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SERVICE MANUAL - Otto Arc Systems

1. 1 1 gas off Output 1 gas on O 2 2 Gas II Reserved 3 gas off Output 1 cut off 0 3 3 5 Temporary voltage connect Output l l 1 inverter O 4 4 H Sampling switch edd Output 1 start O stop 5 5 2 Rotation leftwards Output Rotation 1 start 0 stop 4 rightwards A Output Wire feeding 1 start 0 stop 6 leftwards i Output Wire feeding 1 start O stop 8 rightwards Function Item Terminal Interface Channel Function Status Note Output To head control 1 1 L1 1 panel send 1 Output To head control 2 2 3 L2 EL2008 panel send 2 2 Output 3 3 5 Output 4 4 7 25 OTTO ARC SYSTEMS INC Output 1 start O 3 2 Water pump control stop Output Compressed air 1 start O valve control stop Output 7 6 Output 8 8 3 7 EL3162 2 channel analog input terminal 0 10V EL3162 analog input terminal is able to get signal between OV 10V There are 2 input channels for this terminal respectively used for current sampling and voltage sampling 26 OTTO ARC SYSTEMS INC LA O LI J ieis 1 1 C gt A desi E wa 1 Ta dl D eis Function Item Terminal Interface Channel Function Status Note A i Channel Current 0 10V corresponding to 1 sampling 0 400A External power 2 2 EL3162 24V External power 3 3 24V
2. Left View 14 OTTO ARC SYSTEMS INC X Open the right cover for inspection inverter output DC drive board aviation plug Right View 15 OTTO ARC SYSTEMS INC X Open the top cover for inspection control transformer power switch Beckhoff modular display BH power board 10C8 1 10C8 2 10C8 3 Top View 16 OTTO ARC SYSTEMS INC 3 Beckhoff modular description 3 1 OW Arc400 power source Beckhoff modular x Beckhoff screen 1 set x Beckhoff modular 1 set B Li EE E A 03 45 00 06 m gm EE ETE 6 d se d d d W ke ker DE um Connection port Number Connection port Beckhoff modular appearance Notice 17 OTTO ARC SYSTEMS INC 1 All the Beckhoff modular is installed in sequence The sequence is EK1100 EL1008 2 EL1512 EL2008 2 EL3162 EL4004 EL2622 BK1250 KL2541 2 KL9010 2 There are two sets of number beside the port for the ELxxxx series modular one set is connection port number near the connection port and another set is communication number far away the connection port Please refer to the picture above 3 Beckhoff modular power supply a BUS power provide power for communication b external power provide all the external control signal c KL2541 drive power supply provide step motor All the three power supply is mutually i
3. OTTO ARC SYSTEMS INC signal and recognize button message The emergency stop button head clamping button and head release buttons are not in the matrix but their voltages DC24V are provided BK1250 EL1008 2 interface 5 emergency stop interface 6 clamp and interface 7 release scan and recognize 6 Troubleshooting 6 1 Power on gt 40s screen no response dark screen gt Under normal condition dark screen 25s the main screen pops up after 40s including dark screen time Check power supply OW Arc 400 power supply is controlled by power switch which is contactor switch power input is AC380V 415V or 460V Check power switch output i e power switch 1 and power switch 2 both of them output should be DC24V Check screen power supply plug DC24V supply If all the check phenomena is normal then we could judge the screen is broken Change the screen 6 2 Power on the screen shows Windows desktop but the system does not run program automatically gt Turn off the machine restart the machine If the phenomenon is still happen we could judge it is the software error Please contact OTTO ARC Technology Center and reload the program 6 3 Power on the system automatically run program but only emergency button is available all the other buttons are not available 57 OTTO ARC SYSTEMS INC gt Check Beckhoff modules observe the LED lights on the modules to dete
4. emen 53 5 8 Current control i 53 5 9 Rotation control 53 5 10 Wire E H d EE 54 5 11 AN COMICON m 54 5 12 OSC control M 54 5 13 Warning gathering entrer reae ede aei eere gege SEO 54 5 14 Rotation counting nennen ennt nne nn rnnr sient nnns sene rnnn sensns 55 5 15 Current sampling eene nennen nenne nnne enne 55 5 16 Voltage samplng eene nnnm nennen nnne nn nnnns snnt nnn sensns 55 5 17 Control pendani a 56 5 18 Welding head control panel AAA 56 Troubleshooting AAA 57 6 1 Power on gt 40s screen no response dark screen 57 6 2 Power on the screen shows Windows desktop but the system does not run program automatically i 57 6 3 Power on the system automatically run program but only emergency button is available all the other buttons are not available 57 6 4 There is warning message and cannot cancel i 58 OTTO ARC SYSTEMS INC 6 5 Inching rotation wire feeding motor does not work 60 6 6 AVC and OSC motor do not work A 61 6 7 Touch lift function does not work 61 6 8 Start welding process no protective gas 62 6 9 ING compressed QUI cas ai ee E penn en ane nen ke ne e e neye An 63 6 10 Water pump does not work enne ren 63 6 11 No high frequency erre nennen nene nnrnen nre 64 6 12 Arc ignition CU DE 65 6 13 Arc stops after ignited 000000900 00000000 000000000 600 66 6 14 After p
5. Pin Pin Plug Number Function Function Number Number D A wire feeding J1 1 VCC empty J1 9 speed J1 2 VCC empty J1 10 SURW empty J1 3 ROTL rotation rightward J1 11 L empty JI J1 4 ROTL rotation leftward J1 12 GND Flat cable J1 5 D A rotation speed J1 13 GND plug J1 6 SURR encoder feedback J1 14 VSS empty WIRER wire feeding J1 7 J1 15 Empty rightward rotation WIREL wire feeding J1 8 J1 16 Empty leftward rotation D A wire feeding J2 1 VCC empty J2 9 speed J2 2 VCC empty J2 10 SURW empty J2 3 ROTL rotation rightward J2 11 L empty a J2 4 ROTL rotation leftward J2 12 GND J2 5 D A rotation speed J2 13 GND Mini plug J2 6 SURR encoder feedback J2 14 VSS empty WIRER wire feeding J2 7 J2 15 Empty rightward rotation WIREL wire feeding J2 8 J2 16 Empty leftward rotation 4 4 Filter board 10C8 4 piece 41 OTTO ARC SYSTEMS INC lt gt Function filtering It is able to replace with each other JK3 Notice The pin number of JK3 JK2 in the table below is corresponding to the positioned pin number on JK1 and they communicate with each other Therefore the sequence may reverse Filter board 10C8 1 interface table Plug Pin Pin Function Function Number Number Number Control pendant power Control pendant power JK1 1 JK1 9 OV 12V EK1100 2 24V external EK1100 3 OV external JK1 2 JK1 10 power power J
6. 4 4 S Shielding 27 OTTO ARC SYSTEMS INC interface Channel Voltage 0 10V corresponding to 5 2 sampling 0 60V External power 24V External power 24V S Shielding interface 3 8 EL4004 4 channel analog output 0 10V EL4004 analog output terminal is to output 0 10V signal There are four output channels on this terminal respectively used for inverter current control rotation speed control and wire feeding speed control 28 OTTO ARC SYSTEMS INC Function Item Terminal Interface Channel Function Status Note i i Channel citi 0 10V corresponding to 1 0 400A 2 2 G EL4004 Channel Rotation 0 10V corresponding to gt 3 Ee 55 1100Hz 4 4 G 5 5 Channel Wire feeding 0 10V corresponding to 29 OTTO ARC SYSTEMS INC 2 control 55 1100Hz 6 G Channel 7 4 8 G 3 9 EL2622 2 channel relay output terminal There are two independent relay inside of EL2622 output terminal each relay has one single normal open contact which respectively used for inverter start control and high frequency start control 30 OTTO ARC SYSTEMS INC S z eu ps eie Function Item Terminal Inte
