ESAB FP-200 User manual

Firepower MST-200,

Firepower FP-200

Service manual

0463 803 001  GB  20210426

Valid for: Serial number: HA105-,

HA106-xxxx-xxxx

Ordering no. Product Notes Serial no.

1444-3200

1444-1200

Firepower MST-200

Firepower FP-200

Europe, CE HA105-, HA106-xxxx-xxxx

TABLE OF CONTENTS

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1 READ THIS FIRST

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

5

1.1 Read this first

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

5

2 BEFORE STARTING SERVICE

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

6

2.1 Before starting the service

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

6

2.2 Recommended measuring devices

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

6

2.3 ESAB tools

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

6

3 INTRODUCTION

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

7

3.1 Introduction

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

7

3.2 Design structure of the power source

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

7

3.3 FP-200

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

8

3.4 MST-200

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

9

3.5 FP-200, SMT-200

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

10

3.6 Rating plates: FP-200

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

11

3.7 Rating plates: MST-200

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

11

3.8 Installation of MIG

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

12

3.9 Connections

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

12

3.10 Schematic diagram FP-200, MST-200

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

13

3.11 Parts table

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

13

4 ERROR CODES

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

14

4.1 Error codes

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

14

4.2 Thermal error

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

14

4.3 Exception display description

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

14

5 WIRING DIAGRAM

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

15

5.1 FP-200, MST-200

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

17

5.2 Component description

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

18

6 TECHNICAL DATA

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

23

7 PANEL OPERATION INSTRUCTIONS

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

26

7.1 Panel operation instructions

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

26

8 TROUBLESHOOTING

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

27

8.1 Fault tracing

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

27

8.1.1 Pre power up checks

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

27

8.1.2 Visual Inspection

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

27

8.1.3 Components testing

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

27

8.1.4 Restoring the power source after pre power up checks

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

30

8.2 Power up checks

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

31

8.2.1 Position voltage and waveform test

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

31

8.2.2 Power on tests

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

33

8.3 Advanced measurements

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

43

8.3.1 IGBT (Q1-Q6) GE drive waveform test

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

43

8.3.2 Main transformer secondary waveform test

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

44

9 IN-SERVICE INSPECTION AND TESTING

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

45

9.1 General requirements

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

45

9.2 Periodic inspection and test

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

45

9.3 Cleaning instruction

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

45

TABLE OF CONTENTS

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9.4 After repair, inspection and test

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

46

9.5 Visual inspection

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

46

9.6 Electrical test

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

47

9.7 Functional test

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

48

9.8 Test report

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

49

SPARE PARTS AND ACCESSORIES

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

50

1  READ THIS FIRST

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1 READ THIS FIRST

1.1 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

2021.

The manual is valid for:

• "Firepower FP-200" with serial number HA105-xxxx-xxxx

• "Firepower MST-200" with serial number HA106-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 "Firepower FP-200" and "Firepower MST-200" 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.

2  BEFORE STARTING SERVICE

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2 BEFORE STARTING SERVICE

2.1 Before starting the service

NOTE!

Follow the instructions in Section 9 "IN-SERVICE INSPECTION AND TESTING", page

45, when performing service work on the equipment!

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

2.2 Recommended measuring devices

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

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

2.3 ESAB tools

Tool Ordering number

ESAB test box TB1 0460 868 880

Checkmaster 9000

Checkmaster 9000 DC

Or resistive load with equal performance

3  INTRODUCTION

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3 INTRODUCTION

3.1 Introduction

Firepower MST-200 is a self-contained single phase, multi process welding system that is capable of

performing MIG (GMAW/FCAW), STICK(SMAW) and LIFT TIG (GTAW) welding.

Firepower FP-200 is a self-contained single phase welding system that is capable of performing MIG

(GMAW/FCAW) welding.

The FP-200 and MST-200 power sources are equipped with an integrated wire feed unit, digital

voltage and amperage meters, and other features. The FP-200 and MST-200 power sources have a

single inverter tube, front panel PCB, wire feed control PCB and a main control PCB.

3.2 Design structure of the power source

The modules have the following main functions:

Front panel PCB

For example user function selection, parameter setting, timing control instruction integration control,

including abnormal signal detection and control.

Wire feed control PCB

Adjust and control the wire feeder according to the panel instruction, voltage detection and feedback,

and control the characteristics of each function mode.

Main control PCB

Including input rectifier, filter, inverter, variable voltage, output rectifier and the whole main loop control

integration, at the same time integrated PWM control circuit, current detection, thermal protection

circuit.

