ESAB EMP 205ic AC/DC User manual

EMP 205ic AC/DC
ESAB
Brand
ESAB
Model
EMP 205ic AC/DC
Category
Welding System
Type
User manual
0463 705 001 20190927 Valid for: serial no. 937-xxx-xxxx
EMP 205ic AC/DC
Service manual
TABLE OF CONTENTS
0463 705 001
READ THIS FIRST ..................................................................................................................... 4
BEFORE STARTING SERVICE ...................................................................................................5
Service aid ................................................................................................................................................5
ESAB Tools.................................................................................................................................................5
INTRODUCTION ....................................................................................................................... 6
Equipment ................................................................................................................................................6
ERROR CODES .......................................................................................................................... 7
Error code fault isolation .....................................................................................................................7
ERR 001 - TEMPERATURE FAULT ...............................................................................................7
ERR 002 - TEMPERATURE FAULT ...............................................................................................7
ERR 003 - SYSTEM LOCKED POWER FAULT ...........................................................................8
ERR 004 - SYSTEM LOCKED VRD FAULT..................................................................................9
ERR 005 - PS LOCAL FAULT SERVICE REQUIRED ..................................................................9
ERR 006 - SET PCBA-20AP1 SW2.2 ON ...................................................................................9
ERR 007 - Reserved .......................................................................................................................9
ERR 008 - VOLTAGE FAULT SERVICE REQUIRED ................................................................ 10
ERR 009 - LOW INPUT ................................................................................................................ 10
ERR 010 - Reserved .................................................................................................................... 10
ERR 011 - DEFAULT RESET UNCONFIRMED .......................................................................10
ERR 012 - COMMUNICATION FAULT .....................................................................................11
ERR 013 - Reserved .................................................................................................................... 11
ERR 014 - SENSOR FAULT SERVICE REQUIRED .................................................................. 11
ERR 015 – HARDWARE ERROR ............................................................................................... 11
ERR 016 – AC/DC TEMP TRIP ................................................................................................... 11
ERR 017-019 – Reserved ..........................................................................................................12
ERR 020 – GRAPHICS ERROR .................................................................................................. 12
ERR 021 – GRAPHICS ERROR .................................................................................................. 12
ERR 022 – WRITE MEM Err .......................................................................................................12
ERR 023 – READ MEM Err RETRIEVE FACTORY ................................................................. 12
ERR 024-029 – Reserved ..........................................................................................................12
ERR 030 - FIRMWARE ERROR .................................................................................................. 12
ERR 031 – NVRAM CHECKSUM BAD .................................................................................... 12
DIAGRAM ...............................................................................................................................13
TECHNICAL DATA ..................................................................................................................15
EMP 205ic AC/DC ................................................................................................................................ 15
SOFTWARE UPDATE AND SYSTEM CALIBRATION .............................................................17
TABLE OF CONTENTS
0463 705 001
TROUBLESHOOTING .............................................................................................................18
Power-supply side component modules details ..................................................................... 18
Service modules part numbers............................................................................................. 19
Design structure of the power supply circuit .................................................................. 20
Block diagram .............................................................................................................................20
Subassembly description, location, test points, removal .....................................................21
User interface (UI) - PCB1/1AP1 ............................................................................................ 21
UI disassembly ............................................................................................................................ 21
Main power switch (SW1) and Thermal breaker (CB1) ................................................. 22
Main power switch (SW1) and Thermal breaker (CB1) disassembly ........................ 23
EMI Filter Enclosure ................................................................................................................... 23
EMI Filter Board disassembly ................................................................................................. 24
Main power board - PCB2/15AP1......................................................................................... 25
Main power board (PCB2/15AP1) disassembly ...............................................................25
Control board - PCB3/20AP1 .................................................................................................27
Control board (PCB3/20AP1) disassembly ........................................................................29
Main transformer - T1 ............................................................................................................... 29
AC/DC module - PCB8/15AP3 ...............................................................................................30
AC/DC module disassembly...................................................................................................30
Output inductor - L2 ................................................................................................................. 33
IPS PCB assembly - PCB4/15AP2 ........................................................................................... 34
IPS board disassembly .............................................................................................................35
HF starter PCB assembly - PCB9/15AP4 ............................................................................. 36
HF starter board disassembly ................................................................................................36
HF bypass board - PCB10/15AP5 ..........................................................................................37
Current sensor - CT .................................................................................................................... 38
Cooling fans - M2, M3 ...............................................................................................................39
Cooling fans disassembly .......................................................................................................39
Gas valves - SOL1, SOL2 ...........................................................................................................41
System fault troubleshooting ......................................................................................................... 41
Preliminary functional checks ............................................................................................... 42
LED status ..................................................................................................................................... 44
Power source does not power up ........................................................................................ 44
No weld output ..........................................................................................................................49
Poor welds .................................................................................................................................... 53
No UI response ............................................................................................................................56
User Interface Main Encoder Knob press does not work ............................................ 57
No gas output ............................................................................................................................. 58
Remote control or torch trigger check ...............................................................................59
SPARE PARTS AND ACCESSORIES ........................................................................................60
READ THIS FIRST
0463 705 001
-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.
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.
The manual is valid for:
• EMP 205ic AC/DC with serial number 937-xxx-xxxx
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for safety and function, of the
specic set-up, lies with the integrator.
The EMP 205ic AC/DC 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.
