ESAB ES 300i User manual

Category
Measuring, testing & control
Type
User manual

This manual is also suitable for

Service manual
0463 424 001 GB 20180627
Valid for: serial no. 627-, 643-, 719-, 721-, 725-, 742-, 815-,
825-xxx-xxxx
ES300i, ET300i, ET300iP
Weldingpowersource
TABLE OF CONTENTS
0463 424 001 © ESAB AB 2018
1
READ THIS FIRST.................................................................................... 6
2
BEFORE STARTING SERVICE................................................................ 7
2.1 Service aid .............................................................................................. 7
2.2 ESAB Tools ............................................................................................. 7
3
INTRODUCTION....................................................................................... 8
3.1 Design structure of the power source.................................................. 8
3.2 Block diagram of ES 300i ...................................................................... 9
3.3 Block diagram of ET 300i/ET 300iP....................................................... 10
3.4 Circuit board positions .......................................................................... 11
3.5 Left and right sides of the power source ............................................. 11
4
WIRING DIAGRAM................................................................................... 12
4.1 Component description ......................................................................... 12
4.2 ES 300i, valid for serial no. 627-, 643-, 719-xxx-xxxx .......................... 14
4.3 ES 300i, valid for serial no. 725-, 742-xxx-xxxx ................................... 16
4.4 ES 300i, valid from serial no. 815-xxx-xxxx ......................................... 18
4.5 ET 300i and ET 300iP, valid for serial no. 721-, 742-xxx-xxxx............. 20
4.6 ET 300i and ET 300iP, valid from serial no. 815-xxx-xxxx................... 22
5
ERROR CODES........................................................................................ 24
5.1 Error code descriptions and service technician actions.................... 24
5.1.1 Err 1 – Temperature fault...................................................................... 24
5.1.2 Err 2 – Coolant fault ............................................................................. 25
5.1.3 Err 3 – Power supply fault .................................................................... 25
5.1.4 Err 4 – Communication fault................................................................. 26
5.1.5 Err 5 – Memory fault............................................................................. 26
5.1.6 Err 6 – Timing fault ............................................................................... 27
5.1.7 Err 7 – OCV fault .................................................................................. 27
5.1.8 Err 8 – Cooler hose disconnected ........................................................ 27
5.1.9 Measurement points and connectors on circuit boards........................ 28
6
TECHNICAL DATA ................................................................................... 29
7
SOFTWARE UPDATE AND CONFIGURATION....................................... 39
7.1 USB handling .......................................................................................... 39
7.1.1 Script files............................................................................................. 39
7.1.2 System software files ........................................................................... 39
7.2 Files location........................................................................................... 39
7.3 Application software update ................................................................. 40
7.3.1 Troubleshooting application software update ....................................... 40
7.4 Secondary bootloader update............................................................... 41
7.4.1 Troubleshooting secondary bootloader update .................................... 41
7.5 Software configuration .......................................................................... 42
7.5.1 Configuration of the power source according to product ordering
number .................................................................................................
42
TABLE OF CONTENTS
0463 424 001 © ESAB AB 2018
7.5.2 VRD On/Off .......................................................................................... 42
7.5.3 Cellulosic welding process regulator .................................................... 42
7.5.4 Set time ................................................................................................ 43
8
TROUBLESHOOTING .............................................................................. 44
8.1 Extracting power source data and status via USB flash drive .......... 44
8.1.1 Extracting welding statistics ................................................................. 44
8.1.2 Extracting a service log ........................................................................ 44
8.1.3 Interpreting the service log ................................................................... 44
8.1.3.1 Section 2 – db ls................................................................................ 45
8.1.3.2 Section 6 – active .............................................................................. 45
8.1.3.3 Section 7 – syslog ............................................................................. 46
8.1.3.4 Section 8 – log................................................................................... 46
8.1.3.5 Section 13 – cmdProxy 10 (active).................................................... 47
8.1.3.6 Section 14 – cmdProxy 10 (log) ........................................................ 47
8.1.3.7 Section 19 – cmdProxy 5 (active)...................................................... 47
8.1.3.8 Section 20 – cmdProxy 5 (log) .......................................................... 47
8.1.3.9 Section 25 – cmdProxy 2 (active)...................................................... 47
8.1.3.1
0
Section 26 – cmdProxy 2 (log) .......................................................... 47
8.2 Pre power up checks ............................................................................. 48
8.2.1 Visual Inspection .................................................................................. 48
8.2.2 Input module measurements................................................................ 48
8.2.3 Power Board 15AP1 measurements .................................................... 49
8.2.4 Booster Board 27AP1 measurements.................................................. 55
8.2.5 Measurements of interconnections between Power Board 15AP1 and
Control Board 20AP1 ...........................................................................