3  INTRODUCTION

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3.3 FP-200

FP-200

1 Spool gun indicator 14 Right button

2 MIG indicator 15 Voltage display

3 Wire speed/current display 16 Inductance indicator

4 Left button 17 2T/4T indicator

5 Wire feeder adjust knob 18 Thermal/warning indicator

6 Torch connector 19 Wire shaft

7 Positive output connector 20 Wire feeder

8 Torch control connector 21 Manual wire feed button

9 Polarity switching cable 22 Gas input connector

10 Negative output connector 23 Voltage switch

11 Voltage adjust knob 24 Power line

12 Right button 25 Power switch

13 Voltage adjust knob

3  INTRODUCTION

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3.4 MST-200

MST-200

1 Spool gun indicator 14 Right button

2 Wire speed/current display 15 Remote control indicator

3 MIG indicator 16 Inductance indicator

4 MMA indicator 17 2T/4T indicator

5 TIG indicator 18 Voltage adjust knob

6 Left button 19 Thermal/warning indicator

7 Wire feeder adjust knob 20 Wire shaft

8 Torch connector 21 Wire feeder

9 Positive output connector 22 Manual wire feed button

10 Torch control connector 23 Gas input connector

11 Polarity switching cable 24 Voltage switch

12 Negative output connector 25 Power line

13 Voltage adjust knob 26 Power switch

3  INTRODUCTION

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3.5 FP-200, SMT-200

1 Handle 4 Right logo sticker

2 Logo sticker 5 Nameplate

3 Warning sticker 6 Left logo sticker

1 Warning sticker 2 MMA/TIG welding parameter (MST-200)

3  INTRODUCTION

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3.6 Rating plates: FP-200

3.7 Rating plates: MST-200

3  INTRODUCTION

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3.8 Installation of MIG

1 Gas and gas meter 4 Ground cable

2 Output cable 5 Welding power source

3 Torch 6 Input power

Connection between welder and the power source

• input voltage of FP-200 and MST-200 is 120/230V, 50/60 Hz.

3.9 Connections

1) Install the regulator on the gas cylinder and connect the gas hose to the regulator and the gas

input connector.

2) Choose the corresponding voltage on the rear panel switch and connect the plug to the 120/230 V

socket.

3) Connect the MIG torch and the 8 pin control connector.

4) Connect the ground cable to the negative output connector.

5) When welding flux core wire, connect the polarity switching cable to negative connector and the

ground cable to the positive connector.

6) To weld with flux core wire, connect the polarity switching cable to the negative connector, and the

ground cable to positive connector.

3  INTRODUCTION

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3.10 Schematic diagram FP-200, MST-200

3.11 Parts table

Parts Functions

Power input Choose the corresponding voltage on the rear

panel switch and connect the plug to the 120/230

V socket.

Input rectifier Converts input alternating current to direct

current.

Filter Filters direct current.

Inverter Converts direct current to 43 kHz alternating

current.

Voltage transformer Converts high voltage to low voltage to obtain

higher power.

Output rectifier Converts output alternating current to direct

current.

Output filtering Filters output direct current.

Output Output welding current through positive and

negative electrodes.

Output feedback Gets feedbacks on welding.

Sequential control Function control, control function module and

circuit execution.

PWM control Pulse width modulation control.

Input testing When starting the machine, the input voltage is

detected to prevent the machine from being

damaged due to the wrong voltage input.

Auxiliary power Supplies power to each control section.

Over current protection The current signal is measured and the power

source is protected from over current.

Thermal protection Temperature is measured by a temperature

sensor, and the power source is switched off

when it reaches too high temperatures.

4  ERROR CODES

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4 ERROR CODES

4.1 Error codes

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.

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 8 "TROUBLESHOOTING", page 27.

4.2 Thermal error

If the protection light is on, the power source might be overheated.

1) Wait until the temperature drops and the protection light turns off, the power source will work and

you can return to welding.

2) If the light does not turns off, follow troubleshooting procedure.

4.3 Exception display description

Display Description

Err Vol Input voltage is inconsistent with selected

voltage.

Ovr Cur Over current has happened and over current

protection is active.

Err Sht Output short circuit has happened and output

short circuit protection is active.

5  WIRING DIAGRAM

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5 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

43 kHz high frequency AC.

Main transformer Converts HF high voltage to HF

low voltage power.

5  WIRING DIAGRAM

0463 803 001

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Secondary rectifier

Secondary diode (FRD) Converts HF AC to HF DC

power.

NOTE!

IGBT and FRD look similar.

Read the descriptions carefully before you do repair to make sure you do not use the

wrong part.

5  WIRING DIAGRAM

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5.1 FP-200, MST-200

5  WIRING DIAGRAM

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5.2 Component description

FP-200, MST-200

1 Front panel PCB 4 Hall sensor

2 Filtering PCB 5 Main control PCB

3 Control PCB 6 Fan

5  WIRING DIAGRAM

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Main control PCB

1 Main relay 10 Connector, Main control PCB to front panel

PCB

2 Doubling voltage control relay 11 Connector, Main control PCB to Control PCB

3 Primary rectifier bridge 12 Connector, Main control PCB to control PCB

4 IGBT upper bridge arms 13 Connector with hall sensor

5 Drive transformer 14 Connector with NTC wire

6 IGBT lower bridge arms 15 Main transformer

7 Capacitors 16 NTC wire

8 AC contactor 17 Output rectifier tube

9 Auxiliary transformer

5  WIRING DIAGRAM

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Control PCB board

1 Connector, control PCB with front panel OCB 6 Connector, Gas valve control

2 Connector, control PCB with inductance

adjusting wire

7 +15V Power supply from Main control PCB

3 Power line for wire feeder and manual wire feed

motor

8 Connector, Torch switch control

4 CFET of wire feeder 9 Connector, Output voltage feedback

5 Connector, Main control PCB to Control PCB

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