BEFORE STARTING SERVICE
0463 705 001
-5-
BEFORE STARTING SERVICE
Service aid
ESAB can oer 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
ESAB Tools
CAUTION
HF-starts can permanently damage test equipment, caution should be observed when testing
the EMP205.
Checkmaster 9000
Ordering no. 0740 505 880
Checkmaster 9000 DC - calibrated
Ordering no. 0740 505 881
0460 868 880
ESAB test box TB 1
INTRODUCTION
0463 705 001
-6-
INTRODUCTION
The ESAB REBEL EMP 205ic AC/DC product is a new generation of multi-process (MIG/Stick/TIG:AC or DC) welding power
sources.
All Rebel power sources are designed to match the needs of the user. They are tough, durable, and portable, providing
excellent arc performance across a variety of welding applications.
The EMP 205ic AC/DC features a 4.3 in. (11 cm) color TFT (Thin Film Transistor) user interface (UI) display which provides
quick and easy selection of weld process and parameters, suitable for both newly trained and intermediate-level users. For
more advanced users, any number of functions could be introduced and customized to give maximum exibility.
Equipment
The ESAB EMP 205ic AC/DC power source is supplied with:
• ESAB EMP 205ic AC/DC power source
• ESAB MXL 201 MIG torch, 3 m (10 ft) with contact tips M6 for 0.8 mm and 1.0 mm
• ESAB SR-B 26 TIG Torch with accessories
• Gas hose, 4.5 m (14.8 ft), Quick connector
• MMA welding cable kit 3 m (10 ft)
• Return cable kit 3 m (10 ft)
• Drive roll
0.6 / 0.8 mm (0.023 in. / 0.030 in.) Cored, Steel and Stainless wire (installed on drive system)
0.8 / 1.0 mm (0.030 in. / 0.040 in.) Cored, Steel and Stainless wire (in accessory box)
• Guide tube
1.0 mm - 1.2 mm (0.040 in. - 0.045 in.) (installed on drive system)
0.6 mm - 0.8 mm (0.023 in. - 0.030 in.) (in accessory box)
• Mains cable 3 m (10 ft), xed with plug
• Safety manual
• USB with Operator's Manual
• Material thickness guide
ERROR CODES
0463 705 001
-7-
ERROR CODES
!!
WARNING!
Bus voltage of 400 V DC will be present on the heatsinks of the main power board
while unit is on. Wait 40 seconds after removing power before handling.
Error code fault isolation
This section is for solving error codes appearing at power-up.
Faults resulting from user interaction or only during welding can be isolated using procedures found in other sections
identied below.
ERR 001 - TEMPERATURE FAULT
This section is to isolate a false digital temperature fault. This fault monitors the PFC heatsink, main Inverter heatsink and
main transformer.
Make sure that the system has at least 1 hour in un-powered state to cool down before following these instructions.
A. With power applied, measure with DVMM the voltage between Control Board 20AP1 CN19 pins 6 and 4 (ground).
If voltage is less than 0.25 V DC replace Control Board 20AP1; otherwise go to Step B.
B. (Hint: To prevent pin damage, use at screwdriver to evenly remove wide Control Board 20AP1 connectors).
Remove AC Mains power, remove Control Board 20AP1, and disconnect 15AP1 CN7 from Main Power board
(PCB2/15AP1). Measure resistance across CN7 plug. If it is not ~10K ohms, inspect plug connection or replace Mains
Transformer T1, refer section "Main transformer - T1" on page 28; If measurement is ~10K ohms, go to Step C.
C. Inspect Control 20AP1 CN19 cable assembly and measure resistance for continuity between pin 6 of each end of
the cable, it should be ~0 ohms; If cable reads 0 ohms, inspect for dust or replace faulty 15AP1 Main Power board
(PCB2/15AP1); Otherwise repair/replace the Cable.
ERR 002 - TEMPERATURE FAULT
This section is to isolate a false output diode temperature fault.
Make sure that the system has at least 1 hour in un-powered state to cool down before following these instructions
A. With power applied, measure with DVMM at 20AP1 Control board CN19 pin 3 to pin 4 (Ground). If DC voltage
measurement is between 1.0 - 2.0 Vdc, then replace 20AP1 Control PCB; otherwise go to Step B.
B. Turn o power, unplug Rebel from AC mains power, disconnect CN14 from 20AP1 Control Board, measure resistance
across CN3 connector leads pin 3 and pin 4 on 15AP3 AC/DC Board. Please refer image below for measurement.
10k ± 2k
Pin 3
Pin 4
Figure 1. Reference for Err 002
ERROR CODES
0463 705 001
-8-
If measured value is 10K +/- 2K ohms at 25 °C ambient, then there is a cable issue, go to Step C.
If measured value is not 10K +/- 2K, replace 15AP3 AC/DC Board.
C. Measure continuity between 15AP3 CN3 PCBA connector leads on the PCB and 20AP1 CN14 connector plug pins
3 and pin 4. If the continuity is bad or intermittent, inspect wire harness #14739 for damage and replace it.
ERR 003 - SYSTEM LOCKED POWER FAULT
This section is to isolate a persistent low voltage fault at power up when the unit is in standby or idle mode. This fault can
temporarily happen under heavy load conditions, in which case, is a warning that the 400 V DC bus voltage has momen-
tarily gone below 350 V DC due to input mains voltage sag caused by low AC input voltage, long line length or thin gauge
extension cords, causing a excessive voltage drop before reaching the Rebel. For the service personnel having this fault
continuously at power up follow the below procedure.