57
8.2.6 Measurements of interconnections between Booster Board 27AP1
and Control Board 20AP1 ....................................................................
58
8.2.7 Testing the electrolytic DC bus capacitor 15C1 .................................... 58
8.2.8 Restoring the power source after pre power up checks ....................... 59
8.3 Power up checks .................................................................................... 59
8.3.1 General................................................................................................. 59
8.3.2 Electrical test ........................................................................................ 60
8.3.2.1 EMC filter board 2AP1 measurement................................................ 60
8.3.2.2 Power Board 15AP1 measurements ................................................. 60
8.3.2.3 Control Board 20AP1 measurements................................................ 64
8.3.2.4 Booster Board 27AP1 measurements............................................... 67
TABLE OF CONTENTS
0463 424 001 © ESAB AB 2018
8.3.3 Electrical test – TIG specific functions (applicable only to ET 300i and
ET 300iP) .............................................................................................
68
8.3.3.1 Torch trigger function – Control Board 20AP1 measurements .......... 68
8.3.3.2 HF spark generation – TIG Board 10AP1 measurements................. 70
8.3.3.3 Gas valve control............................................................................... 71
8.4 Status indications on circuit boards .................................................... 72
8.4.1 Setting panel board 1AP1 – Indication of operational status................ 72
8.4.2 Control board 20AP1 – Indication of software run level ....................... 73
9
DISASSEMBLY AND REASSEMBLY ...................................................... 74
10
CALIBRATION OF VOLTAGE AND CURRENT....................................... 78
10.1 General USB procedure ......................................................................... 78
10.2 Tooling needed ....................................................................................... 78
10.3 Extracting present calibration parameters from power source ......... 78
10.4 Performing measurements .................................................................... 79
10.5 Calculate new calibration parameters .................................................. 79
10.6 Downloading new calibration parameters to power source............... 80
11
REPLACEMENT INSTRUCTIONS ........................................................... 81
11.1 Replacing the setting knob.................................................................... 81
11.2 Replacing the setting panel................................................................... 82
11.3 Replacing the encoder and the setting knob....................................... 83
11.4 Replacing the mains cable .................................................................... 84
11.5 Replacing the mains switch .................................................................. 86
11.6 Replacing the fan.................................................................................... 87
11.7 Replacing the welding output terminals (ES 300i) .............................. 88
11.8 Replacing the welding output terminals (ET 300i and ET 300iP) ....... 89
11.9 Replacing the current sensor................................................................ 90
11.10 Replacing the front panel (ES 300i) ...................................................... 91
11.11 Replacing the front panel (ET 300i and ET 300iP) ............................... 92
11.12 Replacing the EMCfilter board ............................................................. 93
11.13 Replacing the control board.................................................................. 94
11.14 Replacing the PFC inductor .................................................................. 96
11.15 Replacing the power board ................................................................... 97
11.16 Replacing the DC bus capacitor ........................................................... 100
11.17 Replacing the booster board................................................................. 101
11.18 Replacing the thermal switch on the secondary heat sink ................ 103
11.19 Replacing the secondary rectifier diode modules .............................. 104
11.20 Replacing the output inductor module and/or the transformer
module.....................................................................................................
