ESAB ES 180i Pro User manual

Service manual

0463 714 001 GB 20201008

Valid for: Serial No. HA017-, HA018-, HA019-, HA020-, HA026-,

HA027-xxxx-xxxx

ES150i, ES180i,

ES180iPro,ES200iPro,

ET180i, ET 200iP, ET 200iP Pro

TABLE OF CONTENTS

0463 714 001 © ESAB AB 2020

READ THIS FIRST

....................................................................................

4

BEFORE STARTING SERVICE

...............................................................

6

Service aid

..............................................................................................

6

ESAB tools

..............................................................................................

6

Recommended measuring devices

......................................................

6

INTRODUCTION

.......................................................................................

7

Design structure of the power source

..................................................

7

Welding equipment

................................................................................

8

Installation of MMA

.................................................................................

12

ERROR CODES/ERROR DESCRIPTIONS IN THE SERVICE LOG

.......

15

Error code descriptions and service technician actions

....................

15

WIRING DIAGRAM

...................................................................................

16

ES 150i, ES 180i

......................................................................................

18

ES 180i Pro, ES 200i Pro

........................................................................

19

ET 180i

.....................................................................................................

21

ET 200iP

..................................................................................................

22

ET 200iP Pro

...........................................................................................

23

Components description

.......................................................................

24

ES 150i, ES 180i .................................................................................. 24

ES 180i Pro, ES 200i Pro ..................................................................... 28

ET 180i, ET 200iP, ET 200iP PRO ....................................................... 33

TECHNICAL DATA

...................................................................................

34

ES 150i, ES 180i

......................................................................................

34

ES 180i Pro, ES 200i Pro

........................................................................

35

ET 180i

.....................................................................................................

37

ET 200iP

..................................................................................................

39

ET 200iP Pro

...........................................................................................

40

PANEL OPERATION INSTRUCTIONS

....................................................

42

Power source output high current regulation

.....................................

42

Hidden functions

....................................................................................

42

VRD ON and OFF

....................................................................................

43

TROUBLESHOOTING

..............................................................................

44

Fault tracing

............................................................................................

44

Visual Inspection

....................................................................................

44

Components testing

...............................................................................

44

Restoring the power source after pre power up checks

....................

46

Power up checks

....................................................................................

46

Advanced measurements

......................................................................

52

IN-SERVICE INSPECTION AND TESTING

..............................................

55

General requirements

............................................................................

55

TABLE OF CONTENTS

0463 714 001 © ESAB AB 2020

Periodic inspection and test

..................................................................

55

Cleaning instruction

...............................................................................

55

After repair, inspection and test

...........................................................

56

Visual inspection

....................................................................................

57

Electrical test

..........................................................................................

58

Functional test

........................................................................................

59

Test report

...............................................................................................

60

SPARE PARTS AND ACCESSORIES

.....................................................

62

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 714 001

- 4 -

READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit boards

are divided into numbered blocks, which are described individually in more detail in the

description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS AND

ACCESSORIES" chapter in this manual.

This manual contains details of design changes that have been made up to and including

January 2020.

Product Valid from serial

number

The manual is valid for:

ES 150i, Europe HA017-xxxx-xxxx

ES 180i, Europe HA018-xxxx-xxxx

ES 180i Pro, Europe HA019-xxxx-xxxx

ES 200i Pro, Europe HA020-xxxx-xxxx

ES 200i Pro, Middle East HA020-xxxx-xxxx

ES 200i Pro, India HA020-xxxx-xxxx

ES 200i Pro, SEA HA020-xxxx-xxxx

ET 180iP, Europe HA026-xxxx-xxxx

ET 200iP, India HA027-xxxx-xxxx

ET 200iP Pro, Europe HA027-xxxx-xxxx

ET 200iP Pro, Middle East HA027-xxxx-xxxx

ET 200iP Pro, India HA027-xxxx-xxxx

ET 200iP Pro, South East Asia HA027-xxxx-xxxx

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

The "ES 150i", "ES 180i", "ES 180i Pro", "ES 200i Pro", "ET 180iP", "ET 200iP" and

"ET200iPPro" are designed and tested in accordance with the standards stated in the

instruction manual. On completion of service or repair work, it is the responsibility of the

person(s) performing the work to ensure that the product still complies with the requirements

of the involved standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

READ THIS FIRST

0463 714 001

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CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

BEFORE STARTING SERVICE

0463 714 001

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BEFORE STARTING SERVICE

NOTE!