A. Caution High Voltage Measurement: With power applied, measure on 15AP1 with DVMM the DC voltage between
heat sink terminal at D50 and R88 resistor lead. See"Figure 2. DC BUS Voltage Test Point on Power Board" on page
8. If voltage measured is 400 V DC +/- 10V go to Step B, if not go to section MACHINE DOES NOT POWER UP, (6)
IPS CHECK.
B. With power applied, measure at Control Board 20AP1 CN19 pin 5 w.r.t. pin 4 (Gnd). If the DC voltage is less than
0.25V and the fault Error 4 persist, replace Control Board 20AP1; otherwise go to Step C.
C. (Hint: To prevent pin damage, use at screwdriver to evenly remove wide Control Board 20AP1 connectors). Remove
AC Mains power, remove Control Board 20AP1. With 20AP1 removed, check continuity of pins 4 and 5 end-to-end
across cable assembly #14737. If cable continuity is good, replace 15AP1 Main Power board (PCB2/15AP1) otherwise
repair/replace cable assembly.
400 Vdc ± 10 V
Figure 2. DC BUS Voltage Test Point on Power Board
ERROR CODES
0463 705 001
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ERR 004 - SYSTEM LOCKED VRD FAULT
This section isolates failure of output (OKC) voltage being too high when VRD is enabled. It applies to Australia Models only.
VRD indication in MMA mode on other models indicate improper dip switch settings. Please see "Figure 3. Control Board
SW2 Positions" on page 9 for proper switch positions for non-Australian models and Australian models.
A. Check proper switch position (SW2), check latest software is loaded.
B. If Step A checks out OK, then replace 20AP1 Control Board.
Figure 3. Control Board SW2 Positions
ERR 005 - PS LOCAL FAULT SERVICE REQUIRED
This section isolates Low Voltage of Internal Power Supply, IPS Error. This error code gets set when the 24 V DC supply is less
than 22.5 V DC. This can happen from overload from a faulty peripheral, PCBA or wire feeder.
A. With power applied, measure with a DVMM 20AP1 CN2 between pins 1 and pins 7. If 23-24 V DC is present replace
20AP1 Control PCB. Otherwise go to step B.
B. Turn o power, disconnect the following 20AP1 connectors; CN7, CN9, CN10, CN11, CN13, CN14. Reapply power, if
the fault clears restore connectors one at a time to isolate bad subassembly (fan, solenoid, motor, etc). Otherwise
go to Step C.
C. Turn o power, remove 20AP1 CN17 and CN19 of the Control PCB. Reapply power, if the fault clears replace 20AP1
Control Board; otherwise go to Step D.
D. Turn o power, remove 20AP1 CN2 of the Control PCB. Reapply power, measure the voltage of plug sourcing 20AP1
CN2 between pins 1 and 7. If the voltage is not ~24 V DC replace 15AP2 IPS Board. Otherwise replace 20AP1 Control
Board.
ERR 006 - SET PCBA-20AP1 SW2.2 ON
This section isolates VRD Conguration Error. This Error happens when the VRD enable switch 20AP1 S2.1 is enabled but
VRD Capability switch 20AP1 S2.2 is disabled. Please see "Figure 3. Control Board SW2 Positions" on page 9, for proper
switch positions of S2 for non-VRD use.
A. Check proper switch position (all o for non-Australian models), exercise the switch leaving in proper position,
check latest software is loaded.
B. If Step A checks good, replace 15AP1 Control Board.
ERR 007 - Reserved
ERROR CODES
0463 705 001
-10-
ERR 008 - VOLTAGE FAULT SERVICE REQUIRED
This error occurs when the OCK terminal voltage is not properly sensed when a voltage is expected to be present, for instance
when in MMA mode and the output is enabled. It takes 10 continuous second of no output to trip this fault. First attempt
a software update to the latest version before troubleshooting this fault.
A. Apply power, place unit in MMA mode, observe D33 on 20AP1 Control Board (PCB3/20AP1) while enabling the out-
put. Verify the green LED ashes bright momentarily and remains on dimly. If the LED ashes or stays on brightly
go to Step B. If the LED does not ash replace 20AP1 Control Board.
B. With MMA enabled, measure the across OKC +/- terminals. If the voltage is greater than 50 V DC remove AC power
with SW1 and perform the following continuity cable checks: If voltage is ~0 V DC go to section 'NO WELD OUTPUT',
step 9 to 13.
Check continuity of cable connection at PCB3/20AP1 CN1 pin 1 to XS1 (OKC+).
Check continuity of cable connection at PCB3/20AP1 CN1 pin 2 to 15AP3 TP39.
Check continuity of cable connection at 20AP1 CN15 pin 1 to XS2 (OKC-).
If any are not ~0 ohms repair/replace cable assembly.
If the cables connections are good replace Control Board (PCB3/20AP1).
ERR 009 - LOW INPUT
This section isolates persistent Low Voltage Error. AC Mains voltage is monitored at the Control Board. This fault can tem-
porarily appear under heavy load conditions, in which case, this is a warning and not a failure. Weld performance is aected
by AC input voltage droop. Long input power cords can result in signicant voltage drop when under heavy output loads.
For service personnel having this fault continuously, and at power up, follow the below procedure.
A. Apply power and check AC voltage at 20AP1 CN19 across pin 10 and pin11 for:
When connected to 120 V AC check monitor voltage of 7.85 AC Vrms +/-0.4V.
When connected to 230 V AC check monitor voltage of 15.0 AC Vrms +/-0.75V.
The conversion factor is (AC Vrms IN/15.25).
If the voltage is correct, replace the 20AP1 Control PCB; otherwise go to step B.
B. Turn o power, disconnect from wall outlet, and remove PCB3/20AP1 Control Board. Check continuity of cable
assembly #14028 end-to-end of pins 10 and 11.
Repair/Replace if cable is faulty.
If cable is good replace Power board (PCB2/15AP1).
ERR 010 - Reserved
ERR 011 - DEFAULT RESET UNCONFIRMED
This error happens when the 20AP1 does not report it has applied factory default values to software. It is extremely rare to
have this fault and dicult to isolate to component. Perform the following steps in the event of this error.
A. Power up system navigate to the setup menu.
B. Attempt perform a factory reset.
If the error message continues to appear, attempt a full software update to the latest version and repeat Steps A and B.
C. If step B does not clear the issue, replace 20AP1 Control PCB. Update to the latest software and repeat Step A and B.
D. If step C does not correct the fault replace 1AP1 User Interface Board.
ERROR CODES
0463 705 001
-11-
ERR 012 - COMMUNICATION FAULT
This fault happens when one side of the communication link has not responded for 5 seconds or more.
This can happen due to faulty cabling, high noise interference or faulty PCBs. Update to the latest software version and
recheck before troubleshooting hardware for this issue.
A. If the issue occurs during welding then check service bulletin to apply Si180410.
B. If the issue occurs during idle state check cable assembly #10746G continuity, if cable is good replace 1AP1 User
Interface Board and do a recheck.
C. If step B does not solve the issue replace 20AP1 Control Board and do a recheck.
ERR 013 - Reserved
ERR 014 - SENSOR FAULT SERVICE REQUIRED
ERR 015 – HARDWARE ERROR
This section isolates fault occurring when the presence of AC/DC inverter board (PCB8/15AP3) is not detected by the Control
Board (PCB3/20AP1).
A. Check for physical connection of the 7 pin wire harness #14739 between the Control Board (PCB3/20AP1) CN14
connector and AC/DC Inverter Board (PCB8/15AP3) CN3 connector.
B. Check for LED D28 illuminating solid Green on AC/DC Inverter Board (PCB8/15AP3), if D28 LED is ON go to Step C.
Otherwise go to Step E.
C. Measure the DC voltage at 20AP1/PCB3 CN14 between pin 5 and pin 3. If measured voltage is ~12 Vdc +/-1V,
replace Control Board (PCB3/20AP1). Otherwise go to Step D.
D. Disconnect cable assembly #14739 from CN14 on Control Board (PCB3/20AP1) and CN3 on AC/DC Inverter Board
(PCB8/15AP3) and check cable continuity between both connector ends for pin 5 and pin 3 resp. If continuity is
good, replace AC/DC Inverter Board (PCB8/15AP3); otherwise repair/replace cable #14739.
E. Disconnect cable assembly #14739 from CN14 on Control Board (PCB3/20AP1). Check for 24 V DC voltage across
CN14 connector pin 7 w.r.t. pin 3 on Control board (PCB3/20AP1). If voltage is present then go to Step F. Otherwise
replace Control Board (PCB3/20AP1)
F. Reconnect the cable assembly #14739 at CN14 on Control Board (PCB3/20AP1) and disconnect the cable from
CN3 connector on AC/DC Inverter board (PCB8/15AP3) and measure voltage at disconnected end of cable #14739
across pin 7 and pin 3 for ~24 V DC +/- 1 V DC. If voltage is not present replace/repair #14739 harness. If voltage
is present replace AC/DC Inverter Board (PCB8/15AP3).
ERR 016 – AC/DC TEMP TRIP
This section isolates faults occurring when the AC/DC inverter board (PCB8/15AP3) is tripping due to the temperature fault.
A. Check for physical connection of the 7 pin wire harness #14739 between the Control Board (PCB3/20AP1) CN14
connector and AC/DC Inverter Board (PCB8/15AP3) CN3 connector.
B. Check for LED D28 illuminating solid Green on AC/DC Inverter Board (PCB8/15AP3), if D28 LED is ON go to Step C.
Otherwise go to Step E.
C. Measure the DC voltage at 20AP1/PCB3 CN14 between pin 5 and pin 3. If voltage measured is ~12 Vdc to 13Vdc,
replace Control Board (PCB3/20AP1). Otherwise go to Step D.
D. Disconnect cable assembly #14739 from CN14 on Control Board (PCB3/20AP1) and CN3 on AC/DC Inverter Board
(PCB8/15AP3) and check cable continuity between both connector ends for pin 5 and pin 3 resp. If continuity is
good, replace AC/DC Inverter Board (PCB8/15AP3); otherwise repair/replace cable #14739.
ERROR CODES
0463 705 001
-12-
E. Disconnect cable assembly #14739 from CN14 on Control Board (PCB3/20AP1). Check for 24 V DC voltage across
CN14 connector pin 7 w.r.t. pin 3 on Control board (PCB3/20AP1). If voltage is present then go to Step F. Otherwise
replace Control Board (PCB3/20AP1)
F. Disconnect cable assembly #14739 from CN3 connector on AC/DC Inverter board (PCB8/15AP3) and measure volt-
age at disconnected end of cable #14739 across pin 7 and pin 3 for ~24 V DC +/- 1 V DC. If voltage is not present
replace/repair #14739 harness. If voltage is present replace AC/DC Inverter Board (PCB8/15AP3).
