ESAB ES 300i User manual

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

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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

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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

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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

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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

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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

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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

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3.2 Block diagram of ES 300i

3 INTRODUCTION

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3.3 Block diagram of ET 300i/ET 300iP

3 INTRODUCTION

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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

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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

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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

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4.2 ES 300i, valid for serial no. 627-, 643-, 719-xxx-xxxx

4 WIRING DIAGRAM

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4 WIRING DIAGRAM

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4.3 ES 300i, valid for serial no. 725-, 742-xxx-xxxx

4 WIRING DIAGRAM

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4 WIRING DIAGRAM

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4.4 ES 300i, valid from serial no. 815-xxx-xxxx

4 WIRING DIAGRAM

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4 WIRING DIAGRAM

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4.5 ET 300i and ET 300iP, valid for serial no. 721-, 742-xxx-xxxx

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ESAB ES 300i, ET 300i, ET 300iP User manual

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