Follow the instructions in chapter "IN-SERVICE INSPECTION AND TESTING",

page55 when performing service work on the equipment!

Service aid

ESAB can offer a number of service tools that will simplify the service.

Antistatic service kit

Ordering no. 0740 511 001

The kit makes it easier to protect sensitive

components from electrostatic discharge.

Contents:

• A conductive mat (size 610×610mm /

24×24in.)

• A 1.5m (3.28ft) long ground cable with

a crocodile clip

• An adjustable wrist strap and cable with

a built-in protective resistor

ESAB tools

Tool Ordering number

ESAB test box TB1 0460 868 880

Checkmaster 9000

Checkmaster 9000 DC

Or resistive load with equal performance

Recommended measuring devices

• For safety test: Fluke 1503, Fluke 1507, Fluke 1577 and Fluke 1587.

• For measurements: Fluke 175, Fluke 177 and Fluke 179.

INTRODUCTION

0463 714 001

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INTRODUCTION

The "ES 150i", "ES 180i", "ES 180i Pro" and "ES 200i Pro" are an inverter-based power

sources intended for MMA (Manual Metal Arc) and TIG (Tungsten Inert Gas) welding.

The "ET 180i", "ET 200iP" and "ET 200iP Pro" are an inverter-based power sources

intended for MMA (Manual Metal Arc), TIG (Tungsten Inert Gas) welding and HF TIG (High

Frequency Tungsten Inert Gas) welding.

Design structure of the power source

The "ES 150i", "ES 180i", "ES 180i Pro", "ES 200i Pro", "ET 180i", "ET 200iP" and

"ET200iPPro" power sources are transistor-controlled, operating on the inverter principle. It

consists of a number of function modules. Each module has a module number, which is

always included as the first part of the name/identification of components in the module. The

modules have the following main functions:

The modules have the following main functions:

Setting panel module

The main function is for the user to define welding process settings.

Input module

The main function is to convert power mains input voltage to stable voltage free from

conducted disturbances as required by the EMC directive.

TIG module (valid for ET 180iP, ET 200iP Pro)

The main function of the TIG module is to produce high voltage, high frequency pulses, thus

enabling non-contact ignition of the electric welding arc.

Primary module

The main function is a full bridge inverter operating at a switching frequency of 97kHz. IGBT

transistors are used as switching elements.

Transformer module

The main function is to transform high voltage / low current to high current / low voltage.

Output inductor module

The main function is to supply the welding current. The module contains an inductor and a

current sensor.

Control module

This is the master of the system. The module handles the system status. It is a hub for

events/errors occurring in the system, and it collects meta-data on other boards in the

system.

Secondary module

The main function is to supply the welding current. This module contains an additional board

for increasing the output voltage at low currents, to enable higher welding performance for

cellulosic electrodes.

INTRODUCTION

0463 714 001

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Welding equipment

ES 150i, ES180i

1. Current display 6. VRD indicator

2. Positive probe 7. Thermal protection indicator

3. Negative probe 8. Current adjusting knob

4. Power cable 9. Welding selection mode button

5. Power switch 10. Plastic front panel

INTRODUCTION

0463 714 001

- 9 -

ES 180i Pro, ES 200i Pro

1. Current display 7. Thermal protection indicator

2. Positive output 8. Current adjusting knob

3. Negative output 9. Welding mode selection button

4. Power cable 10. Plastic front panel

5. Power switch 11. Aviation socket harness

6. VRD indicator

ES 150i, ES 180i, ES 180i Pro, ES 200i Pro

1. Handle 3. Rogue label

2. Left side panel

INTRODUCTION

0463 714 001

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1. Warning label 3. ESAB label

2. Left side panel

1. Rating plate 2. Bottom panel

INTRODUCTION

0463 714 001

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Rating plates: ES 150i, ES 180i

Rating plates: ES 180i Pro, ES 200i Pro

INTRODUCTION

0463 714 001

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Installation of MMA

Connection between Welder and Power Source

• ES 150i, ES 180i output voltage is 220-240VAC,50/60 Hz

• ES 180i Pro, ES 200i Pro output voltage is 90-260VAC,50/60 Hz

Installation of optional TIG torch

1. Remove the ground cable and the electrode holder from the weld output connections.

Install the ground cable to the positive(+) weld output connection.

2. Secure the ground clamp to the work piece.

3. Connect a regulator to a bottle of ARGON gas. Then connect the gas connection from

the TIG torch to the regulator.

4. Connect the TIG torch weld cable to the Negative(-) weld output connection

5. Set desired amperage on the amperage control knob on the front panel of the welder.

6. Turn on the input power switch on the welder.

INTRODUCTION

0463 714 001

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Schematic diagram ES 150i, ES 180i

Schematic diagram ES 180i Pro, ES 200i Pro

Parts Functions

START PROTECTION

CONTROL

To avoid equipment breakdown, the power source

measures the mains voltage when the power switch is

turned ON. To protect the power source, check that the

mains voltage is correct according to the rating (230 VAC)

before switching on the PFC.

RECTIFY AND FILTER Transfer the power from AC into DC.

INTRODUCTION

0463 714 001

- 14 -

Parts Functions

INVERTER Increases the frequency (97 kHz) and transfer the power

from DC into AC.

DECREASE VOLTAGE Changes the high voltage into lower to get high energy.

SECOND TIME RECTIFY Transfer the power from AC into DC.

CONTROL CIRCUIT Estimates the PWM signal and controls the entire process.

DRIVING CIRCUIT Controls the switch for inverter circuit.

AUXILIARY POWER SUPPLY Supply power for CONTROL CIRCUIT and DRIVING

CIRCUIT.

FEEDBACK CIRCUIT Gets sampling from the output, sends feedback to

CONTROL CIRCUIT.

PFC Power factor correction.

ERROR CODES/ERROR DESCRIPTIONS IN THE SERVICE LOG

0463 714 001

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ERROR CODES/ERROR DESCRIPTIONS IN THE SERVICE LOG

The error code is used to indicate that a fault has occurred in the equipment. Errors are

indicated by the text "Err" and the error code number flashing alternately in the power source

display.

Error code descriptions and service technician actions

Suggested service technician actions for error codes are described in the sub-sections

below. Measurement points and connectors on the circuit boards, referred to in the text are to

be found in section "TROUBLESHOOTING", page44

 E01  Thermal protection

1. Turn off the mains power supply to reset the unit.

2. If the error persists, take actions according to Troubleshooting procedures.

WIRING DIAGRAM

0463 714 001

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WIRING DIAGRAM

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

The power source consists of a number of function modules. The circuit board and

component names and the wire numbers in the wiring diagram, show to which module each

board/component/wire belongs. The function modules, circuit boards and components are

listed in the component description below.

Input rectifier and Filter circuit

Primary rectifier Converts AC to DC.

Electrolytic capacitor Smooths the DC voltage.

Inverter circuit

IGBT Converts low frequency DC to

48kHz high frequency AC.

Main transformer Converts HF high voltage to HF

low voltage power.

WIRING DIAGRAM

0463 714 001

- 17 -

Secondary rectifier

Secondary diode (FRD) Converts HF AC to HF DC

power.

NOTE!

IGBT and FRD look very similar. Read the descriptions carefully before you do

repair to make sure you do not use the wrong part.

WIRING DIAGRAM

0463 714 001

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ES 150i, ES 180i

Valid from serial number: HA017-xxxx-xxxx, HA018-xxxx-xxxx

WIRING DIAGRAM

0463 714 001

- 19 -

ES 180i Pro, ES 200i Pro

Valid from serial number: HA019-xxxx-xxxx, HA020-xxxx-xxxx

WIRING DIAGRAM

0463 714 001

- 20 -

Valid from serial number: HA019-xxxx-xxxx, HA020-xxxx-xxxx

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