ESAB YardFeed 200 User manual

0740 800 148 Valid for serial no. 238--xxx--xxxx to 612--xxx--xxxx060619
ESABFeed 30- 2 M11
YardFeed 200
OrigotM13y
ESAB YardFeed 200
Service manual

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Rights reserved to alter specifications without notice.
READ THIS FIRST 3.................................................................
INTRODUCTION 3...................................................................
TECHNICAL DATA 5.................................................................
WIRING DIAGRAM 6.................................................................
Component description 6..........................................................
ESABFeed 30--2 M11 7.............................................................
YardFeed 200 8...................................................................
DESCRIPTION OF OPERATION 10.....................................................
13AP1 Control board 10............................................................
13AP1:1 Power supply 10...........................................................
13AP1:2 2--stroke / 4--stroke 11......................................................
13AP1:3 Start / Stop 12............................................................
13AP1:4 Current relay, Creep start / Normal start 12....................................
13AP1:5 Motor driving / braking 13...................................................
13AP1:6 Tachometer input 14.......................................................
13AP1:7 Burn--back time 14.........................................................
13AP1:8 Wire feed speed 14........................................................
13AP1:9 Gas valve 15..............................................................
13AP1:10 Activation, contactor 15.....................................................
13AP1:11 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--2 M11 24..........................................
Lifting instructions YardFeed 200 24................................................
OPERATION 25....................................................................
Connections and control devices ESABFeed 30--2 M11 25............................
Connections and control devices YardFeed 200 25...................................
Water connection 26...............................................................
Safety contact switch YardFeed 200 26..............................................
Gasflow control and burnback time YardFeed 200 26.................................
Setting the wire feed pressure 26...................................................
MAINTENANCE 27.................................................................
SPARE PARTS 27....................................................................
NOTES 28...........................................................................

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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 all design changes that have been made up to and
including May 2006.
The manual is valid for:
ESABFeed 30--2 M11 with serial no. 238--xxx--xxxx, 410--xxx--xxxx, 440--xxx--xxxx.
ESAB 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 above standard.
INTRODUCTION
The ESAB YardFeed 200 is renamed, the new name is YardFeed 200.
The wire feed unit ESABFeed 30--2 with control panel M11 is
intended for MIG/MAG--welding together with step controlled
welding power sources.
It can be used together with wire on ESAB’s MarathonPact,
or on wire bobbin (standard Ø 300 mm, accessory Ø 440 mm).
The wire feed unit can be installed either at the power source,
suspended above the workplace, on a support arm or on the
floor with or without wheel set.
The wire feed unit YardFeed 200 with control panel M13y, is intended for MIG/MAG welding
together with stepped and thyristor--controlled welding power sources.

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TECHNICAL DATA
ESABFeed 30--2 M11 YardFeed 200
Power supply 42 V 50 -- 60 Hz 42 V 50 -- 60 Hz
Power requirement 150 VA 150 VA
Motor current Imax 3.5 A 3.5 A
Settings data
Wire feed speed
Burnback time
2/4 stroke
Creep start
Gas purge
Wire inching
1.9 -- 20.0 m/min
0--0.5 s
2strokeor4stroke
OFF or ON
not available
not available
1.9 -- 25.0 m/min
0--0.5 s
2strokeor4stroke
ON
--
--
Welding gun connection EURO EURO
Max. diameter wire bobbin 300 mm (*440mm) 200 mm
Wire dimension
Fe & Ss
Al
Cored wire
0.6 -- 1.2 mm
1.0 -- 1.2 mm
0.8 -- 1.2 mm
0.6 -- 1.2 mm
1.0 -- 1.2 mm
0.8 -- 1.2 mm
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
*Accessory
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
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.
Equipment marked IP2X is designed for indoor use.

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WIRING DIAGRAM
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
SObserve precautions for handling electrostatic--
sensitive devices.
SUse proper static--proof bags and boxes.
ESD
This component description refers to the wiring diagrams. In the description of operation on
page 10 there is a more detailed description of the components and their function.
Component Description
ESAB
Feed M11 YardFeed 200
13AP1 13AP1 Main circuit board with control electronics.
See the description on page 10.
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.
13S1 13S1 Microswitch, monitoring the water connection. The pump in the
water cooling unit starts when the switch is closed.
13S2 ’Safety contact switch’, 3 position switch.
See the description on page 26.
13SA1 13S3 Switch, 2/4--stroke changeover.
13S4 Switch, gas purge / inching.
13SA2 Switch, creep start ON/OFF.
13XP . . 13XP . . Plug connectors.
13XS . . 13XS . . Socket connectors.
13YV1 13YV1 Gas valve.

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ESABFeed 30--2 M11

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YardFeed 200

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DESCRIPTION OF OPERATION
13AP1 Control board
Sections 13AP1:1 to 13AP1:13 below refer to the diagrams on pages 7 to 9.
From serial no. 410--xxx--xxxx a new version of the control board (0487 162 880) is fitted to
the ESABFeed 30--2 M11. The new and old versions of the control board are fully
interchangeable.
Control board 0487 162 881 is used for the YardFeed 200.
13AP1:1 Power 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--regulator which reduces the voltage from 60 V to 20 V.
Q8 is current--limited to about 200 mA. If the 20 V supply drops below 13 V, the
wire feed unit stops.
VR1 and VR2 are 5 V and 15 V voltage regulators respectively.

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The power supply in the YardFeed 200 works as described on previous page
with one exception: switch 13S2.
See: ’Safety contact switch YardFeed 200’ on page 26.
YardFeed 200
13AP1:2 2--stroke / 4--stroke
2--stroke
When the switch is open, 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 source contactor.
Releasing 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 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 is in operation, welding ceases when the burn--back time has
elapsed.

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13AP1:3 Start / Stop
The welding gun switch is supplied with 42 V AC. Closing the switch activates
optocoupler IC1, causing the voltage across C35 to go low.
The new version of the control board, 0487 162 880:
When wire feed starts, 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 gun switch is released.
The first version of the control 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 start
means that the motor runs at a speed of 1.9 m/minute until the current relay is
activated. When the relay operates, the speed increases to the set speed.
The new version of the control board, 0487 162 880:
If the current relay does not operate within three seconds after starting, the
motor speed increases to the set speed in any case.

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The first version of the control board, 0486 991 880:
If the current relay does not operate within one second after starting, the motor
speed increases to the set speed in any case.
YardFeed 200
The creep start function is always activated.
13AP1:5 Motor driving / braking
Driving
The motor is powered from the smoothed +60 V supply. Motor speed is
controlled by pulse width modulation of transistor Q1. The pulse frequency is
39 kHz, the old version of the board has a pulse frequency of 12 kHz. The
maximum conducting time of the pulses is 99% of the pulse cycle time. During
the pulse spaces, the motor current freewheels through diode D8.
At 24 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 162 880) has a dynamic current
limit controlled by the processor. The current limit is 11 A on starting. When the
set speed is achieved, this is reduced to 7 A.
The first version of the control board (0486 991 880) has a fixed current limit at
7A.
Braking
When the motor starts, capacitor C43 charges up via diode D28: the voltage is
limited to 15 V by zener diodes D10 and D21. When the motor is to brake, the
LED in optocoupler IC8 lights, causing the transistor in IC8 to conduct and

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discharge capacitor C43 (15 V) to the gate of transistor Q3. The transistor
conducts and short--circuits the motor voltage through resistors R51 and R64,
which limit the current to about 20 A.
13AP1:6 Tachometer input
Tachometer 13G1 is fitted in the motor casing.
Comparator IC4/IC11:2 converts the sine wave signal from the tachometer to a
square wave at the same frequency.
The new version of the control board, 0487 162 88X:The tachometer frequency is
814 Hz for a wire feed speed of 20 metres per minute.
The first 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 metres per minute for the
ESABFeed M11 and 1.9 to 25 metres per minute for the YardFeed.
A 5 V reference voltage signal at connection A02 represents a speed of 20
metres per minute.
The processor monitors the wire feed speed. If the wire speed deviates from
the set value by more than 1.5 m/min for more than five seconds, wire feed will
be stopped.

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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.

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13AP1:12 Processor, Starting sequence
Processor
The processor stores the machine program. It monitors the power supply
voltages: if the voltages drop to too low a level, wire feed is stopped, as
described in section 13AP1:1 above.
Starting sequence, circuit board 0487 162 880 / 0487 162 881
The circuit board displays the starting sequence from power--up.
1. LED1 lights 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 described in
paragraphs 2 and 3 above.
Boards with software version prior to 0.27A have no LED indication.
The software version is indicated by a label on the processor, IC6.
LEDs on circuit board 13AP1

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13AP1 Component positions
The new version of the control board, 0487 162 880 / 0487 162 881

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The first version of the control board, 0486 991 880

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13AP2 Digital display
The digital display unit is standard or can be ordered as an accessory to the YardFeed 200.
The digital display unit can be used only when the wire feeder is connected to a Mig 400t,
Mig 500t, ESABMig 400t, ESABMig 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. Voltage regulator VR1 produces a 5 V output.
13AP2 Component positions
cmek0e03

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13AP2 Circuit diagram