 High temp in AC block Action Clean the air filters in the power source to improve the airflow 4205 High temp in AC block 2 Action Clean the air filters in the...

Страница 53: ...ties are stopped and welding start is prevented The error may have been caused by an open circuit in the connection e g in the CAN cable between the welding data unit and another unit The applicable u...

Страница 54: ...cables are OK replace the encoder or and the motor F001 Welding equipment has been stopped because of error F003 Node error on another unit reported via CAN 2 Action Check the following Information se...

Страница 55: ...vented 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 ch...

Страница 56: ...C ordering no 0458 847 881 NOTE The software of the weld data unit 1AP1 can be updated from a USB memory stick without using the ESAT service tool This is described in Welding data unit 1AP1 page 57 R...

Страница 57: ...re your computer to show extensions for known file types The file update txt To make a software upgrade the USB memory must contain a text file named update txt The update txt file specify the path to...

Страница 58: ...tware files ending with hex sre fcf The file reset txt To make a reset of a unit the USB memory must contain a text file named reset txt The reset txt file must be located directly at the root of the...

Страница 59: ...29 0 0 44 0 255 Set the machine id to 44 PEK 29 0 0 46 0 255 Set the machine id to 46 PAB Set baudrate Line Comment 28 0 0 0 0 255 Set CAN bus bauderate to 1000 kbit s 28 0 0 1 0 255 Set CAN bus baude...

Страница 60: ...vent accidental removal of data 3 To change the machine id to 44 PEK node id to 8 general reset and set baudrate to 500 kbit s 4 To change the machine id to 46 PAB node id to 8 general reset and set b...

Страница 61: ...off the power or removing the USB memory 7 Turn off the power source s main switch 8 Remove the USB memory with the software upgrade 9 Turn on the power source s main switch 10 The software upgrade i...

Страница 62: ...ng off the power or removing the USB memory 7 Wait for the unit to perform a general start 8 Turn off the power source s main switch 9 Remove the USB memory with the file reset txt 10 Turn on the powe...

Страница 63: ...SPARE PARTS 0740 801 028 63 ESAB AB 2017 SPARE PARTS The spare parts list is published in a separate document that can be downloaded from the Internet www esab com Filename Product 0459 839 036 PEK...

Страница 64: ...Henares MADRID 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 SWI...

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