ESAB Aristo RoboFeed 3004w User manual

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

TABLE OF CONTENTS
0740 800 169 © ESAB AB 2014
READ THIS FIRST................................................................................................ 3
TECHNICAL DATA ............................................................................................... 4
WIRING DIAGRAM............................................................................................... 5
Component description.......................................................................................5
RoboFeed 3004w & Aristo RoboFeed 30-4, valid for serial no.
501-xxx-xxxx & 620-xxx-xxxx ..........................................................................6
RoboFeed 3004w, valid for serial no. 745-xxx-xxxx..........................................8
RoboFeed 3004w, valid for serial no. 310-xxx-xxxx........................................10
DESCRIPTION OF OPERATION........................................................................ 12
13AP1 Control board .........................................................................................12
13AP1:1 Power supply..................................................................................... 12
13AP1:2a Start / Stop ...................................................................................... 13
13AP1:2b Monitoring the cooling water connection ......................................... 13
13AP1:3 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 INSTRUCTIONS................................................................................. 25
What is ESD?...................................................................................................... 25
Service aid .......................................................................................................... 25
Replacing the old gas flow guard.....................................................................26
Adjusting the gas pressure pre-set value for the pressure guard ................29
Replacing rubber dampers with bakelit bars ..................................................29
SPARE PARTS ................................................................................................... 32
Rights reserved to alter specifications without notice.

READ THIS FIRST
0740 800 169 -3- © ESAB AB 2014
READ THIS FIRST
Maintenance and repair work must 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 boards
are divided into numbered blocks, which are described individually in more detail in the
description of operation. Component names in the wiring diagram are listed in the
component description.
Use the spare parts list as 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 RoboFeed 30-4 and RoboFeed 3004w are designed and tested in
accordance with international and European standard 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.
The wire feed unit is renamed:
New name Old name
RoboFeed 3004w Aristo RoboFeed 30-4

TECHNICAL DATA
0740 800 169 -4- © ESAB AB 2014
TECHNICAL DATA
Power supply 42 V, 50–60 Hz
Power requirement 147 VA
Motor current Imax 8 A
Wire feed speed 0.8–30 m/min in applications with W82
0.8–25 m/min in other applications
Welding torch connection EURO
Wire dimension Fe: 0.6–1.6 mm
Ss: 0.6–1.2 mm
Al: 1.0–1.6 mm
Cored wire: 0.8–1.6 mm
Weight 7.3 kg
Dimensions (l × w × h) 362 × 246 × 235 mm
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.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP2X is intended for indoor use.

WIRING DIAGRAM
0740 800 169 -5- © ESAB AB 2014
WIRING DIAGRAM
Component description
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling
electrostaticsensitive devices.
• Use proper static-proof bags and boxes.
The component description below should be read in conjunction with the wiring diagram. The
"DESCRIPTION OF OPERATION" chapter contains a more detailed description of the
functions of the components.
Component Description
13AP1 Main circuit board with the control electronics, 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 ser.no. 745-xxx-xxxx)
13S1 Micro-switch, ELP, water connection monitoring (From ser.no. 745-xxx-xxxx)
13SB1 Push-button, reversed wire feed
13SB2 Push-button, gas purging
13SB3 Push-button, inching
13SL1 Micro-switch, pressure guard
13XP... Plug connectors
13XS... Socket connectors
13YV1 Solenoid valve for welding gas
13YV2 Solenoid valve for air

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

WIRING DIAGRAM
0740 800 169 -7- © ESAB AB 2014

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

WIRING DIAGRAM
0740 800 169 -9- © ESAB AB 2014

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

WIRING DIAGRAM
0740 800 169 - 11 - © ESAB AB 2014

DESCRIPTION OF OPERATION
0740 800 169 - 12 - © ESAB AB 2014
DESCRIPTION OF OPERATION
13AP1 Control board
This description is valid for control circuit board 0487 187 880, which is fitted in the
RoboFeed 3004w and in Aristo RoboFeed 30-4 from serial no. 501-xxx-xxxx.
Circuit board identity
The control board has a machine ID, a hardware ID and a unit type number. To read this you
need the ESAT service kit, see Section “Service aid”, page25.
• The machine ID determines which type of wire feed unit the board is intended for.
• The hardware ID shows design and type of circuit board.
• The unit type is used for identification on the 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 rectify the 42 V AC supply. The rectified voltage is used to power the
wire feed motor(s). It also powers the switched voltage regulator.
IC21, IC8, Q12, L1 and D37 forms a switched voltage regulator. The +24 V output voltage of
the regulator supplies the +15 V and +5 V regulators, VR2 and VR1. It also supplies the
reference circuit IC22, which generates +2.5 V reference voltage, this is used by the
analogue inputs of the processor.

