ESAB cmek2de1 User Manual

MEK 2

Service manual

0740 800 094

020531

LIST OF CONTENTS Page

READ THIS FIRST 2..................................

COMPONENT DESCRIPTION 4........................

CONNECTION DIAGRAM 5............................

DESCRIPTION OF OPERATION 6......................

1 Power supply 7.........................................

2 2--stroke / 4--stroke 8....................................

3 Start / Stop 8...........................................

4 Current relay, Creep start / Normal start 9..................

5 Motor driving / braking 10..................................

6 Tachometer input 1 1......................................

7 Burn--back time 1 1.......................................

8 Wire feed speed 1 1.......................................

9 Gas valve 12............................................

10 Activation, contactor 12...................................

11 Processor 12............................................

TECHNICAL DATA 13..................................

MAINTENANCE 13....................................

SETTING THE WIRE FEED PRESSURE 14...............

CONTROL PANEL AND CONNECTIONS 15..............

ACCESSORIES 16.....................................

SPARE PARTS LIST 17.................................

NOTES 24............................................

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 connection diagram as a form of index for the d escription 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 connection diagram are listed in
the component description.

This manual contains details of all design changes that have been made up to and including
May 2002.

The MEK 2 is designed and tested in accordance with international and European
standard IEC/EN 60974--1 and EN 50199.
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.

Rights reserved to alter specifications without notice.

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WARNING !

STATIC ELECTRICITY can damage circuit
boards and electronic components.

SSSS Observe precautions for handling electrostatic

sensitive devices.

ESD

SSSS Use proper static--proof bags and boxes.

WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU­TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and

the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING!

Rotating parts can cause injury, take great care

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COMPONENT DESCRIPTION

This component description refers to the connection diagram. In the description of operation
on page 7 there is a more detailed description of the components and their function.

AP01 Main circuit board with control electronics.
C01 Capacitor 0.1 ←F 125 VAC, decoupling.
G01 Tachogenerator, incorporated in motor M01.
M01 Motor, rated voltage 24 V.
R3 Potentiometer, for setting the burn--back time.
RP01 Potentiometer, 10 kτ, for setting the wire feed speed.
SW1 Switch, 2/4--stroke changeover.
SW2 Switch, creep start ON/OFF
XP01 23--pole connector, for connection to the welding power unit.
XP02 Terminal for welding current connection from the power unit.
XS01 -- XS09 Sleeve connectors.
YV01 Solenoid valve

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CONNECTION DIAGRAM MEK 2

The numerals 1 -- 11 refer to the description of operation.

R3

0V

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DESCRIPTION OF OPERATION

Component positions, circuit board AP01

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Sections1to11belowrefertothediagramonpage5.
The circuit board is screened by a metal casing, connected to 0 V in the wire feed unit.

1 Power supply

The feeder obtains a 42 V supply from the control power supply tr ansformer in the
power unit via contact XP01. Its power demand at maximum load is 3.5 A.

42 V AC is used for the welding torch trigger switch and as the power supply to the
gas solenoid valve and the main contactor. In addition, 42 V is also available on
contacts H01 and H02.

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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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2 2--stroke / 4--stroke

2--STROKE

When SW1 is open, the unit operates in 2--stroke mode. Operating the trigger on the
welding torch starts the motor, opens the gas valve and energises the power unit
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 SW1 is closed, the unit operates in 4--stroke mode. Operating the trigger on
the welding torch opens the gas valve: releasing the trigger then starts the motor and
energises the power unit contactor.

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Operating the trigger switch for a second time stops the motor and de--energises the
contactor in the power unit: releasing the switch then closes the gas solenoid valve.
If burn--back is in operation, welding ceases when the burn--back time has elapsed..

3 Start / Stop

The welding torch switch is supplied with 42 V AC. Closing the switch activates
optocoupler IC1, causing the voltage across C35 to go low.

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4 Current relay, Creep start / Normal start

The current relay is activated when the welding current exceeds 20 A.

Creep start means that the motor runs at 1.9 m/minute until the current relay
operates, after which the speed increases to the set speed. If the current relay does
not operate within one second after starting, the m otor speed increases to the set
speed in any case.

Selector switch SW2 on the circuit board selects Creep Start On/Off. Closing the
switch on to the 0 V rail disengages creep start.

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5 Motor driving / braking

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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 12 kHz, and the
maximum on--time is 97% 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 212 r/min.

Resistor R19 produces a voltage drop proportional to the motor current. If the
current exceeds 7 A, IC5:2 turns off the gate pulses to Q1. When the current falls,
Q1 conducts again at the next gate pulse.