7. OTTO ARC SYSTEMS INC SERVICE MANUAL ODEL OW Arc 400 Safety Depends on You DO NOT install repair this equipment without reading this manual and the safety precautions contained throughout lt MOST IMPORTANTLY think before you act and be careful gt OTTO ARC SYSTEMS INC Dear Reader Thank you for choosing OTTO ARC SYSTEM INC This instruction manual will help you get to know your new machine Read the manual carefully and you will soon be familiar with all the great features Please also take special note of the safety instruction and observe them In this way you will help to ensure more safety at you product location And of course if you treat your machine carefully this definitely helps to prolong its enduring quality and reliability things which are both essential prerequisites for getting outstanding results OTTO ARC SYSTEMS INC Contents SERVICE MANUAL EE 1 Preface sao ee ee ee ee ee ee eer ea 11 Machine description CAA iena 12 2 1 laut 12 2 2 Components description rear emen 12 2 3 System components layoUut rr rere rer eroi ei eerte 14 Beckhoff modular description enne 17 3 1 OW Arc400 power source Beckhoff modular eee 17 3 2 Beckhoff screen nennen nnne nnne 18 3 3 EKTIO0ZEtherC AT coupler ces ee se ee 19 3 4 EL1008 8 channel digital input terminal 24V DC sees
8. If the light is off module or software problem if the light is on high frequency is started please check as follow gt Short JK1 1 pin and JK1 2 pin on high frequency board directly If there is high frequency connection cable problem if there is no high frequency inverter or 64 OTTO ARC SYSTEMS INC head problem 6 12 Arc ignition failed gt Observe the high frequency strikes moment if the system and control pendant have restoration phenomena check power source grounding cable and control pendant grounding cable meanwhile keep away from any other high frequency disturbing source and try again gt Please ensure there is no system warning If any please refer to pint 6 4 there is warning message and cannot cancel and check gt Please ensure the protective gas is provided normally if not please refer to point 6 8 start welding process no protective gas and check gt Please ensure high frequency is normal if not please refer to point 6 11 no high frequency and check gt Check and ensure the open circuit voltage is under normal condition When check open circuit please plug out the JK1 plug on high frequency board 10C3 no high frequency Use the multi meter volt position DC220V to test the power source output and under normal condition the voltage is approximately DC 75V gt Ifthe open circuit voltage is normal M Use tungsten electrode to sc
9. 2 53 OTTO ARC SYSTEMS INC filtering board and DC drive adapter board gt Rotation speed is controlled by EL4004 interface3 output 0 10V It is connected to J11 5 pin on DC drive board through10C8 2 filtering board 5 10Wire feeding control gt The wire feeding is control by EL2008 1 interface 7 interface 8 It is connected to J11 7 pin and J11 8 pin on DC drive board through 10C8 2 filtering board and DC drive adapter board gt Wire feeding speed is controlled by EL4004 interface5 output 0 10V It is connected to J11 9 pin on DC drive board through10C8 2 filtering board 5 11AVC control gt AVC step motor is controlled by KL2541 1 The head model is critical important during the programming otherwise the power source will not drive the AVC properly 5 120SC control gt OSC step motor is controlled by KL2541 2 The head model is critical important during the programming otherwise the power source will not drive the AVC properly 5 13Warning gathering gt Inverter error warning inverter error on the screen it is provided by JK10 12 pin on inverter board and it is connected toEL1008 1 interface 1 through 10C8 3 on filtering board 1 normal O error gt Arc ignition failed warning it is provided by JK10 8 pin on inverter board and 54 OTTO ARC SYSTEMS INC it is connected to EL1008 1 interface 2 through 10C8 3 on filtering board 1 failed 0 successf
10. 59 OTTO ARC SYSTEMS INC E Ifthe water pump is working properly check the water inspection sensor connection cable one terminal connects to DC24V another terminal connects to EL1008 1 interface 8 W Ifthe connection and DC24V power supply are no problem please check the water circuit and ensure sure there is no bending or blocking W If all the checks could not solve the problem we could determine it is the water inspection sensor is breakdown gt Display arc ignition failure warning This warning is normally caused by EL1008 1 interface 2 input signal Please refer to point 6 12 arc ignition failed 6 5 Inching rotation wire feeding motor does not work gt First of all check and ensure the Beckhoff modules are working properly observe the LED lights flash gt Inching rotation press wire feeding button you could hear the relay operate sound gt Ifthe relay does operate B Check 0 10V analog value during the inching movement the analog value is 8V Rotation analog output EL 4004 interface 3 wire feeding analog output EL4004 interface 5 Check the analog interface on DC drive board Press the button on control pendant for inching movement and test the corresponding motor voltage on DC drive board it is dozens grades voltage If you could get the value we could determine it is the motor or motor connection cable problem if you could not get the value we could determine it is the DC
11. Q Q lt 2 d g S E L m m E E lo E ZS lh A a Z IS ou Q 1 San gt gt 9 T o S Bo a iw D g S Sl gt del OQ OG A E 2 g B m E E m a E Ela In E A de A Z Ir E on E 3 a Z 49 OTTO ARC SYSTEMS INC J2 1 Torch voltage J2 3 Empty se J2 2 Empty J2 4 Work piece J3 1 Empty J3 3 Empty di J3 2 Empty J3 4 Empty J4 1 BH interface board J1 3 J4 4 BH interface board J1 1 torch torch J4 J4 2 BH interface board J1 6 J4 5 BH interface board J1 4 inverter inverter J4 3 Empty J4 6 Empty 5 Machine schematic diagram 5 1 Machine control description gt OW Arc 400 program is preloaded in Beckhoff screen the screen itself is originally industrial PC which connects and communicates with Beckhoff module group via the Ethernet Using of the Beckhoff modules is equal to one set of PLC respectively to the functions in terms of digit input digit output analog input analog output replay output counting and drive etc In OW Arc 400 digit input signal includes all fault signal inspection and head button scan receive digit output signal includes gas control water pump control temporary voltage switchover sampling voltage switchover DC motor direction control and head button scan send analog input signal includes welding current sampling and welding voltage sampling analog output signal includes welding current setu
12. dk esst Use eki ell Dito ef j Beer Ke a eco Va wem i T9 wa MMI gt Ee NI UV YU r e js nt kre Plug Number Pin Number Function Pin Number Function OTTO ARC SYSTEMS INC E iiio D A wire feeding VCC empty speed J11 2 VCC empty J11 10 SURW empty J11 3 ROTR rotation rightward J11 11 L empty J11 Flat cable J11 4 ROTL rotation leftward J11 12 GND plug J11 5 D A rotation speed J11 13 GND J11 6 SURR encoder feedback J11 14 VSS empty J11 7 WIRER wire feeding J11 15 Empty rightward rotation J11 8 WIREL wire feeding J11 16 Empty leftward rotation J2 1 Empty J2 5 Empty J2 2 Empty J2 6 Empty J2 J2 3 Empty J2 7 Empty J2 4 Empty J2 8 Empty J4 1 Rotation U J4 4 15V J4 J4 2 Rotation U J4 5 Rotation feedback J4 3 15V J4 6 OV J6 1 Wire feeding U J6 4 15V J6 2 J6 5 Wire feeding J6 Wire feeding U feedback J6 3 15V J6 6 OV J8 1 AC 0V J8 3 AC 18V J8 J8 2 Empty J8 4 AC 18V 48 OTTO ARC SYSTEMS INC AC 0V AC 0V J9 2 J10 2 AC 42V Ac 42V J9 1 J10 1 J9 J10 4 6 Inductance board lt Function filtering high frequency 5 o Oo o d o o 5 O o S gt om o S B GG a G 2 V lt 2 E H