ERR 017-019 – Reserved
ERR 020 – GRAPHICS ERROR
This section isolates an error related to memory on the UI panel. When this error occurs, it is indication the software image
library le was corrupted or not present or the memory device has failed on the Display PCAB.
A. Attempt to update the system with the latest software. If that does not correct the issue replace User Interface
Board (PCB1/1AP1) and update to the latest software.
ERR 021 – GRAPHICS ERROR
Follow Err 20 procedure to isolate this fault.
ERR 022 – WRITE MEM Err
Follow Err 20 procedure to isolate this fault.
ERR 023 – READ MEM Err RETRIEVE FACTORY
Follow Err 20 procedure to isolate this fault.
ERR 024-029 – Reserved
ERR 030 - FIRMWARE ERROR
This error is a result of the control software self-check failed. This can happen during software update if poor cables are used
or high noise environment. If it happens outside of a software upgrade, it could be a Control Board (PCB3/20AP1) failure.
A. Attempt to update the system with latest software. If unable to load new software or failure returns replace Control
Board (PCB3/20A1).
ERR 031 – NVRAM CHECKSUM BAD
Use ERR 030 procedure to trouble shoot this error.
DIAGRAM
0463 705 001
-13-
DIAGRAM
System wiring diagram
PFC BOOST
CONTROLLER
47KHz
PWM
GATE
DRIVE
A
B
A
B
RED
BLK
RED
RED
BLK
BLK
CN2 CN2
CN4
BLU
RED
YEL
BLK
ORG
GRN
BLU
YEL
GRN
RED
BLK
CN19
YEL
BLU
ORG
RED
ORG
RED
GRN
GRN
ORG
BLK
CN1
CN17
GATE DRIVE B
GATE DRIVE A
SKU ID2
SKU ID1
SENSOR PRI 1
SENSOR PRI 2
SKU ID3
T5 20: 1
MAIN SENSE
MAIN SENSE
TRIGGER AC2
TRIGGER AC1
SKU ID4
/ TEMP OK
/ BUS V OK
INVERTER HS
TEMP CIRCUIT
TEMP ANALOG
10K
NTC 3
4: 1
T1
TRANSF1
TRANSF2
Q4
Q7
Q3
Q6
400V DC
D49
D50
C35-38
Q19
+24V_SEC
+18V_PRI
VDC_SEC
SEC_GND
PRI_GND
+18V_PRI OK
+24V_SEC OK
D53
D42
+24V_PWR
+15V_1
-15V_1
SEC_GND
+5V_1
PS OK
D35
+5V_1 OK
D86
+3.3V_1
+15V_UI
REMOTE
+10.3V_VB +10.3V_VB OK
D85
+3.3V_1 OK
D36
MIG GAS
CN9
CN7
CN10
+
SOL1
M2
M3
USER INTERFACE PCB1 / (1AP1)
CN12
ENCODER PCB7
(1AP4)
WFM
SW
J1RED
BLK
GRN
PUR
BLU
BRM
BLK
WHT
LINE1
LINE2
VR1
BR1
RED
BRN
BR+
BR-
L1
177uH
IND-1
R88
PRI_GND
CN28
SEC1
SEC2
D167
D168
D181
D180
AC DC INVERTER PCB8 / 15AP3
M1
WFM
+
TX P
TX N
RX CAN N
RX CAN P
MOTOR +
SPOOL_MOTOR -
SPOOL_MOTOR +
MOTOR -
CN13
CN5
WFM
SUPPLY
INTERNAL
WFM DRIVE
EXTERNAL
WFM DRIVE
TRIGGER -
TRIGGER +
REMOTE_POT
REMOTE_DET
0VB
0 VB
REMOTE
+10.3_VB
CN3
CN1 CN18
AC1
0.5V/100A
-15V_1
+15V_1
IGBT G ATE D RIV E A
47KHZ PWM
BUS V ERR
<350V
D43
U1 COM
D44
uP OK
D45
MIG SOL ON
TIG SOL ON
D87
D89
RX CAN P
RX CAN N
TX N
TX P
+3.3V_2
+5V_2
+15V_2
EN3-B
EN3 SWITCH
+3.3 V_2
SPOOL
GUN
FEED PLATE
POLARITY
CABLE
CONTROL PCB3 / (20AP1)
MAIN POWER PCB2 / (15AP1)
2
4
5
7
1
3
6
2
4
5
7
1
3
6
8
9
11
2
4
5
7
1
3
6
10
8
9
11
2
4
5
7
1
3
6
10
8
9
11
2
4
5
7
1
3
6
10
12
8
9
11
2
4
5
7
1
3
6
10
12
ORG
2
1
CN9
TEMP ANALOG
NTC 2
PFC HS
NTC 1
AC1
AC2
BLK
WHT
R89
0.005ɏ 0.005ɏ
FERRITE
RINGS
10K
NTC 10
2
1
25Hz - 400Hz
PWM
GATE DRIVE
1B
4
2A
1A
Q1A
Q4
Q3
Q2A
C8
CN1
2
1
SEC_GND
HVDC_POS
T2
1.2mH
1:15
2
4
1
3
1
2
CN4
AC INVERTER HEAT SINK
+ Ve
DIODE
HEAT SINK
D1
D4
D3
D2
OUT+
CN3
AC_GND