DESCRIPTION OF OPERATION
0740 800 169 - 13 - © ESAB AB 2014
Voltage monitoring
If the +60 V supply drops below 42 V or exceeds 78 V, the U8 displays fault code 9. This fault
does not disable any functions.
The +24 V is monitored by IC12 and potential divider R129/R130. If the voltage drops to 19.5
V or less, IC12 generates a warning signal to the processor, which responds by stopping the
wire feed and then all communication on the bus. The U8 displays fault code 4.
The +15 V is monitored by the processor and potential divider R152/R153. If the 15 V supply
drops below 13 V or exceeds 17 V, the U8 panel displays fault code 8. This fault does not
disable any functions.
13AP1:2a Start / Stop
In normal operation the Start and Stop commands come from the robot, via the CAN bus.
The welding torch switch input can be used 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 released.
13AP1:2b Monitoring the cooling water connection
The wire feed unit is equipped with a detection system ELP (ESAB Logic Pump) which
checks that the water hoses are connected. When connecting a water-cooled welding torch,
the water pump starts.
Micro-switch 13S1 senses whether a water-cooled welding torch is connected to the wire
feed unit: a closed switch indicates that the cooling water hoses are connected, and so
provides a Start Enable signal to the system for the water pump.
The resistors connected to input E3 form a potential divider of the 15 V supply, to produce
about +6 V for an open input.

DESCRIPTION OF OPERATION
0740 800 169 - 14 - © ESAB AB 2014
13AP1:3 Gas valve
The gas valve is controlled by the microprocessor. In normal operation the gas valve opens
when the start signal is activated by the robot. The gas valve can also be opened by a
separate signal from the robot.
13AP1:4 Motor driving / 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 the pulse off periods.
The feed roller speed at the maximum wire feed speed of 25 m/min is 273 r/min.

DESCRIPTION OF OPERATION
0740 800 169 - 15 - © ESAB AB 2014
Current monitoring
Resistor R114 generates a voltage signal proportional to the motor current. This voltage is
applied to potential divider R105/R106 and the output is compared with a reference voltage
at voltage comparator IC14:11. The reference voltage is provided by the microprocessor via
R104.
The current limit is between 15 and 18 A on starting. After one second, this is reduced to a
lower value. The current limit is related to the pulse peak current.
If the current exceeds the current limit, IC14:2 interrupts the gate pulse to Q4. The current
falls, and Q4 conducts on the next gate pulse, which is again interrupted if the current is still
too high. This sequence continues until the motor current has 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 optocoupler IC11 is energised, its output transistor conducts and connects capacitor
C67 to the gate of transistor Q2, which conducts and short-circuits the motor supply via
dynamic braking resistors R71 and R79. The resistors limit the current to about 20 A.
Reversed feed
Activation of relay RE13 reverses the feed direction, see Section “13AP2:2 Input signals”,
page20.
13AP1:5 Pulse generator input
The pulse generator, 13G1, is fitted to drive motor 13M1. It generates 60 pulses per
revolution, which means that, at a wire feed speed of 25 m/min, the pulse frequency is 6552
Hz.

DESCRIPTION OF OPERATION
0740 800 169 - 16 - © ESAB AB 2014
13AP1:6 Monitoring gas pressure
The RoboFeed is prepared for monitoring gas supply.
The control panel displays a fault code 32 if the inputs are open.
Inputs K1 – K2 are not used.
13AP1:7 The CAN bus
The circuit board includes a driver for the CAN bus, IC2, which looks after communication
with the U8 and with other units in the system.
Although the welding power source supplies 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 the wire feed unit
is in the application program, LED1 flashes continuously
with a green light.
LEDs on circuit board 13AP1
There is more information about the operation of the CAN bus in the service manual for the
power source.

DESCRIPTION OF OPERATION
0740 800 169 - 17 - © ESAB AB 2014
Communication interruptions
The U8 displays fault codes 12 and/or 14 if communication between the panel and the wire
feed unit or power source fails. Check the following points in the event of problems with CAN
communication:
• That a terminating resistor is fitted.
• The control cable:
○ Check that the correct type of cable is being used, i.e. the same as that between the
power source and the wire feed unit when the equipment was delivered.
○ Check that the cores are correctly connected. CAN H and CAN L must be carried by
the twinned pair.
• Check that all screen connections are sound.
• RoboFeed: Check 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 the above, replace circuit board 13AP1.
13AP1:8 I/O
Terminal BA is the interface connection to the I/O board, see Section “13AP2 I/O board”,
page20.
13AP1:9 Arc voltage sensing
In order to avoid spurious volt drops when measuring the welding arc voltage, the power
source senses the arc voltage via the filler wire and the feeder unit motor. Socket 13XS1 and
wire 1320 are intended for connection to a second feed unit when double wire feeders are
used.

DESCRIPTION OF OPERATION
0740 800 169 - 18 - © ESAB AB 2014
13AP1 Component positions

DESCRIPTION OF OPERATION
0740 800 169 - 19 - © ESAB AB 2014

DESCRIPTION OF OPERATION
0740 800 169 - 20 - © ESAB AB 2014
13AP2 I/O board
There are two versions of this board, they are fully interchangeable. The second version,
0487 083 880, is used from serial number 501-613-5722.
13AP2:1 Power supply
The I/O board is voltage supplied by the control board.
13AP2:2 Input signals
Inching
When switch 13SB3 is pressed, the wire is fed forward with the latest used wire feed speed.
The welding power source 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 contact. When the input opens, the
control board sends a fault message to the robot via the CAN bus. If no Anti collision is
connected, the inputs (S and T or C and D in 13XS16) should be bridged to avoid fault
messages, see circuit diagram.