13. ensure the Beckhoff modules are working properly observe the LED lights flash gt Check EL2008 1 interface 1 LED status and interface 1 voltage If there is 62 OTTO ARC SYSTEMS INC 24V voltage please check as follow if there is no 24V voltage module or software problem Check BH interface board J6 1 pin voltage If there is 24V voltage please check as follow if there is no 24V voltage connection cable problem Check protective gas valve connection cable voltage If there is 24V voltage please check as follow if there is no 24V voltage BH interface board problem 6 9 No compressed air 6 10 gt gt Compressed air valve is control by EL2008 2 interface6 1 start 0 stop First of all check and ensure the Beckhoff modules are working properly observe the LED lights flash On the head body control penal press clamp and observe EL1008 2 interface6 LED light If the light is off check the control panel and module connection cable if the light is on please check as follow Check EL2008 2 interface 6 LED status and interface 6 voltage If there is 24V voltage please check as follow if there is no 24V voltage module or software problem Check BH interface J6 2 pin voltage If there is 24V voltage please check as follow if there is no 24V voltage connection problem Check the voltage for compressed air valve If there is 24V voltage valve problem if there is no 24V voltage B
14. interface 5 properly 6 15 Welding current does not match setup value gt Test EL4004 interface 1 voltage output value multi meter is used for DC welding and oscillograph is used for pulsing welding calculate and compare the actual value and setup value match or not 0 10V is corresponding to 0 400A 66 OTTO ARC SYSTEMS INC gt If they match H Test inverter board JK10 1 pin voltage multi meter is used for DC welding and oscillograph is used for pulsing welding check if it is the same as EL4004 interface 1 voltage If they are the same inverter problem if they are not the same connection problem gt Inthey do not match W Disconnect EL4004 interface 1 connection and measure the voltage here if it does not match we could determine it is module or software problem 6 16 Rotation speed does not match setup value gt First of all choose correct head model and work piece OD on the power source gt Test EL4004 interface 3 voltage output value oscillograph is used for pulsing rotation calculate and compare the actual value and setup value match or not 0 10V is corresponding to 55Hz 1 1 KHz gt If they match W Test DC drive board J11 5 pin voltage oscillograph is used for pulsing rotation check if it is the same as EL4004 interface 3 voltage If they are the same DC drive board or motor problem if they are not the same connection problem gt If they do not match E Disconnect EL4004 int
15. plugs Ensure that other people who spend time in the working area are not inconvenienced by the noise OTTO ARC SYSTEMS INC Secure gas cylinder ey Place shielding gas cylinders in the holders provided for them and secure with safety chains Take care when handling cylinders do not throw or heat guard against them toppling over When moving by crane take off the gas cylinder from the welding machine Caution Interference by electrical and electromagnetic fields if possible e g from A the welding machine or from the high voltage pulses of ht ignition unit E As laid down in electromagnetic compatibility standard EN50199 the machines are intended for use in industrial areas if they are operated e g in residential environments problems can occur in ensuring electromagnetic compatibility The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine Malfunctioning of electronic equipment in the vicinity of the welding location is possible Other mains supply leads trip leads signal and telecommunications leads above under and near the welding device may be subject to interference Warning Electromagnetic interference must be reduced to such a level that with no longer constitutes interference Possible reduction measures Welding machines should be regularly maintained Welding leads should be as short as possible and run closely toge
16. voltage or torch voltage incl temporary lt gt voltage switch and sampling voltage switch function 4 set error signal sampling incl inverter error arc ignition failure work piece short water test 1 set remote pendant control RS232 communication 1 set torch panel control keyboard matrix scan 2 2 Components description 12 9 lt gt OTTO ARC SYSTEMS INC OW Arc400 is made up of Beckhoff screen 1 set Beckhoff module 1 set Control transformer DC24V power switch 2set Power board 1 set Interface board 1 set Inductance board 1 set DC drive board 1 set DC drive interface board voltage converter 15V 24V 1 set 10C8 filter board 4 set Protective gas circuit 1 set Compressed air circuit 1 set Water circuit 1 set TIG400 inverter 1 set OW Arc400 alarm signal is 24V the rests are 15V 13 OTTO ARC SYSTEMS INC 2 3 System components layout We need to open three covers for maintenance i e top cover left cover and right cover Please refer to pictures below X Open the left cover for inspection inverter power amplifier board inverter mainboard high frequency board BH interface board inductance board pump water detection inverter heat dissipation fan water circuit cooling fan 1 s 9 al ses ka A SCH d E SU isca a z Ta 5 2 I A VA V g P E We T E
17. 0 5A DC Driver Power Supply AC42V 0 5A AC24V 0 5A JK3 10CB1 Inverter Output SS Electrical Drawings 3 OTTO ARC SYSTEM INC JOWJOJSUBI AVG Y T8 00T TMA Buen eme Z T O lt I 8 veis wanno G ist AND VI xoeqpeejjueun Z ano 7 t men 691 691 EV OO n SOLO sp CO CY r OO M OLIO lt CO CX r 8 L 9 iS v G I OO d O LO P CO NA TSEDI SLK Guiurem SUNIEH O lt I ON ON ON ON oo HOHS JeteM ON T 800TTH duing sl Jejem 49U4J0JSUEJ F d OO OLI C Qd pJeoq eouejonpu vf 1S9 J9JeM ONI WALSAS OUY OLLO p sbuimesg BOU 29 F No 2 Stepping Motor KL2541 2 Do api BI 2 E BIS ped ov 8 Magnet Ring Round No 1 Stepping Motor KL2541 1 Magnet Ring __Round IO Bi 2 ps HMH 143 Er Dei e ov Ts Two L 139 AL 159 161 10C8 2 JI BH Connectio Board BH100 RISO Onb 01 H Inductance Board HC4 Magnet Ring 9 wires 207 207 1 200 1209 209 209 3 211 WON gt H aro o jJnverter Output Torch Workpiece Electrical Drawings 5 OTTO ARC SYSTEM INC 1 AC OV 2 3 AC18V 4 AC18V emporary Voltage Sampling Swithc Rdtate Right Rptater Left Feed wire Feedback wire 1 AC42V 2 0V Encoder ISS E P H HC5 1 AC42V Wire Motor 2 0V Plug 5 wires EL4004 p O O S N
18. 2 SI 3 3 Input 3 S2 Two set of 4 EL1008 4 Input 4 S3 connected 5 2 5 Input 5 PSTOP 1 ON 0 OFF Two set of 6 6 Input 6 Head clamp 1 ON 0 OFF connected 7 7 Input 7 Head release 1 ON 0 OFF 8 8 Input 8 3 5 EL1512 2 channel plus minus counter terminal 24V DC 1kHz EL1512 counter terminal to measure pulse signal We use DC drive encoder feedback signal to determine rotation position and other related control 22 OTTO ARC SYSTEMS INC Function Item Terminal Interface Channel Function Status Note 1 1 F 2 2 External power 24 V 3 3 External power 24V 4 EL1512 4 1 5 5 P Encoder feedback 6 6 External power 24 V 7 7 External power 24 23 OTTO ARC SYSTEMS INC 3 6 EL2008 8 channel digital output terminal 24V DC 0 54 EL2008 digital input terminal includes 8 channels digital output interface Each channel maximum current is 0 5A All the channel status is showed by corresponding LED indicator The light on is 1 and light off is 0 Function Item Terminal Interface Channel Function Status Note 1 EL2008 1 Output Gas I 1 gas on 0 24 OTTO ARC SYSTEMS INC
