Castolin Castotig 2002 ( mw2000?)

[Newweldtig2002]

Guess what: today I got my fast diodes from China. Mounted them and the castotig functions as it should! Ignites, welds perfect. Question is of course how long the diodes will last. But till now I'm very pleased with these cheap replacements.

 

[Newweldtig2002]

And the resistors that I replaced with 9 watt models just get a little bit warm. I think I did a good job...

 

[TNM]

Hi All, I have the same issue as a couple pages back with the HF start not functioning. Have narrowed it down to the output coil of the ignition unit. Before I buy new, @brockenhammer do you still happen to have the one you mentioned?

​

 

[Perry77]

Hello,

I'm new on this forum so I will first introduce myself.
My name is Perry and I come from the Netherlands.
I like welding and fabrication and have always worked with metal.
Also I want to thank everyone here for all the fantastic information on this forum.

Well, let's go!...

I've just bought myself a nice present, a Lastek investig 2020 ac dc.
This machine was on my wishlist for quite a while so I'm very happy with it..
Even got the Tr 50-mc pulse remote control with it.

Checked it out and there are a few issues with it so if anyone has some suggestions what the problem can be that would be very much appreciated.

For starters the 2 capacitors (RIFA PME 271 Y 40/100/56/B and 22n Y2) on the circuit board where the ground goes trough ( NF224 4.070.474 V1.1A) on the machines right side are both blown but the machine still works.
So I'm going to replace those.

Other issue is that the up and down function doesn't work.
I haven't got the original torch with the machine but that isn't a problem as I will convert another torch or make a switch to get into the machines menu.
For now to look if the machine works I've rigged some wires to the connector.
I connected everything to the right connections (double-checked it 10 times) but no up/down..

All 8 led's on the top circuit board are ON.. so that's a good thing.

The machine also reacts when I connect the common (pin 9) to main welding current I1 (pin 5) I haven't welded with it yet but the previous owner said it worked ok.
I will check that of course when I have replaced the capacitors.

So if anyone can tell me what the issue with the up/down function can be that would be great!

 

[Dutch Welder]

Welcome here, Dutchman myself as well, from Oss.
Capacitors are probably for smoothing the ripple, I would replace them indeed.
Also, what do you want to get to function, a 2 button torch/or 2 buttons to adjust the menu, or are you actually wanting adjustable amps on the torch (with a slider or roller)
As I do believe the later function is not there on these machines, and most torches do not have enough wiring present (Binzel for example have a 3 wire cord in it as standard, so you can use them with a single button or a 2 button switch, and on some types of machines even ampcontrol, but as these machines require 5 wires to the torch for that (as you are essentially recreating a footpedal on your torch) those are special order from Binzel.

The 2 buttons should work, but as I recall the schematics of the pins were actually different on the Investig I had, as the plug itself was rotated 30 degrees, so the top pin (which in the manuals from Fronius is 1 was actually 2 on my Investig, or something like that)
And there is a wire bridge also present, which I believe is not shown on all diagrams, that would also make the buttons not working.
I believe from the top of my head 1-2 is up, 1 and 3 is down, but 3 and 4 should be connected machineside, but thats going wildly out off the top of my head, but I do know for sure there is a wire bridge present at the connector of my Magicwave.

 

[Perry77]

Thanks for the reply Dutch Welder, I had success! up/down function finally works!

At first I thought it must have something to do with pin 8, the torch ID but no..
Searched through all the post's here, then through all the electric diagrams again and then through all the post's again and I knew that I was missing something.. then my eye fell on a picture which Richard (also a member here) had posted. I had already seen it but now looked better at it and Eureka... I got it.. And thank you very much for mentioning the wire bridge, that and the picture did the trick in my brain.. all puzzles fell together..

About the torch, my plan was to get a 2 switch torch and then make a momentary centre off toggle switch similar to the mode selector so I can set my preferred settings in the menu.

But if the machine has the function of adjusting the amperage while welding then I'll order a torch with a 4 switch.. main current I1/crater fill current I2 and up/down..

So can anyone tell me if the magic wave 2000 has the ability of amperage control while welding?

I have another important question too.. before disassembling the machine to solder in the 2 new capacitors must I discharge something from the machine?

I know that some electric components can store a lot of energy..

 

[Perry77]

 

[Perry77]

I bridged them like this and connect to common..

 

[Dutch Welder]

I am not sure that's correct.

Did you get Magicwave manual with your Investig??

Variable amp control is not possible, but there are 2 amp settings available I believe.
But that would be a thing you would need to find out, the menu's and settings change a bit between different MW2000 copy versions.
A Fronius MW2000 has the 3 level menu structure, whereas the SAF PRestotig has all options in 1 menu, so I am not even sure that the genuine Fronius MW2000 has the SFS or STS setting that is needed for 2 amp levels and that is mentioned in the SAF manual.
I had a Castolin (yet another MW2000 in yet another package, Fronius sure where hammering them out for each and every other company) and that had the 3 level menu like a MW2000, but items within these 3 levels were in different places.
Codeprotection is menu 3 on Fronius, but was menu 1 on the Castolin.
So I'm guessing that options being available or even named the same depend on firmware version, or something like that.