SEC_GND
CN2
SEC_GND
+24V_SEC
IPS
+24V_SEC
+16V_1
-10V_1
+15V
+5V
PWM_P
PWM_N
HF_ON
HF_INV
PWM_P
PWM_N
LOAD/HF
CN14
AC_GND
AC_GND
HF BYPASS
PCB10 /15AP5
XS1
XS2
2
1
1
3
HF STARTER PCB9 / 15AP4
CN1
CN2
CN3 CN4
SEC_GND
15V
PRI_GND
400V
400V
10V
GATE PULSE
400V
C9
D6
Q5
TX1
T3
1
2
8
2
4
5
7
1
3
6
2
1
2
1
2
1
2
1
2
4
1
3
8
2
4
5
7
1
3
6
+
-
ID
FAN
+
FAN
+
GAS
SS / AL
FAN ON
D 90
FAN
+24V
+24V
TRIGGER ON
D88
REMOTE_GND
REMOTE_POWER
IGB T G ATE D RI VE B
47KHZ PWM
R34
R642
MAX I CAL WFS CAL
+24V
PWM
D33
SW2
2 VRD
OFF/ON
J1 REMOTE
8
7
6
4
5
3
2
1
ESAB
REBEL 205ic AC/DC CE
VN
DRAWN BY
10 Dec 2019
REV F
SHEET
# 1 of 1
PIN
1
2
3
4
5
6
7
8
FUNCTION
SPOOL GUN MOTOR (-)
SPOOL GUN TRIGGER
SPOOL GUN TRIGGER
SPOOL GUN MOTOR (+) +24VDC
POT (+) MAX CW
POT (-) MIN CCW
POT WIPER
PERIPHERAL RESISTOR
TFT DISPALY
RIBBON
EN3-A
CN11
ENCODER PCB6
(1AP3)
EN2-B
+3.3 V_2
2
4
1
3
EN2-A
CN10
ENCODER PCB5
(1AP2)
+3.3 V_2
2
4
1
3
EN1-B
EN1-A
RED
BLK
BLK
RED
BLK
BLK
CN6
CN3
2
4
5
7
1
3
6
2
4
5
7
1
3
6
RED
+15V_UI
+15V_2
TIG GAS
+24V
CN11
SOL2
+
GAS
TS1
AC_1
AC_2
1
AC2
CN15
CN1
E
2
IPS PCB4 / (15AP2)
CN1
1
2
2
1
3
PRI_GND
+18V_PRI
2
1
3
IPS-
IPS+
D61
D62
LINE1
LINE2
IPS_REC
IPS_GND
L2
68uH
IPS+
IPS_REC
CN3
C41
14737
14738
14741
14464
BLK
WHT
RED
14740
CN8
RED
BLK
14739
RED
BLK
14463
14006
14132
RED
BLK
WHT
RED
BLK
WHT
RED
BLK
13949
RED
BLK
14479
HVDC_NEG
14494
RED/WHT
3BLU
2
4
5
1
3
RED/WHT
2
1
NTC 9
10K
2
4
5
7
1
3
6
2
4
5
7
1
3
6
+15V
SEC_GND
AC_DC TEMP
AC_DC TEMP
2
1
3
2
4
5
1
3
6
C9
RED
BLK
WHT
14462
2
1
3
2
1
CN3
CN2
2
1
3
CN21
+3.3V_1
BR2
RED
BRN
BLK
WHT
Q1B
Q2B
2B
3
2
1
3
TIG OPTION DET
+15V
+15V_ OK
D28
HF TRANSFORMER
CORE
CORE
CORE
CORE
CORE
14467
10872
11773
14726
14729
13964
14720
14723
Q21
RY1
PTC
14705
IPS+ IND-2
IPS-
13973
13970
13975
C31
C252
10746
BLK
RED
2
1
CN7
BLK
WHT
BLK
RED
C1 C2
120VAC/
230VAC
1 PH
BROWM
BLUE
GRN/YLW
CB1
40A
BLK
14461
SW1
14777
CHASSIS
GND
J11
J21
PE
EMI FILTER
J31
J41
GND
10873
WHT
14466
12048
C47
2
4
1
3
CT
YEL
RED
GRN
BLK
L2
14uH
OUTPUT
INDUCTOR
CN6
2
RED
BLK
3
1
TH
+24V_SEC
D51
SEC_GND
D78
+24V_PWR
R201
TEMP_ANALOG
+24V_PWR
SEC_GND
CN20
LED PCB
14468
R243
CN4
SEC_GND
+24V_SEC
1
2
1
2
CN1
ORG
WHT
EURO
ADAPTOR
14755
C208
C207
2
1
CN5
C43
C43A
14706
CASE GND
GRN/YLW
8T
4T
4T
CORE
DIAGRAM
0463 705 001
-14-
Functional block diagram
120Vac to 230Vac
± 10%
50/60 Hz
PRIMARY SIDE
INPUT RECTIFIER
BOOST PFC
SECONDARY SIDE
MAIN
TRANSFORMER
SECONDARY RECTIFIER
OUTPUT
INDUCTOR
IPS
BOARD
INPUT
SWITCH
THERMAL
BREAKER
MAIN POWER BOARD
PFC
INDUCTOR
WELD
OUTPUT
RING
CORES
PRIMARY INVERTER
AC INVERTER
TB
AC DC INVERTER BOARD
25 U
USER
INTERFACE/
TFT
DISPLAY
WIRE
FEEDER
GAS
VALVES
WF
GV
FAN 1
HF STARTER
BOARD
CURRENT
SENSOR
HF TRANSFORMER
FAN 2
CONTROL BOARD
HF BYPASS BOARD
EMI
FILTER
PCB2/15AP1
PCB4/15AP2
PCB9/15AP4
PCB3/20AP1
PCB1/1AP1
PCB8/15AP3
PCB10/15AP5
T1
L1
L2
T2
TECHNICAL DATA
0463 705 001
-15-
TECHNICAL DATA
• Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capabilities,
measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and
operation will depend upon correct installation, use, applications, maintenance and service.