19. 20 3 5 EL1512 2 channel plus minus counter terminal 24V DC IK 22 3 6 EL2008 8 channel digital output terminal 24V DC 0 5A se 24 3 7 EL3162 2 channel analog input terminal 0 10V i 26 3 8 EL4004 4 channel analog output 0 10V see 28 3 9 EL2622 2 channel relay output terminal see 30 3 10 BK1250 connection of E BUS and K BUS terminal module compact coupler 32 3 11 KL2541 step motor terminal 50V DC SA 33 3 12 KL9010 K BUS end terminal seem 35 PCB Doard d s riptiOD EE 36 4 1 BH connection board AAA 36 4 2 BH power board rettet ipee trente ner teh tp x cata v ae tada 38 4 3 DC drive adapter b ard onere ette ettet 39 4 4 Filter board 10C8 4 piece A 41 4 5 DC drive board AAA 46 OTTO ARC SYSTEMS INC 4 6 Inductance board eee a a aaattasaaeea ae ooosoosssssasaaoooooooosssssassooooooooe 49 Machine schematic diagram a ooatat aaa tata eene enne nennen nenne 50 5 1 Machine control description cecssesesoresesopescucisenrcessponsuostacecerescuotenencisacusorspueasuoacd 50 5 2 Machine power suppl 52 5 3 Upper layer cooling fan control 52 5 4 ras control ses se sn wv as vn we raio ii tato sf ella AU ia Vane san date ee Had 52 5 5 Water pump Control 53 5 6 Inverter start contioli R E eee I ee 53 5 7 Inverter high frequency control
20. 3 er lon De pd pr uei D E ECH ei je eee Dee m _ 949999 eee Te ese eC Deo ne 1F 102 13 Fes Ree eres 1 oM BM ere D Con ORI Lerzzeite bro C Jent 14 edhe o jh oc e Lec eC J0z0000000 Los onu ia pe rec el ree Ies eire s Plug Pin Pin Number Function Function Number Number J1 1 Torch J1 4 Inverter J1 J1 2 Empty J1 5 Empty J1 3 Torch J1 6 Inverter 36 OTTO ARC SYSTEMS INC J2 1 AC220V input J2 4 AC220V output J2 J2 2 Empty J2 5 Empty J2 3 AC220V input J2 6 AC220 output J3 1 Empty J3 4 Empty J3 J3 2 Empty J3 5 Empty J3 3 Empty J3 6 Empty J4 1 ad d ER J4 7 Protective gas valve DC24 J4 2 PARE d J4 8 Compressed air valve DC24 J4 J4 3 Empty J4 9 Empty J4 4 Empty J4 10 Empty J4 5 Empty J4 11 Empty J4 6 Empty J4 12 Empty J5 1 Empty J5 5 Empty 15 2 Empty J5 6 Voltage feedback n J5 3 Empty J5 7 Work piece short signal J5 4 Empty J5 8 GND J6 1 Protective gas valve J6 5 Empty J6 2 Compressed air valve J6 6 Temporary voltage switchover di J6 3 Empty J6 7 Water pump control J6 4 Empty J6 8 Sampling voltage switchover J7 1 DC24V input J7 3 GND di J7 2 DC34V input J7 4 GND 37 OTTO ARC SYSTEMS INC 4 2 BH power board lt Function provide step motor DC power Beckhoff modules external power control pendant power BH interface board pow
21. 400 connection diagram 1 set 7 pages OW Arc 400 module connection diagram 1 set 3 pages 8 User s Record Please complete and retain with your personal records Model Serial Number Purchase Date Distributor Contact Maintenance Record 71 Connection Plug 14 Wire BK1250 1 7 EL1008 2 5 319 BK1250 1 6 81 J3 DC12V 24V 53 BH Power Boa td 55 EL1008 2 EL1502 EL2008 2 S JOMOd 00 s sI GO On BO OS 99Jno Si Handle Romote RTCO7 1 0 O1 4 N H 2 CP6619 0001 0020 a worn C Power Supply 1 orn o WNOo n 9 lt KL2541 KL2541 KL9010 EL4004 EL2622 D 2 EL3162 Electrical Drawings 1 OTTO ARC SYSTEM INC 32 L24 BH Transformer AC 380V Lil L21 L31 L21 3801 403 WE Main Transformer L24 L32 5 6 KH1 9 10 et L33 L13 Fan For Inverter Output Inverter Output Power Supply 1 Power Supply 2 PE HF100W S 24 PE HF100W S 24 V JK1 10C8 1 Electrical Drawings 2 OTTO ARC SYSTEM INC Main Transformer BH HE AR AC18V 5A DC24V OV Main Transformer AC18V 4A If you want to Stepping motor power choose input supply voltage you 9 AC460V 8 just move L12 wire to the voltage you want AC460V ACA15V 93 AC415V AC380V a 4 JK2 in main transformer ov 55 10C8 1 L24 DC 24V 57 OV 59 J7 BH Connection Board AC42V
22. H _ O Av CO Co O1 NI ta Co QO NO H 257 Rotation Motor N Output 2 OV 24V P input Output 1 0V 24V Gate 93 4004 157 Lo 1511 Encoder N L OI On 4 DD H N CO GR SO O 4 OO a L Ve 010 100 0 W P 0O10 100 O H DC Driver Transfor Board DC Driver Board 161 Stepping Motor 159 KL2541 1 2 Electrical Drawings 6 OTTO ARC SYSTEM INC HCl Buttons on welding head board 14 wires CN c o N E Electrical Drawings 7 OTTO ARC SYSTEM INC
23. H interface board problem Water pump does not work The water pump is controlled by EL2008 2 interface 5 1 start 0 stop Check EL2008 2 interface LED status and interface 5 voltage If there is 24V voltage please check as follow if there is no 24V voltage module or software 63 OTTO ARC SYSTEMS INC problem gt Manually let K7 relay on BH interface board operate Observe water pump works or not gt Ifthe water pump works H Check the connection cable between EL2008 2 interface 5 and BH board J6 7 pin gt Ifthe water pump does not work B Check the voltage AC220V between J2 1 pin and J2 2 pin on BH board If there is voltage please check as follow if there is no voltage please check the AC220V connection here according to the circuit diagram B Check the voltage AC220V between J2 3 pin and J2 4 pin on BH board If there is voltage please check as follow if there is no voltage relay problem B Check water pump voltage AC220V If there is voltage water pump problem if there is no voltage connection problem 6 11 No high frequency gt High frequency start is close loop controlled by EL2622 channel 2 interface 5 and interface 6 1 start 0 stop 66 99 gt First of all please confirm the and cables are connected properly tungsten electrode is installed properly with suitable distance to the work piece gt Start welding observe EL2622 interface 5 LED light status
24. K1 3 Empty JK1 11 Empty JK JK1 4 Empty JK1 12 Empty Control pendant RS232 Control pendant RS232 JK1 5 JK1 13 communication 0V communication RXD Control pendant RS232 JK1 6 JK1 14 Empty communication TXD 42 OTTO ARC SYSTEMS INC J1 7 Power switch 2 ON JK1 15 Power switch 1 0V J1 8 Power switch 2 24V JK1 16 Power switch 1 24V JK3 8 BH power board J3 6 0V JK3 4 BH power board 1 OV JK3 7 BH power board J3 2 JK3 3 BH power board 1 24V JK3 24V JK2 8 PC RS232 JK2 4 PC RS232 communication communication 0V TXD JK2 7 PC RS232 JK2 3 Empty communication RXD JK2 6 JK2 2 EK1100 5 ON JK2 PC OV communicate with power source JK2 5 JK2 1 EK1100 1 24V PC 24V communicate with power source Filter board 10C8 2 interface table Plug Pin Pin Function Function Number Number Number DC drive adapter board JK1 1 Empty JK1 9 wire feeding speed JKI JK1 2 DC drive adapter board JK1 10 Empty JK1 3 Empty JK1 11 DC drive adapter board 43 OTTO ARC SYSTEMS INC wire feeding rotation leftward JK 1 4 Empty JK1 12 Empty BH power board J3 1 JK1 5 JK1 13 BH power board J3 4 0V 24V DC drive adapter board JK 1 6 Empty JK1 14 rotation leftward DC drive adapter board DC drive adapter board 0V J1 7 JK1 15 rotation speed GND DC drive a
25. L2622 1 inverter start JK2 4 EL4004 1 current setup JK2 JK2 7 EL4004 6 OV GND JK2 3 Empty 45 OTTO ARC SYSTEMS INC JK2 6 Empty JK2 2 Empty JK2 5 EL2622 5 high JK2 1 EL2622 6 high frequency frequency start start Filter board 10C8 4 interface table Plug Number Pin Number Function Pin Number Function JK1 1 OSC motor B2 JK1 9 OSC motor A2 JK1 2 OSC motor B1 JK1 10 OSC motor Al JK1 3 Empty JK1 11 Empty JK1 4 Empty JK1 12 Empty JKI JK1 5 Empty JK1 13 Empty JK1 6 Empty JK1 14 Empty J1 7 AVC motor B2 JK1 15 AVC motor A2 J1 8 AVC motor B1 JK1 16 AVC motor Al JK3 8 KL2541 2 6 B2 JK3 4 KL2541 2 5 A2 JI KL2541 2 2 B1 JK3 3 KL2541 2 1 Al Ven JK3 6 Empty JK3 2 Empty JK3 5 Empty JK3 1 Empty JK2 8 Empty JK2 4 Empty JK2 7 Empty JK2 3 Empty JK2 JK2 6 KL2541 1 6 B2 JK2 2 KL2541 1 5 A2 JK2 5 KL2541 1 2 B1 JK2 1 KL 2541 1 Al 4 5 DC drive board 46 OTTO ARC SYSTEMS INC lt gt Function two sets of DC drive The first version OW Arc series power source use modified DC drive board reason Beckhoff provides 24V digital signal but our DC drive direction control signal requires 15V therefore we modified the voltage distribution In the subsequent version we add one more DC drive adapter board C23 Fir e PERES TE ele e