When i'm in the workshop I'll have a quick check if the MW2000 has the STS/SFS settings, I just weld Ali on 1 amp setting, just moving a bit quicker.
And i'll check my torch pinout as well, but I am sure my torch only has 3 wires, and up/down in the menu works,so your 4 wires might do something, but I am not sure they do the right thing.
I really seem to remember the common on my torch is connected to i1, and the up button to 4, and the down button to 2

The SFS/STS settings are very briefly discussed in the SAF 200 Prestotig ACDC manual (which is another Magicwave copy) You can easily find a PDF for it (an not sure a links would be allowed)

But in short you set an amperage % in the menu, and then if you are welding a short tap on the 2nd torch button gives you that % of the amps you set on the main dial
If you set it at 50% and set the welding amps at 150 with a quick tap you get 75 amps, with the main amps at 100 you get 50.
This is not an amperage value, but a percentage of the amps you set with the main dial.
On my Prestotig I set it @ 75-85% for my Aluminium welding, get the piece up the temperature with the full set amps , then when things get hot a quick tap and then you have a slightly lower amperage to weld out the weld.
Another quick tap would give full amps, for when things get to cold for the weld to flow nicely.
STS is for 2 stroke, SFS for 4 stroke arc sequence.

You only need a 2 button torch for all the functions, the toggle swith is not necessary.
If you want buttons for menu changes on the machine then you can just add 2 momentary push buttons tot the same wires the torch buttons are connected to, but as you have plans for a 2 button torch those added buttons serve no function.

You can not enter any menu's when the machine is on already, so it has to be done at startup, so for me I usually had my torch at hand at startup and made adjustments if necessary, I never missed the ability to change those settings on the machine (but that would also be in a big part because you can only change settings on startup. If you could change settings while the machine was on it would be handy to just leave your torch were it was, and tap the buttons on the machine itself.

 

[boe]

AAHM.

Got a locked machine....
But with extended code sections(not only 0-9).

Got it running while dumping unbricked Eprom code into a new one.

I would not like to bother me while bruteforceing 0123456789ABCDEFHG i just get a working dump in it.

Now UP- error occurs.

But pre owner did a lot of mess with it.
Primary stage gone in smoke because of faulty Zeners and Shottky.
Now i got a full dump of proms to get further machine fixed..

Not sure if i can post it here because op IP.

the 93LC46 is containing it.....

If anybody is interested in progress:
Leave me a message.

Got tons of machines here which are ready to repair or are already repaired.

hi there
i got a locked castotig to...some joker was playing with it, and I have all the fun now.
fronius switzerland say the can't unlock it...new board....
my LC46 is in SO package....can i try your code?
thanks

 

[Jan-DIY]

Du hast Post.

 

[Perry77]

Hello Dutch welder, sorry for my late reaction.. I was away for quite a while, also was hospitalized for a while which wasn't that funny but here we are again and still going strong.. I want to thank you for all the information you send me. It was a great help for me. I just picked up working at it again and came to the conclusion that the hf function wasn't working at all.. Checked everything and it was the hf generator. So I ordered a new hf generator from Germany, installed it and everything is working like a charm now.. what a great machine it is.. such a stable arc.. thanks and greetings Perry.

 

[Macfun]

hi there
i got a locked castotig to...some joker was playing with it, and I have all the fun now.
fronius switzerland say the can't unlock it...new board....
my LC46 is in SO package....can i try your code?
thanks

The belgian Castolin representative (a nice old guy with tons of experience) told me that there is a master code for the 2002 (he has a 2002 AC/DC, too).
Of course he doesn't want to share it.
But I would believe him.
Fronius surely doesn't care of your Castotig. You should try Castolin.

 

[Para]

Hello everyone,

Y've a problem with my Fronius magic wave 2000, It no power on. When I switch to power on , no sound, no light, no panel, but I have 325V on DC bus.
No led on inside NMW20 and BPS20 alimentations cards.......

Do you have an idea of the problem ?

Regards

 

[Barking Mat]

@Para , have you read the first few pages 're fault finding ?

(Vous avez lu et compris les premier quelques pages ?)

Calling @HughF and @Dutch Welder

 

[Para]

Yes, @Barking Mat , I've read the firsts few pages.

I can't take the welding machine into MMA mode because command panel don't work.....

 

[Para]

I've just find infinit value resistor on the NMW20 card....

 

[Barking Mat]

I've just find infinit value resistor on the NMW20 card....

View attachment 388795

Bottom left one is an interesting colour too.

 

[Para]

Yes I have unmout these to test. They had good value mesured. But I will purchase the 3 resistors.

 

[Jan-DIY]

Top left resistor ladders often fail.
Afair something around 10k mini melf.