105
11.21 Replacing the TIG board (applicable only to ET 300i and ET 300iP) . 108
11.22 Replacing the analogue remote A/D board .......................................... 109
12
IN-SERVICE INSPECTION AND TESTING.............................................. 110
12.1 General requirements ............................................................................ 110
TABLE OF CONTENTS
0463 424 001 © ESAB AB 2018
12.2 Periodic inspection and test.................................................................. 110
12.3 Cleaning instruction............................................................................... 110
12.4 After repair, inspection and test ........................................................... 114
12.5 Visual inspection .................................................................................... 115
12.6 Electrical test .......................................................................................... 116
12.7 Functional test ........................................................................................ 117
12.8 Test report ............................................................................................... 118
13
SPARE PARTS AND ACCESSORIES ..................................................... 119
Rights reserved to alter specifications without notice.
1 READ THIS FIRST
0463 424 001
- 6 -
© ESAB AB 2018
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.
The circuit boards are divided into numbered blocks. 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" chapter
in this manual.
This manual contains details of design changes that have been made up to and including
June 2018.
The manual is valid for:
ES300i with serial numbers 627-, 643-, 719-, 725-, 742-, 815-, 825-xxx-xxxx
ET 300i and ET 300iP with serial numbers 721-, 742-, 815-, 825-xxx-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300i, ET 300i and ET 300iP 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.
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
2 BEFORE STARTING SERVICE
0463 424 001
- 7 -
© ESAB AB 2018
2 BEFORE STARTING SERVICE
NOTE!
Follow the instructions in chapter "IN-SERVICE INSPECTION AND TESTING",
page110 when performing service work on the equipment!
2.1 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
Antistatic service kit
2.2 ESAB Tools
Checkmaster 9000
Ordering no. 0740 505 880
Checkmaster 9000 DC - calibrated
Ordering no. 0740 505 881
0460 868 880
ESAB test box TB1
For a list of tools needed to perform service, see section "Tooling needed", page78.
3 INTRODUCTION
0463 424 001
- 8 -
© ESAB AB 2018
3 INTRODUCTION
ES300i, ET 300i and ET 300iP are welding power sources intended for welding with coated
electrodes (MMA) and Live TIG welding.
3.1 Design structure of the power source
ES300i, ET 300i and ET 300iP are inverter based power sources with multi voltage
capability which can be run on single-phase and/or three-phase electric power depending on
region. The inverter is controlled by an FPGA (Field Programmable Gate Array) at 100 kHz
switching frequency. The power source control, including the welding process, gives
directions to the FPGA through a serial interface at 10 kHz. The power source control, panel
and remote units communicate using CAN Open.
The modules have the following main functions:
1 Setting panel module
The main function is for the user to define welding process settings.
2 Input module
The main function is to convert power line input voltage to stable voltage free from
conducted disturbances as required by the EMC directive.
10 TIG module (only in ET 300i and ET 300iP)
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.
15 Primary module
The main function is a full bridge inverter operating at a switching frequency of 100kHz.
IGBT transistors are used as switching elements.
16 Transformer module
The main function is to transform high voltage / low current to high current / low voltage.
19 Output inductor module
The main function is to supply the welding current. The module contains an inductor and a
current sensor.
20 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. Data can be extracted from the system using a USB flash drive connected to the
USB connector (located at the rear of the power source). The control board also contains
the FPGA which controls the inverter. From serial no. 815-xxx-xxxx the module also includes
an interface for communication with analogue remote control units.
27 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.
3 INTRODUCTION
0463 424 001
- 9 -
© ESAB AB 2018
3.2 Block diagram of ES 300i
3 INTRODUCTION
0463 424 001
- 10 -
© ESAB AB 2018
3.3 Block diagram of ET 300i/ET 300iP
3 INTRODUCTION
0463 424 001
- 11 -
© ESAB AB 2018
3.4 Circuit board positions
*
)
Only in ET 300i and ET 300iP
**
)
From serial no. 742-xxx-xxxx
***
)
From serial no. 815-xxx-xxxx
3.5 Left and right sides of the power source
The graphic below shows the meaning of "left" and "right" sides of the power source as
referred to throughout this manual.