BRAKING

When the motor starts, capacitor C43 charges up via diode D28: the voltage is
limited to 15 V by zener diode D21. When the motor is to brake, the L ED in
optocoupler IC8 lights, causing the transistor in IC8 to conduct and 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.

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6 Tachometer input

Tachometer G01 is fitted in the motor casing. Tachometer output frequency is
796 Hz for a wire feed speed of 20 meters per minute.
Comparator IC4:2 converts the sine wave signal from the tachometer to a square
wave at the same frequency.

7 Burn --back time

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The burn --back time is the time from when motor braking starts until the main
contactor in the power unit opens. It can be adjusted between 0 and 0.5 seconds by
potentiometer R3, which is mounted on the circuit board.

8 Wire feed speed

The wire feed speed range is from 1.9 to 20 meters per minute.

A 5 V reference voltage signal at connection A02 represents a speed of 20 m/minute.

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9 Gas valve

The gas valve is connected to board contacts G04 and G05. The valve is energised
via triac TC1.

10 Activation, contacto r

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The start signal to the power unit is connected to board contact G03. The contactor
is energised via triac TC2.

11 Processor

The processor incorporates EPROM memory in which the machine’s program is
stored.

The processor monitors the wire feed speed. If the speed deviates from the set speed
by more than 1.5 m/minute for more than five seconds, wire feed will be stopped..

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TECHNICAL DATA

Power supply 42 V 50 -- 60 Hz

Power requirement 150 VA

Feed speed 1.9 -- 20 m/min

Pistol connection EURO

Max. diameter of wire bobbin 300 mm

Weight 15 kg

Dimensions (l x w x h) 645 x 240 x 480 mm

WARNING

There is a risk of tipping if the MEK 4 is fitted with a counterbalance arm. Secure the
equipment, especially if used on an uneven or sloping surface.

Limit the angle of rotation of the wire feed cabinet using the straps supplied.
When moving the equipment, do NOT pull on the torch.

MAINTENANCE

Regular maintenance is important in ensuring safe and reliable operation.

S The feed unit

Clean and replace the wearing parts in the feed mechanism at regular intervals.
Do not set too high a pressure on the pressure rollers, as this can cause abnormal wear of
the pressure rollers,. the feed rollers and wire guide. Instructions for setting the wire feed
pressure are on page 14.

S The pistol

Blow the wire guide clean with compressed air at regular intervals and clean the gas
nozzle.

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SETTING THE WIRE FEED PRESSURE

Start by checking that the wire can run freely through the wire liner, and then adjust the
pressure of the wire feed rollers. It is important that the pressure is not too high.

Figure 1 Figure 2

To check for correct feed pressure, feed the wire out against a piece of insulating material,
such as a piece of wood.

With the pistol held about 5 mm from the wood (Figure 1), the drive rollers should slip.

With the pistol held further away from the wood (about 50 mm, as shown in Figure 2), the
wire should continue to feed out, bending as it does so.

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CONTROL PANEL AND CONNECTIONS

1. Cooling water connections
(only --883 model).

2. Gas connection.

3. Connector for control cable from the

power unit.

4. Connector for welding current cable from

the power unit.

5. Potentiometer, wire feed speed 1.9 -- 20

meter per minute.

6. Cooling water connections to/from the

welding gun (only --883 model).

7. Strap securing points. The strap must be

used to secure the wire feed unit to the
power unit during transport.

8. Hole for fitting wire liner from the ESAB

Marathon Pac.

9. Welding gun connector.

10. Selector switch, 2/4--stroke mode.

11. Selector switch, creep start On/Off.

12. Potentiometer, burn--back time, 0 -- 0.5 seconds.

13. Brake hub.
The hub is adjusted when delivered, if readjustment is required, follow the instructions
below.

Adjust the braking power by means of the two screws (springs) inside the hub.
Turn the adjustment screws clockwise to reduce the braking power.
Adjust the brake hub so that wire is slightly slack when wire feed stops.

S = Adjustment screws

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ACCESSORIES

Item

no.

Ordering no. Denomination

1 469 789-- 880 Lifting eye

2 469 836-- 880

2 469 836-- 885 Connection set, 1.7 meter. When connected to LAX 380W

469 836-- 881 Connection set, 8 meter. When connected to LAX 320/380
469 836-- 886 Connection set, 8 meter. When connected to LAX 380W

4 469 786-- 880 T rolley
5 156 654-- 883 Guide pin (included in LAX)
6 469 792-- 881 Counter balance device and mast
7 469 967-- 880 W ater connection set
8 455 410-- 001 Adapter for 5 kg bobbin

9 0156 746 880 Mast
10 0456 693 880 Counter balance device, sprung coil
11 0457 341 880 Hose reinforcement bracket

Connection set, 1.7 meter. When connected to LAX
320/380

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Spare parts list

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Valid for serial no. 510 --xxx--xxxx to serial no. 826--xxx--xxxx

Ordering numbers for MEK 2

0455 590 881 MEK 2 Without water connection
0455 590 883 MEK 2 With water connection

Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the
cover. Kindly indicate type of unit, serial number, denominations and ordering numbers according to
the spare parts list.

Maintenance and repair work should be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended spare parts.

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Item

Qty Ordering no. Denomination Notes

101a 1 0455 693 001 Cover

101b 1 0456 352 001 Plate With text

102 1 0467 176 001 Handle

103 4 0192 230 105 Cover

104 1 0192 230 112 Cover

105 1 0469 959 001 Side cover

106 4 0467 695 001 Rubber foot

107 2 0469 823 001 Hook

108 2 0369 561 002 Clamp
109 2 0369 561 001 Lock

110 1 0469 960 001 Side cover

111 1 0192 562 104 Cage nut M5

020531

112a -- Chassis Replaced by item 112b
112b 1 0469 779 880 Chassis New design, fits all versions of MEK 4

113 1 0146 967 881 Brake hub

114 1 0416 236 001 Plate

115 1 0192 230 104 Cover

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C = component designation in the circuit diagram

Item Qty Ordering no. Denomination Notes C

201 1 0321 475 882 Knob
202 1 0469 776 001 Cover

203 1 0193 260 092 Cover For 3--pole connector
204 1 0193 260 062 Connector 3-- pole XS07, XS08,

205 1 0191 870 616 Potentiometer 10 kτ RP01, RP02,

206 1 0368 543 005 Pin socket 23-- pole XP01

14 0323 945 004 Pin

XS09, XS10

RP03, RP04

207 1 0190 315 106 Hose L=2x0.65metre, D=16/9.5mm reinforced PVC.

208a 1 0365 803 008 Quick connector Female, red

1 0365 803 009 Quick connector Female, blue

-- -- 0365 803 001 Quick connector Male

208b 1 0365 803 008 Quick connector Female, red Beforeser.no. ... 649 ....

1 0365 803 009 Quick connector Female, blue Beforeser.no. ... 649 ....

208b 1 0365 803 011 Quick connector Female, red Fromser.no. ... 649 ....

1 0365 803 012 Quick connector Female, blue Fromser.no. ... 649 ....

-- -- 0365 803 013 Quick connector Male Fromser.no. ... 649 ....

209 1 0367 149 001 Quick connector Male, the nut is not included

1 Nut M10

-- 0365 803 002 Quick connector Female

210 1 0456 496 001 Hose L=0.33metre, D=9/5mm, reinforced PVC.

211 1 0193 054 002 Solenoid valve YV01
212 1 0456 496 001 Hose L=0.22metre, D=9/5mm, reinforced PVC

213 1 0160 609 881 Welding current connector XP02
214 1 0455 599 880 Busbar With insulation.

215 1 0192 915 013 Capacitor PME 271 0.1 ←F 250 V, without cable lugs C01
216 1 Screw M10x20
217 1 Spring washer ⊘ 20/10.2x1.1
218 1 Washer ⊘ 24/13x2

To be ordered per metre.

To be ordered per metre.

To be ordered per metre.

The picture on the opposite page does not show
the real shape of the busbar.

219 1 0455 517 001 Cover (bottom box) From ser. no. 826 . . . . . . Length = 317mm

220 1 0486 283 880 Circuit board AP01

221 1 0455 518 001 Box (top box) From ser. no. 826 . . . . . . Length = 317mm

222 1 0455 519 001 Cover Fromser.no. 514 ... ....

223 1 0193 260 062 Connector 3-- pole XS01

1 0193 260 091 Cover For 3--pole connector
2 0193 260 150 Connector 2--pole XS05, XS08
2 0193 260 180 Cover For 2--pole connector
1 0193 260 152 Connector 4--pole XS06
1 0193 260 182 Cover For 4--pole connector
1 0193 260 153 Connector 5--pole XS07
1 0193 260 183 Cover For 5--pole connector

224 3 0455 661 019 Plastic rivet Fromser.no.514 ... .... to514718 ....