26. MS INC Function Ite Interfac Terminal Channel Function Status Note m e 1 r A A A a pair of coil 2 2 B B B a pair of coil 3 3 Double terminal KL2541 AVC module Drive 4 1 4 motor left terminal power 4 empty 5 5 A A A a pair of coil 6 6 B B B a pair of coil 34 OTTO ARC SYSTEMS INC 7 T Drive 8 8 power Function Ite Interfac Terminal Channel Function Status Note m e 1 r A A A a pair of coil 2 2 B B B a pair of coil 3 3 a Drive Double terminal KL2541 power osc module 5 2 5 A motor A A a pair of coil left terminal 6 6 B B B a pair of coil empty 7 T Drive 8 8 power 3 12 KL9010 K BUS end terminal KL9010 K BUS end terminal is used for end of K BUS terminal module KLxxxx No external connection ES n 83 Sm Sales 35 OTTO ARC SYSTEMS INC 4 PCB board description 4 1 BH connection board lt Function provide temporary voltage temporary voltage switchover sampling voltage switchover relay control voltage convert Please refer to the attachment MESES Caines T ee ee ees e ele e omet is EE LEE eie SHE epe ros ell e e re eeeeececc e Je ce Tous eras e
27. alue and setup value match or not 0 10V is corresponding to 0 400A If they match B We could determine it is module or software problem 68 OTTO ARC SYSTEMS INC gt Inthey do not match H Test inverter board JK10 2 pin voltage multi meter is used for DC welding and oscillograph is used for pulsing welding check if it is the same as EL3162 interface 1 voltage If they are the same inverter board problem if they are not the same connection problem 6 21 Voltage display value abnormal gt Test EL3162 interface 5 voltage input value multi meter is used for DC welding and oscillograph is used for pulsing welding calculate and compare the actual value and setup value match or not 0 10V is corresponding to 0 60V gt If they match B We could determine it is module or software problem gt Inthey do not match W Test BH interface board J5 6 pin multi meter is used for DC welding and oscillograph is used for pulsing welding check if it is the same as EL3162 interface 5 voltage If they are the same please check as follow if they are not the same connection problem E Test the JI output voltage on BH interface board pin land amp pin 3 are torch voltage pin 4 and pin 6 are inverter voltage both of the voltage here should be corresponding to the actual voltage approximately 10V If they match BH interface board problem if they do not match sampling cable or torch problem 6 22 Arc stop d
28. and connects to other EtherCAT device through X2 OUT down on the same BUS E um BECKHOFF EtherCAT do aiii m es Function Item Terminal Interface Channel Function Status Note BUS power 1 24V 24V 2 OV d BUS power 24V 3 External power Two set of 4 EK1100 External power connected 5 External power Two set of connected 6 External power 7 PE Grounding 8 PE Grounding 3 4 EL1008 8 channel digital input terminal 24V DC 20 OTTO ARC SYSTEMS INC EL1008 digital input terminal interface includes 8 set of digital input 15V 30V is Logic 1 3V 5V is Logic 0 All the channel status is showed by corresponding LED indicator The light on is 1 and light off is 0 Function Item Terminal Interface Channel Function Status Note 1 1 Input 1 Inverter error 2 EL1008 2 Input 2 Arc ignition OK 3 1 3 Input 3 Two set of 4 4 Input 4 connected 21 OTTO ARC SYSTEMS INC 5 3 Input 5 Two set of 6 6 Input 6 connected 7 7 Input 7 Work piece short 8 8 Input 8 Water pressure test Function Item Terminal Interface Channel Function Status Note 1 1 Input 1 SO 2 2 Input
29. ard JK10 4 pin voltage This point provides DC24V power for inverter warning signal W If all the checks could not solve the problem we could determine it is the inverter board is breakdown gt Display work piece short warning This warning is normally caused by EL1008 1 interface 7 input signal W First of all check and ensure the Beckhoff modules are working properly observe the LED lights flash Check if the tungsten touches the work piece or not B Check the LED lights on EL1008 1 interface 7 and interface 7 voltage If the voltage gt 15V then we could determine it is the module or software problem if the voltage 5V please check as follow B Check BH interface board is under normal condition or not VDD 15V VSS 15V B Check the TPI voltage on BH interface board If the voltage lt 5V we could determine it is BH interface board problem We have to be careful that if the 29 sampling cable and connect wrongly there is no temporary voltage K6 close will cut temporary voltage CONO damage will disconnect temporary voltage gt Display lack of water warning This warning is normally caused by EL1008 1 interface 8 input signal E First of all check and ensure the Beckhoff modules are working properly observe the LED lights flash H Ensure the water pump is working properly if it does not work properly please refer to point 6 10 water pump does not work to solve the problem
30. dapter board DC drive adapter board J1 8 JK1 16 rotation encoder feedback rotation rightward JK3 8 JK3 4 EL4004 5 wire feeding Empty speed JK3 7 EL2008 2 8 wire JK3 3 feeding rotation Empty JK3 A rightward JK3 6 JK3 2 EL2008 2 7 wire feeding Empty rotation leftward JK3 5 Empty JK3 1 Empty JK2 8 KL2541 4 step motor JK2 4 KL2541 8 step motor drive drive power power JK2 7 5 JK2 3 EL2008 2 5 rotation mpt d id leftward JK2 6 EL4004 3 rotation speed JK2 2 EL1512 3 0V JK2 5 EL1512 5 rotation JK2 1 EL2008 2 6 rotation 44 OTTO ARC SYSTEMS INC encoder feedback rightward Filter board 10C8 3 interface table Plug Pin Pin Function Function Number Number Number Inverter board power Inverter board arc ignition JK1 1 JK1 9 error successful I gt 0 BH interface board J5 7 JK1 2 i JK1 10 Empty work piece short JK1 3 Empty JK1 11 Empty JKI JK1 4 Inverter board JK1 12 Empty JK1 5 Inverter board JK1 13 Inverter board current setup JK1 6 Inverter board JK1 14 Empty J1 7 Empty JK1 15 Empty High frequency board High frequency arc ignition J1 8 3 3 d JK1 16 E A d i high frequency start board high frequency start JK3 8 EL1008 1 1 power JK3 4 EL1008 1 2 arc ignition error successful I gt 0 JK3 7 EL1008 1 7 work JK3 3 Empty JK3 piece short JK3 5 EL3162 1 current JK3 1 Empty feedback JK2 8 E
31. drive board problem 60 OTTO ARC SYSTEMS INC gt It the relay does not operate B Check EL2008 1 interface 5 rotation leftward interface 6 rotation rightward interface 7 wire feeding rotation leftward interface 8 wire feeding rotation rightward In the first version sample machine the logic relationship is 1 is stop and O is start in the subsequent version machine because of using DC drive adapter board the logic relationship is changed to 1 is start and O is stop B Check DC drive board direction signal is controlled or not B Change the DC drive board 6 6 AVC and OSC motor do not work First of all check and ensure the Beckhoff modules are working properly observe the LED lights flash gt Confirm that the setup head model the same as actual head gt Check if any warning on KL2541 module yellow or red LED light gt Check KL2541 module power supply KL2541 interface 4 is KL2541 interface 8 is the value between DC8V DCSOV is all acceptable gt Check step motor connection cable Method cut off the power use multi meter Ohm position respectively test the resistance value between interface 1 and 5 2 and 6 on KL2541 Under normal condition it is able to get dozens grade ohm resistance value if there is no value please check the connection cable between the KL2541 and step motor based on circuit diagram gt Ifthere is no abnormal phenomenon res
32. e DC drive adapter board is added to control DC motor direction which is to converter 24V logic 1 voltage to available 15V logic 1 voltage gt Beckhoff system analog output signal is 0 10V power source inverter control 51 OTTO ARC SYSTEMS INC voltage DC drive voltage i e 0 10V is corresponding to current 0 400A rotation speed 55Hz 1 1 KHz gt Beckhoff system analog input signal is 0 10V Welding current is 0 400A the corresponding ratio adjustment is on inverter board for instance 0 10V is corresponding to 0 400A welding voltage is 0 60V the corresponding ratio adjustment is on BH interface board for instance 0 10V is corresponding to 0 60V 5 2 Machine power supply gt AC 3380 3 415 and 3 460 V for OW Arc 400 input gt Contactor switch KMI is used after AC380 power connected gt Contactor switch KM1 is control by S1 on control panel 5 3 Upper layer cooling fan control gt The EL1512 interface 6 and interface 7 provide power to the upper layer cooling fan The fan will run after power connected 5 4 Gas control gt Protective gas is controlled by protective gas valve through EL2008 1 interface 1 which connecting to J6 1 pin on BH interface board and control of the K1 relay on BH interface board The protective gas valve working voltage is DC24V which is provided by BH interface board Compressed air is controlled by compressed air valve through EL2008 2 inter