• The Eective Input Current should be used for the determination of cable size and supply requirements.
• Motor start fuses, or thermal circuit breakers are recommended for this application. Check local requirements for your
situation in this regard.
• Generator Requirements at the Maximum Output Cycle.
• Due to large variations in performance and specications of dierent brands and types of generators, ESAB cannot
guarantee full welding output power or duty cycle on every brand or type of generator. ESAB recommends that when
selecting a generator, that the power source/generator combination be adequately tested to ensure the combination
performs to the user’s expectations without notice.
EMP 205ic AC/DC
EMP 205ic AC/DC
Voltage 230 V,1 ph, 50/60 Hz 120 V, 1 ph, 50/60 Hz
Primary current
I
max.
GMAW - MIG 29.6 A
Breaker 20 A: 27.1 A
Breaker 15 A: 20.2 A
I
max.
GTAW - DC TIG 24.0 A Breaker 15 A: 20.7 A
I
max.
GTAW - AC TIG 26.5 A Breaker 15 A: 21.4 A
I
max.
SMAW - Stick 28.3 A Breaker 15 A: 20.5 A
I
e.
GMAW - MIG 14.8 A
Breaker 20 A: 15.8 A
Breaker 15 A: 14.5 A
I
e.
GTAW - DC TIG 12 A Breaker 15 A: 14.3 A
I
e.
GTAW - AC TIG 13.3 A Breaker 15 A: 14.9 A
I
e.
SMAW - Stick 14.1 A Breaker 15 A: 14.4 A
Permissible load at GMAW - MIG
100% duty cycle* 110 A (V
out
= 19.5 V)
Breaker 15 A: 65 A (V
out
= 17.25 V)
Breaker 20 A: 70 A (V
out
= 17.5 V)
60% duty cycle* 125 A (V
out
= 20.25 V)
Breaker 15 A: 85 A (V
out
= 18.25 V)
Breaker 20 A: 90 A (V
out
= 18.5 V)
40% duty cycle* 150 A (V
out
= 21.5 V) Breaker 15 A: 90 A (V
out
= 18.5 V)
25% duty cycle* 205 A (V
out
= 24.25 V) -
20% duty cycle* - Breaker 20 A: 115 A (V
out
= 19.75 V)
Setting range (DC)
15 A (V
out
= 14.75 V) -
235 A (V
out
= 26.0 V)
15 A (V
out
= 14.75 V) -
130 A (V
out
= 20.5 V)
Permissible load at GTAW - DC TIG
100% duty cycle* 110 A (V
out
= 14.4 V) Breaker 15 A: 80 A (V
out
= 13.2 V)
60% duty cycle* 125 A (V
out
= 15.0 V) Breaker 15 A: 100 A (V
out
= 14.0 V)
40% duty cycle* - Breaker 15 A: 110 A (V
out
= 14.4 V)
25% duty cycle* 205 A (V
out
= 18.2 V)
Setting range (DC)
5 A (V
out
= 10.2 V) -
205 A (V
out
= 18.2 V)
5 A (V
out
= 10.2 V) -
130 A (V
out
= 15.2 V)
TECHNICAL DATA
0463 705 001
-16-
EMP 205ic AC/DC
Permissible load at GTAW - AC TIG
100% duty cycle* 110 A (V
out
= 14.4 V) Breaker 15 A: 75 A (V
out
= 13.0 V)
60% duty cycle* 125 A (V
out
= 15.0 V) Breaker 15 A: 95 A (V
out
= 13.8 V)
40% duty cycle* - Breaker 15 A: 105 A (V
out
= 14.2 V)
25% duty cycle* 205 A (V
out
= 18.2 V)
Setting range (AC)
5 A (V
out
= 10.2 V) -
205 A (V
out
= 18.2 V)
5 A (V
out
= 10.2 V) -
130 A (V
out
= 15.2 V)
Permissible load at SMAW - Stick
100% duty cycle* 100 A (V
out
= 24 V) 55 A (V
out
= 22.2 V)
60% duty cycle* 125 A (V
out
= 25 V) 70 A (V
out
= 22.8 V)
40% duty cycle* - 75 A (V
out
= 23.0 V)
25% duty cycle* 170 A (V
out
= 26.8 V) -
Setting range (DC)
16 A (V
out
= 20.6 V) -
180 A (V
out
= 27.2 V)
16 A (V
out
= 20.6 V) -
130 A (V
out
= 25.2 V)
Open circuit voltage (OCV)
VRD deactivated 68 V
VRD activated 35V (Peak)
Eciency 78%
Power factor 0.98
Wire feed speed 2-12.1 m/min (80-475 in./min)
Wire diameter
Mild steel solid wire 0.6 - 0.9 mm (0.023 - 0.035 in.)
Stainless steel solid wire 0.8 - 0.9 mm (0.030 - 0.035 in.)
Flux-cored wire 0.8 - 1.1 mm (0.030 - 0.045 in.)
Aluminium 0.8 - 1.2 mm (0.030 - 0.047 in.)