4 WIRING DIAGRAM
0463 424 001
- 12 -
© ESAB AB 2018
4 WIRING DIAGRAM
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.
Wires/cables within modules are marked 100 - 6999.
Wires/cables between modules are marked 7000 - 7999.
Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors
XS1 - XS99 (S = socket), XT1 - XT99 (T = terminal).
Circuit boards within each module have names such as 20AP1 - 20AP99.
20 = module association, 1-69
AP = circuit board
1 = individual identification number, 0-99
Transistors within particular modules have identification numbers such as 15Q1 - 15Q99.
15 = module association, 1-69
Q = transistor
1 = individual identification number, 0-99
4.1 Component description
Component Description
1 Setting panel module Wire numbers 100–199
1AP1 Setting panel board
2 Input module Wire numbers 200–299
2AP1 EMCfilter board
2XS1 Connection block
2SW1 Mains switch
2L1-2L4 Ferrite ring cores (valid only for products with ordering no. 0445100880,
0445100883, 0445100900, 0445100903, 0445100920 and
0445100923)
10 TIG module (only in ET 300i and ET 300iP)
10AP1 TIG board (only in ET 300i and ET 300iP)
10TV1 HF TIG coil (only in ET 300i and ET 300iP)
10XS1 Cooler connector (only in ET 300i and ET 300iP)
10XS2 Torch connector (only in ET 300i and ET 300iP)
10YV1 Gas valve (only in ET 300i and ET 300iP)
15 Primary module Wire numbers 1500–1599
15AP1 Power board
15AP2 Surge protection board (from serial no. 742-xxx-xxxx)
15PM1 Power module
15PM2–15PM4 Secondary rectifier diode modules. Each module consists of two diodes.
15C1 DC bus capacitor
4 WIRING DIAGRAM
0463 424 001
- 13 -
© ESAB AB 2018
Component Description
15EV1 Fan
FU1 Fuse 1A
16 Transformer module
16T1 Main transformer
16SW1 Thermal switch transformer
19 Output inductor module
19L1 Output inductor
19CS1 Current sensor
20 Control module Wire numbers 2000–2099
20AP1 Control board
20AP2 Analogue remote A/D board (from serial no. 815-xxx-xxxx)
20L1–20L2 Ferrite ring cores
20XS1 Remote connector
20XS2 USB connector
20XS3 Fan socket connector
20XP1 Fan pin connector
20C1 Capacitor
27 Secondary module Wire numbers 2700–2799
27AP1 Booster board
27SW1 Thermal switch secondary heat sink
TR41 Current transformer
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
4 WIRING DIAGRAM
0463 424 001
- 14 -
© ESAB AB 2018
4.2 ES 300i, valid for serial no. 627-, 643-, 719-xxx-xxxx
4 WIRING DIAGRAM
0463 424 001
- 15 -
© ESAB AB 2018
4 WIRING DIAGRAM
0463 424 001
- 16 -
© ESAB AB 2018
4.3 ES 300i, valid for serial no. 725-, 742-xxx-xxxx
4 WIRING DIAGRAM
0463 424 001
- 17 -
© ESAB AB 2018
4 WIRING DIAGRAM
0463 424 001
- 18 -
© ESAB AB 2018
4.4 ES 300i, valid from serial no. 815-xxx-xxxx
4 WIRING DIAGRAM
0463 424 001
- 19 -
© ESAB AB 2018
4 WIRING DIAGRAM
0463 424 001
- 20 -
© ESAB AB 2018
4.5 ET 300i and ET 300iP, valid for serial no. 721-, 742-xxx-xxxx
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110
  • Page 111 111
  • Page 112 112
  • Page 113 113
  • Page 114 114
  • Page 115 115
  • Page 116 116
  • Page 117 117
  • Page 118 118
  • Page 119 119
  • Page 120 120

ESAB ES 300i User manual

Category
Measuring, testing & control
Type
User manual
This manual is also suitable for

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI