Esab Ultrarex UXD-P2000 Upgrade Project

Enjoy

So the inductor got fried because of over current.

1. Check if C12 failed and is shorted out
2. Check whatever is connected to the 24V "TO/FROM NC" for something that might draw too much current. 0.6A is not exactly a lot. Maybe you connected some new hardware to that?

-Remove burned inductor, solder a thin piece of wire instead.
-Find the smallest laptop adapter you can that has 19 or 19.5 or 20V output, anything above 1A is OK. Used original adapters only, not cheap cr@p.
-Unscrew V2 rectifier near the transformers,
--find the + wire, unplug it and wire it to + of laptop adapter
--find the - wire, unplug it and wire it to - of laptop adapter
--mount the rectifier back in place with the 2 remaining wires intact
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The added relay for Torch ON, check the A1 and A2 pins, should not be 0 resistance, if it is replace the relay, reverse the existing wires going to A1 and A2.
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Unplug the Mesa 7i77 output connector, plug it to other outputs.
Edit the hal file to reflect the changed outputs for enable, torch, etc
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This is the 4th time i am writing this same exact stuff, so no more whatsapp.

Esaber wrote:

As I said before we measured the voltage on the V2 +/- wires going to the board and we do see 19v DC coming out of the rectifier but on V1 we see 72v DC !!

That is all good, 72V on V1 is for powering the servo drives, from the big toroidal transformer.
The V2 19V is from the small toroidal transformer.
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Off topic,
I might take on building 2 to 4 custom welding and cutting cnc machines, so whatever spare time i had, i will have no more. For 2 already started gathering parts today as after having a final chat with customer, i have 3-4 days to build a working prototype of a 4 axis cnc welding machine.
Oh hell .....
But i do check the forum every time i go for a coffee.