Bobbin size 100-200 mm (4- 8 in.)
Dimensions L×W×H 548 × 229 × 406 mm (23 × 9 × 16 in.)
Weight 25.5 kg ( 56 lb,)
Operating temperature -10 ° to + 40 °C (14 ° to 104 °F)
Enclosure class** IP23S
Application classication***
S
*Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without
overloading. The duty cycle is valid for 40 °C (104 °F) or below.
**Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water.
Equipment marked IP 23S is intended for indoor and outdoor use; however, should not be operated in precipitation.
***Application class
S
This symbol indicates that the power source is designed for use in areas with increased electrical hazard.
SOFTWARE UPDATE AND SYSTEM CALIBRATION
0463 705 001
-17-
SOFTWARE UPDATE AND SYSTEM CALIBRATION
All the Rebel systems use Rebel Service Tool for software update and system calibration.
All available versions of system software and Service Tool are accessible to download through a link on each country/regions
local partner login site at:
www.esab.com
Figure 4. ESAB Partner Login Software Download Location
Who have access to the Software-download?
Everyone that already have access to regional partner login and are an authorized service partner.
If I can’t see the Software-download link or don’t have access to partner login?
Please contact your local Service coordinator/After-sales Manager for help.
When Rebel 205ic machine software is updated using Rebel Service Tool it reads the calibration data and restores after the
software update. Rebel 205ic machine requires three software les for full system software update. Use the instruction
manual located on ESAB Portal website for service tool for the variant software les location and instructions for updating
the software and system calibration.
Voltage, WFS and Current Calibration: Calibration of Voltage, WFS and Current is done when replacing 20AP1/PCB3, Wire
Feed Motor or Current Sensor respectively.
Equipment needed:
• Digital Multi-Meter (DMM)
• Tachometer
• Load Bank
• Plastic adjustment tool
After the calibration, recycle power to the rebel machine to apply new calibration parameters and also save the calibration
data onto permanent memory.
TROUBLESHOOTING
0463 705 001
-18-
TROUBLESHOOTING
!!
WARNING
Bus voltage of 400 V DC will be present on the heatsinks of the main power board while unit is
on. Wait 40 seconds after removing power before handling.
Power-supply side component modules details
UI Panel
IPS Board
HF Starter
Board
Mains
Transformer
HF
Transformer
Wire Feeder
Motor
Weld
Output
Control
Board
Current
Sensor
Output
Inductor
AC DC Inverter
Board
Mains
Switch
Main Power
Board
PFC Boost
Inductor
Fan
Mains Cable
Input
EMI Filter
L-N Core
Fan
EMI GND
Core
Figure 5a. Power Side Components Location
EMI Filter
Enclosure
Thermal Breaker
(CB1)
24V_LED
Board
Figure 5b. Power Side Components Location on Spool Side
TROUBLESHOOTING
0463 705 001
-19-
Service modules part numbers
Figure 6. Power Side Components Spare Parts List
Item Part no. Denomination Ref. Designator Qty.
1 0464 637 006 AC/DC module PCB8/15AP3 1
2 0464 637 007 Main power PCBA PCB2/15AP1 1
3 0464 637 008 Control PCBA PCB3/20AP1 1
4 0464 637 009 Output inductor assembly L2 1
5 0464 637 010 Main transformer assembly T1 1
6 0464 637 011 HF Transformer assembly T2 1
7 0558 102 657 HF Starter PCBA PCB9/15AP4 1
8 0464 637 012 HF bypass PCBA PCB10/15AP5 1
9 0464 637 013 IPS PCBA PCB4/15AP2 1
10 0558 102 662 Mains cable strain relief - 1
11 0464 637 014 Mains cable with input power plug - 1
12 0464 637 015 EMI PCBA with housing - 1
13 0558 102 417 Current Sensor - 1
TROUBLESHOOTING
0463 705 001
-20-
Design structure of the power supply circuit
The EMP 205ic AC/DC power source operates on the inverter principle. It consists of several function modules.
The modules have the following main functions:
• User interface module - The user interface is a 4.3-inch TFT (Thin Film Transistor) display with 3 encoders attached to it.
• Power module - Power board includes primary rectier, PFC section, auxiliary power supply, full bridge inverter. Main
transformer, secondary inductor and secondary diode modules are physically mounted separately but function with the
power module. The power board also contains torch trigger isolation circuitry.
• Control module - The control board, with a microprocessor, that monitors and controls the welding process.
• AC/DC inverter module – This module includes output diode section, full bridge converter, IPS section for AC/DC module
and converts DC current to AC current.
• IPS Module – This module generates power for housekeeping and wire feeder motor.
• HF Stareter module – This module generates high voltage with help of HF Transformer.
• Main switch (this is connected to enclosure).
Block diagram
The primary rectier, recties the input AC voltage. Main PFC section boosts this voltage to 400 V DC with a 0.99 power factor.
The main inverter of the power source is a 4-transistor IGBT (Insulated Gate Bipolar Transistor) full bridge, operating at a
switching frequency of 47 kHz.
The primary inverter output is connected to a main transformer with 18:4 step-down turns ratio.
The main transformer output is connected to a secondary rectier which contains four diode modules.
Refer "Functional block diagram" on page 14
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ESAB EMP 205ic AC/DC User manual

EMP 205ic AC/DC
ESAB
Brand
ESAB
Model
EMP 205ic AC/DC
Category
Welding System
Type
User manual
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