33. er Please refer to the attachment 0150800080400007 E3 E4 ES eres Sie rr E ETs Plug Pin Pin Function Function Number Number Number ita Step motor drive input wa Step motor drive input JI AC17V AC34V 17V AC34V J1 2 Beckhoff module external J1 5 Beckhoff module external 38 OTTO ARC SYSTEMS INC power AC18V power AC18V ua Control pendant power ile Control pendant power AC8 5V AC8 5V BH interface board power J2 1 J2 4 OV 5 input AC18V J BH interface board power J2 2 J2 5 OV input AC18V p Step motor drive input jid Step motor drive input i DC24V DC50V DC24V DC50V Beckhoff module external Beckhoff module external J3 J3 2 J3 5 power DC24V power DC24V Control pendant power Control pendant power J3 3 p P J3 6 p j DC12V DC12V SCH BH interface board power ua BH interface board power j output DC24V output 0V J BH interface board power BH interface board power J4 2 J4 4 output DC24V output OV 4 3 DC drive adapter board 39 OTTO ARC SYSTEMS INC lt Beckhoff digital signal is 24V and DC drive direction control signal is 15V It is to switchover the corresponding voltage R3 N2 R4 RI NI R2 ntes C C e e R5 N3 R6 R N4 R8 entes 3 C 2001170013097000 40 OTTO ARC SYSTEMS INC
34. erface 3 connection and measure the voltage here if it does not match we could determine it is module or software problem 6 17 Wire feeding speed does not match setup value gt First of all choose correct head model and work piece OD on the power source gt Test EL4004 interface 5 voltage output value oscillograph is used for pulsing 67 OTTO ARC SYSTEMS INC 6 18 6 20 rotation calculate and compare the actual value and setup value match or not 0 10V is corresponding to 55Hz 1 1 KHz If they match W Test DC drive board J11 9 pin voltage oscillograph is used for pulsing rotation check if it is the same as EL4004 interface 5 voltage If they are the same DC drive board or motor problem if they are not the same connection problem If they do not match E Disconnect EL4004 interface 5 connection and measure the voltage here if it does not match we could determine it is module or software problem AVC motor outofstep or does not move First of all choose correct head model on the power source Check and ensure standard motor is used for the head OSC motor outofstep or does not move First of all choose correct head model on the power source Check and ensure standard motor is used for the head Current display value abnormal Test EL3162 interface 1 voltage input value multi meter is used for DC welding and oscillograph is used for pulsing welding calculate and compare the actual v
35. face 1 which connecting to J6 2 pin on BH interface board and control of the K2 relay on BH interface board The compressed air valve working voltage is DC2AV which is provided by BH interface board 52 OTTO ARC SYSTEMS INC 5 5 Water pump control gt Water pump is controlled by water pump relay through EL2008 2 interface 5 which connecting to J6 7 pin on BH interface board and control of the K7 relay on BH interface board The water pump working voltage is AC220V which is converted by control transformer self couple from AC380V The water heat eliminate cooling fan working voltage is AC220V which connects to water pump power cable 5 6 Inverter start control gt Inverter start is controlled by EL2622 communication port 1 signal interface 1 interface 2 It is connected to JK10 5 pin on inverter board through 10C8 3 filtering board 5 7 Inverter high frequency control Inverter start is controlled by EL2622 communication port 2 signal interface 5 interface 6 It is connected to JK1 1 pin and JK1 2 pin on inverter high frequency arc ignition board through 10C8 3 filtering board 5 8 Current control gt The current is control by EL4004 interface 1 output 0 10V It is connected to JK10 1 pin on inverter board through 10C8 3 5 9 Rotation control gt The rotation direction is control by EL2008 1 interface 5 interface 6 It is connected to J11 3 pin and J11 4 pin on DC drive board through 10C8
36. l vapour Unusual vibrations or jolts Excessive quantities of dust such as grinding dust etc Severe weather conditions Unusual conditions near the coast or on board ship When setting up the machine ensure a free inlet and outlet of air The machine is tested to protection class IP23 49999929 10 OTTO ARC SYSTEMS INC 1 Preface lt OW Arc400 power source is one of the most important new developed orbital welding power sources in 2008 2009 which is using of BECKHOFF control modular from Germany standard TIG400 inverter and we develop new generation control pendant which is easily for programming operation display and service etc We may encounter problem during the practical application so we hope to perfect the power source as early as possible under all departments efforts lt Please read OW Arc400 welding power source operator s manual and ensures you are master of basic operation before reading the service manual 11 OTTO ARC SYSTEMS INC 2 Machine description 2 1 Main function 1 set protective gas control 1 set compressed air control 1 set circuit water control 2 set DC drive control incl 4 set direction signal 2 set simulation signal 2 set step drive control 1 set inverter enable control 1 set inverter high frequency control 1 set inverter simulation output 9 1 set inverter current sampling 1 set voltage sampling inverter
37. ly repaired plug or damaged mains cable insulation can cause electric shocks The machine may only be opened by qualified and authorized personnel Before opening pull out the mains plug Switching off is not sufficient Wait for 2 minutes until capacitors are discharged Always put down welding torch stick electrode holder in an insulated condition Even touching low voltages can cause you to jump and lead to accidents so to 99 Safeguard yourself against falls e g from a platform or scaffolding When welding operate earth tongs torch and work piece properly not in ways for which they are not intended Do not touch live parts with bare skin Only replace electrodes when wearing dry gloves Never use torches or earth cables with damaged insulation Smoke and gases can lead to breathing difficulties and poisoning Do not breathe in smoke and gases Ensure that there is sufficient fresh air Keep solvent vapors away from the arc radiation area Chlorinated hydrocarbon fumes can be converted into poisonous phosgene by ultraviolet radiation A OTTO ARC SYSTEMS INC Work piece flying sparks and droplets are hot Keep children and animals well away from the working area Their behavior is unpredictable Move containers with inflammable or explosive liquids away from the working area There is a danger of fire and explosion Never heat explosive liquids dusts or gases by welding or c
38. ndependent Please be careful when you execute the measurement Xx BUS power EK1100 24V interface and BK1250 OV interface X External power EK1100 interface and BK1250 interface EL1512 interface and EL3162 interface are also connected All 6 99 the are equipotential points meanwhile all the are equipotential 6 99 points as well All the interface are normally used for external power supply measurement Xx KL2541 drive power supply KL2541 interface 4 and 8 3 2 Beckhoff screen 18 OTTO ARC SYSTEMS INC Item Interface Channel Function Note A Grounding bolt B X106 24V IN Power interface LAN2 C X104 Connect to PC 10 100M Reverse connection of X104 LANI Connect to EK1100 X1 IN and X105 are not allowed D X105 10 100M interface i Cover screw used for Flash and battery replacement F X102 USB1 1 USB socket X103 USB2 0 USB socket H X101 COMI RS232 interface 3 3 EK1100 EtherCAT coupler EK1100 coupler is used for the connection of EtherCAT the screen and EtherCAT terminal ELxxxx One modular is made up of one EK1100 coupler 19 OTTO ARC SYSTEMS INC and sever MAX 65535 EtherCAT terminal and one BUS end terminal The coupler and E BUS signal will converter with each other though LAN The coupler connects to the Beckhoff screen through X1 IN LAN port up
39. p and DC motor rotation wire feeding rotation speed control relay output signal includes inverter start and high frequency start drive includes AVC motor drive and OSC motor drive 50 OTTO ARC SYSTEMS INC gt Control system power supply EH Beckhoff screen DC24V power supply power supply mode DC24V power switch EH Beckhoff modules communication DC24V power supply power supply mode DC24V power switch B Beckhoff modules external DC24V power supply power supply mode transformer control BH power board current rectify E Step motor drive module KL2541 drive power DC8V DC50V power supply power supply mode transformer control BH power board current rectify B Control pendant DC12V power supply power supply mode transformer control BH power board current rectify W BH interface board 24V power supply power supply mode BH power board current rectify B DC drive board ACI8V 0V AC18V power supply power supply mode transformer control B DC drive board AC42V 2 power supply power supply mode transformer control gt Beckhoff system input logic signal 1 is 15V 30V logic signal 0 is 3V 5V Therefore the inverter board alarm signal output is increase from 15V to 24V this is the critical difference between OW Arc 400 gt Beckhoff system output logic signal 1 is Beckhoff external power supply voltage approximately 24V logic signal 0 is OV Therefore th
40. ratch between the tungsten and work piece to see if it is able to ignite the arc if arc is ignited please check the gas and high frequency H If scratching still could not ignite arc please check the inverter and check if inverter error or phase lack gt If open circuit voltage is abnormal no voltage or low voltage H The inverter start is close loop controlled by EL2622 channel 1 interface 1 65 OTTO ARC SYSTEMS INC and interface 2 1 start O stop B Check EL2622 interface 1 LED light status and interface 1 voltage If voltage 24V module or software problem if voltage 0V please check as follow EH Check inverter board 10CB1 JK10 5 pin If voltage 24V connection cable problem if voltagez0V main board or inverter problem 6 13 Arc stops after ignited gt Observe arc stopping moment if the system and control pendant have restoration phenomena check power source grounding cable and control pendant grounding cable meanwhile keep away from any other high frequency disturbing source and try again gt Ensure there is no warning if warning comes out please refer to point 6 14 there is warning message and cannot cancel and check gt Please check if the arc stops because the distance between the tungsten and work piece is too big or too small 6 14 After pre melt normal welding process does not execute gt Check rotation motor Check if the encoder feedback signal is sent to EL1512
41. re melt normal welding process does not execute 66 6 15 Welding current does not match setup value 66 6 16 Rotation speed does not match setup value 67 6 17 Wire feeding speed does not match setup value 67 6 18 AVC motor outofstep or does not move rs 68 6 19 OSC motor outofstep or does not MOVE ii 68 6 20 Current display value abnormal eene eee 68 6 21 Voltage display value abnormal nennen enne 69 6 22 Arc stop during welding process seen 69 6 23 No downslope or downslope process abnormal eee 70 6 24 Other occasional fault phenomenon i 70 T SADDODOIX ss A A Rn 71 8 User s Record aaa as EU SEU ENOT CAA ED eee eee 71 OTTO ARC SYSTEMS INC Safety Instructions A Do For your own safety Warning Observe accident prevention regulations Ignoring the following safety procedures can be fatal Before undertaking welding tasks put on prescribed dry protective clothing e g gloves Protect eyes and face with protective visor Electric shocks can be fatal 09 OF The machine may only be connected to correctly earthed sockets Only operate with intact connection lead including protective conductor and safety plug An improper
42. rface Channel Function Status Note 1 1 Channel 1 Current start 1 start O stop 2 2 Channel 1 3 3 EL2622 4 4 PE 5 5 Channel 2 High frequency start 1 start 0 stop 6 6 Channel 2 31 OTTO ARC SYSTEMS INC 3 10 BK1250 connection of E BUS and K BUS terminal module compact coupler In the BUS station application mixing with E BUS terminal module ELxxxx and K BUS terminal module KLxxxx BK 1250 is called BUS coupler with terminal module shell BK 1250 is able to combine 300 kinds of K BUS terminal module including special terminal module and high speed communication and big bandwidth EtherCAT terminal module very well 32 OTTO ARC SYSTEMS INC Function Item Terminal Interface Channel Function Status Note 1 24V BUS power 24V 2 OV BUS power 24V 3 BUS power 24V 4 4 BUS power 24V E K BUS EL1250 5 BUS power 24V switchover 6 E BUS power 24V 7 PE Grounding 8 PE Grounding 3 11 KL2541 step motor terminal 50V DC 5A KL2541 step motor terminal is used for medium performance step motor We only need to adjust several parameters and KL2541 will be able to be suitable for particular motor and application 64 micro step to ensure the motor running stable and accurate 33 OTTO ARC SYSTE
43. rmine whether it is under normal condition or not and the most obvious phenomena is the LED lights on EL2008 2 interface 1 interface2 is continuously flash under standby status gt Ifthe LED lights flash is normal E Check control pendant change the control pendant if it is available B Check the connection cable broken or not between the control pendant and screen RS232 communication cable gt Ifthe LED lights do not flash B Check all Beckhoff modules terminals are connected properly B Check the 24V voltage between 24V OV on EK1100 B Check the 24V voltage between on EK1100 the voltage here between 22V 28V is normal B Check the Ethernet cable connection from screen to modules LANI on screen to X1 IN on EK1100 6 4 There is warning message and cannot cancel gt Display inverter error warning This warning is normally caused by EL1008 1 interface 1 input signal B Firstly of all check and ensure the Beckhoff modules are working properly observe the LED lights flash H Ensure the EL 1008 1 interface 1 LED light status and interface 1 voltage If the voltage gt 15V we could determine it is the module or software problem if the voltage 5V please check as follow B Check the inverter board JK10 12 pin voltage If the voltage gt 15V we could determine it is the connection problem if the voltage lt 5V please check as 58 OTTO ARC SYSTEMS INC follow B Check the inverter bo