225 3 0193 517 342 Screw Plastic Fromser.no. 514718 ....

226 3 0194 019 001 Spacer Plastic Fromser.no. 514718 ....

232 1 0458 918 880 Front flange with PC board Current relay

When a cover with another length is replaced
also item 221 must be replaced.

When a box with another length is replaced also
item 219 must be replaced. With this box items
228, 225 and 226 must be used.

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C = component designation in the circuit diagram

Item Qty Ordering no. Denomination Notes C

-- -- 0455 890 881 Feed unit Complete, contains items 301 -- 332

300 1 0469 833 880 Pressure arm (W) Complete, contains items 301 -- 305
301 1 0455 053 880 Geared adapter (W)
302 1 0369 728 001 Pressure roller (W)

0466 262 001 Pressure roller (W) (A) Knurled

303 1 Locking washer SGA D8
304 1 Holder
305 1 Shaft

306 1 0455 896 001 Spring

308 1 0455 597 001 Drive unit With tachometer M01, G01
309 1 0215 701 007 Locking washer Included in item 308
310 1 0191 496 114 Key Included in item 308

311 1 0466 074 001 Inlet nozzle (W)

312 1 0367 528 001 Pin bolt
313 1 0368 749 880 Pressure transducer

314 2 0368 750 001 Insulating sleeve

315a 1 0455 894 001 Insert tube (W) (A) For Al wire, must be used together with item

315b 1 0455 889 001 Insert tube (W) Steel, must be used together with item 316b

316a 1 0455 885 001 Outlet nozzle (W) (A) Must be used together with item 315a
316b 1 0455 886 001 Outlet nozzle (W) Must be used together with item 315b

317 1 0455 882 001 Current sleeve

318 1 0455 883 001 Spacer sleeve ⊘ 16/8.2x0.9
319 1 Washer ⊘ 16/8.4x1.5
320 1 Screw M8x20

321 1 0455 881 001 Protection plate
322 1 0215 201 202 O--ring
323 1 0455 898 001 Screw (M5x12)

324 1 Screw M4x12
325 2 Screw M3x16
326 1 0193 104 002 Washer
327 1 0369 557 001 Feed roller (W) (A) (V)For ⊘ 0.6 -- 0.8 mm Fe, Ss and cored wire

1 0369 557 002 Feed roller (W) (A) (V)For ⊘ 0.8 -- 1.0 mm Fe, Ss and cored wire
1 0369 557 003 Feed roller (W) (V)For ⊘ 1.0 -- 1.2 mm Fe, Ss and cored wire
1 0369 557 007 Feed roller (W) (A) (V)For ⊘ 1.2 -- 1.6 mm Fe, Ss and cored wire
1 0369 557 010 Feed roller (W) (A) (V)For ⊘ 1.2 mm x 2 Fe, Ss and cored wire
1 0369 557 013 Feed roller (W) (A) (V)For ⊘ 1.4 --1.6 mm Fe, Ss and cored wire
1 0369 557 004 Feed roller (W) (A) (K)(V) For ⊘1.0 -- 1.2 / 1.4 -- 1.6 mm cored wire
1 0369 557 005 Feed roller (W) (A) (K)(V) For ⊘1.4--1.6 / (2.0-- 2.4) mm cored wire
1 0369 557 006 Feed roller (W) (A) (U) For ⊘ 1.0 -- 1.2 mm Al wire
1 0369 557 008 Feed roller (W) (A) (U) For ⊘ 1.6 mm Al wire
1 0369 557 011 Feed roller (W) (A) (U) For ⊘ 0,8 -- 0,9 mm Al wire

328 1 0369 716 001 Geared adapter (W)

316a

Delivered from machine no. XXX 647 XXX

Delivered from machine no. XXX 647 XXX

329 1 0455 893 001 Shaft

330 1 0455 884 001 Gear housing
331 3 Screw M6x16
332 1 0332 351 013 Drive shaft with pinion Included in item 308

(W) = wear part (A) = accessory (K) = knurled rollers (V) = V--groove (U) = U--groove

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NOTES

-- 2 4 --notes

-- 2 5 --notes

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Copenhagen--Valby
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.z.o.o
Warszaw
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB International AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

AUSTRALIA

ESAB Australia Pty Ltd
Ermington
Tel: [phone]
Fax: [phone]

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. Esabindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Singapore Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyung--Nam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA--CIS

ESAB Representative Office
Moscow
Tel: [phone]
Fax: [phone]

ESAB Representative Office
St Petersburg
Tel: [phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone [phone]
Fax [phone]

www.esab.com

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