44. tart the power source If the problem still happens we could determine that it is KL2541 problem or software error 6 7 Touch lift function does not work 61 OTTO ARC SYSTEMS INC gt First of all check and ensure the Beckhoff modules are working properly observe the LED lights flash gt Move down the torch and touch the work piece check the EL1008 1 interface 7 LED light status and interface 7 voltage gt Ifthe EL1008 1 interface 7 LED light is still on E Short step motor aviation plug 7 pin and sampling aviation plug 1 pin observe EL1008 1 interface 7 LED light status Light is on please check as follow light is off sampling cable problem E Short 1 pin and 3 pin on BH interface board observe EL1008 1 interface 7 LED light status Light is on please check as follow light is off connection cable problem B Check if the K8 relay operates or not under standby status the relay should not operate E If there is no abnormal phenomenon we could determine it is BH interface board problem gt Ifthe LED light on EL1008 1 interface 7 is off B Check the voltage on EL1008 1 interface 7 Voltage 5V please check as follow voltage gt 5V module problem W Please check the step motor according to point 6 6 AVC and OSC motor do not work 6 8 Start welding process no protective gas gt The protective gas is control by EL2008 1 interface 1 1 start O stop First of all check and
45. ther on or near to the ground Selective shielding of other leads and equipment in the environment can reduce radiation Caution Repairs and modifications may only be carried out by authorized trained specialist personnel The warranty becomes null and void in the event of unauthorized interference EK OTTO ARC SYSTEMS INC Our operating instructions will provide you with an introduction into the safe use of the machine Therefore please read them carefully and only start with when you are familiar with them Transportation and installation The machine may only be transported and operated in an upright position Before carrying away or moving please pull out main plug and place the machine properly OTTO ARC SYSTEMS INC Ambient conditions This machine must not be operated and storage in any area where any risk of explosion exists The following conditions must be observed during operation Temperature range of the ambient air lt During welding 10 C to 40 C lt gt For transport and storage 25 C to 55 C lt Using the appropriate coolant Relative air humidity lt gt Upto 50 at 40 C lt gt Upto 90 at 20 C The ambient air must be free of unusual amounts of dust acids corrosive gases or substances etc assuming these are not produced by the welding process Examples of unusual operating conditions Unusual corrosive smoke Vapour Excessive oi
46. ul gt Work piece short warning it is provided by J5 7 pin on the BH interface board and it is connected to EL1008 1 interface 7 through 10C8 3 on filtering board 1 normal 0 short gt Water pressure inspection warning lack of water on the screen the water inspection sensor connects to EL1008 1 interface 8directly and the EL3162 interface 6 provides power for water inspection sensor 1 have water O lack of water 5 14Rotation counting gt The DC drive board provides rotation counting and it is connected to EL1512 interface 5 through DC drive adapter board 10C8 2 filtering board 5 15Current sampling gt The inverter board JK10 2 pin provides 0 10V analog for current sampling and it is connected to EL3162 interface 1 through 10C8 3 filtering board 5 16 Voltage sampling gt Torch voltage sampling by 1 pin of 4 pin aviation plug and Opin of 9 pin of 9 pin aviation plug through inductance board after high frequency filtering to BH board J1 1 pin and J1 3 pin gt Inverter voltage sampling by J3 pin and J5 pin on inverter high frequency arc ignition board through inductance board after high frequency filtering to BH board J1 4 pin and J1 6 pin gt The two voltage signals are on BH interface board and controlled by K8 relay 55 OTTO ARC SYSTEMS INC switch through EL2008 1 interface 4 notice temporary voltage is connected here and it is controlled b
47. uring welding process gt If arc stop phenomenon happens we have to differentiate it is the control 69 OTTO ARC SYSTEMS INC problem or inverter problem gt If you judge it is control problem please check if the Beckhoff modules run under normal condition or not gt Please ensure protective gas supply is under normal condition gt Please ensure the inverter start signal breaks off and current analog by oscillograph are under normal condition or not gt If there is no abnormal phenomenon our initial assessment is inverter problem B Check Hall sensor feedback signal B Check program if the value i e if the base peak value time is too small lt 0 1s if peak value and base value ratio is too big gt 3 1 if base value current is too small 30A B Check the inverter board version if it is the old version please try to combine R23 and capacitance 103 replace C9 by capacitance 104 to solve the problem 6 23 No downslope or downslope process abnormal gt Please refer to point 6 22 arc stop during welding process 6 24 Other occasional fault phenomenon gt For the other faults phenomena which are not listed here are considered occasional failure Please cut off the power gt 30s and restart the system Please contact Engineering Technology Center if you could not solve the problem 70 OTTO ARC SYSTEMS INC 7 Appendix gt Appendix includes OW Arc
48. utting There is also a danger of explosion if apparently harmless substances in closed containers are able to build up excess pressure when they are heated Take care to avoid fire hazards 9 9 Any kind of fire hazards must be avoided Flames can form e g when sparks are flying when parts are glowing or hot slag is present A constant check must be kept on whether fire hazards have been created in the working area Highly inflammable objects such as matches and cigarette lighters for example must not be carried in trouser pockets You must ensure that fire extinguishing equipment appropriate to the welding process is available close to the welding work area and that easy access is possible Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding begins It is not sufficient simply for the receptacle to be empty After a work piece has been welded it must only be touched or brought into contact with inflammable material when it has cooled down sufficiently Loose welding connections can completely destroy protective conductor systems of interior installations and cause fires Before beginning welding work ensure that the earth tongs are properly fixed to the work piece or welding bench and that there is a direct electrical connection from the work piece to the power source Noise exceeding 70 dBA can cause permanent hearing damage Wear suitable earmuffs or
49. y K6 relay switch though EL2008 1 interface 3 After rectification and ratio adjustment converter the voltage from 0 60V to 0 10V and provide to EL3162 interface 5 through J5 6 pin on BH interface board 5 17Control pendant gt In order to coordinate with OW Arc series power source we develop new control pendant model RTC06 The RTCO6 uses of DSP2407 as processor with 128x64 LCD display 4 7 input keyboard and RS232 communication gt The control pendant is totally different from RTCO1 There is only one button board for RTCOI control pendant button matrix function it has 6m cable connecting with the power source and communicate to CPU board through I2C communication mode after scanning and recognized by 8574 gt There are one button board and one control board for RTC06 control pendant matric function and it is connecting to the Beckhoff screen through RS232 communication mode after scanning and recognized by control board gt RCTO6 control pendant 14 pin AMP aviation plug each pin description 1 pin DC12V 2 pin DC12V 3 pin RS232 communication 4 pin RS232 communication receive 5 pin RS232 communication send 6 pin shielding 5 18Welding head control panel gt In order to compatible with various function on different head gt The head control penal is controlled by EL2008 2 interface 1 and interface 2 signal matrix scanning the EL1008 2 interface 1 interface 4 to receive button 56

SERVICE MANUAL - Otto Arc Systems

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