ESAB Fabricator EM 400i User manual

Brand: ESAB

Model: Fabricator EM 400i

Category: Welding System

Type: User manual

This manual is also suitable for

Fabricator EM 500i

FabricatorEM400i,

FabricatorEM500i

Service manual

0446 574 001 GB 20200908

Valid for: Serial no. 008-xxx-xxxx

TABLE OF CONTENTS

0446 574 001

- 2 -

1 READ THIS FIRST

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

2 BEFORE STARTING SERVICE

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

3 INTRODUCTION

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

3.1 Design structure of the power source

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

3.2 Block diagram

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

4 TECHNICAL DATA

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

5 WIRING DIAGRAM

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

5.1 Fabricator EM400i / Fabricator EM500i

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

5.2 Position of components

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

6 ERROR CODES

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

6.1 Fault code description, power source

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

7 TROUBLESHOOTING

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

7.1 Pre power-up checks

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

7.1.1 Visual inspection

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

7.1.2 Input measurements

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

7.1.3 Power board 15AP1 measurements

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

7.2 Power-up checks

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

7.2.1 General

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

7.2.2 Electrical test

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

8 CALIBRATION AND VALIDATION

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

9 DISASSEMBLY AND REASSEMBLY

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

9.1 Tightening torque for screw joints on power components

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

10 REPLACEMENT INSTRUCTIONS

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

10.1 Replacing the mains switch

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

10.2 Replacing the fan

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

10.3 Replacing the power board

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

10.4 Replacing the secondary rectifier diode modules

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

10.5 Replacing the current sensor

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

10.6 Replacing the control board

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

10.7 Replacing input EMC board

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

10.8 Replacing the mains cable

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

11 IN-SERVICE, MAINTENANCE AND PERIODIC INSPECTION PROCEDURE

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

11.1 Visual inspection in accordance with clause 5.1 in

IEC60974-4:2016/EN60974-4:2016

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

11.2 Intermediate cables

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

11.3 Enclosure

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

11.4 Return clamp

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

11.5 Welding gun/torch

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

11.6 Welding circuit

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

11.7 General condition

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

11.8 Wire feeder/ wear parts

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

11.9 Solenoid gas valve

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

11.10 Controls and indicators

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

11.11 Cleaning the equipment

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

11.11.1 Welding equipment

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

11.11.2 Replacing and cleaning

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

11.12 Labelling and report

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

11.13 Maintenance and inspection procedure

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

TABLE OF CONTENTS

0446 574 001

- 3 -

12 SPARE PARTS AND ACCESSORIES

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

1   READ THIS FIRST

0446 574 001

- 4 -

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 September

2020.

The manual is valid for:

• FabricatorEM400i and FabricatorEM500i with serial number 008-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 FabricatorEM400i and FabricatorEM500i 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

0446 574 001

- 5 -

2 BEFORE STARTING SERVICE

NOTE!

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

ESAB Tools

Tool Ordering number

ESAB test box TB1 0460 868 880

Resistive load bank (20kW or more)

(Reference: Checkmaster 9000)

Recommended measuring devices:

• For general measurements: Fluke 175, Fluke 177 and Fluke 179 or with equal performance.

• For safety test: Fluke 1503, Fluke 1507, Fluke 1577 and Fluke 1587 or any other multimeter with

equal performance.

3   INTRODUCTION

0446 574 001

- 6 -

3 INTRODUCTION

The FabricatorEM400i and FabricatorEM500i are welding power sources intended for MIG/MAG

welding, Welding with powder filled cored wire (FCAW-S) and welding with coated electrodes (MMA).

The power sources are intended for use with the following wire feed units:

• Feed364

• FabricatorFeed 364

3.1 Design structure of the power source

The FabricatorEM400i and FabricatorEM500i power sources are transistor controlled, operating on

the inverter principle. It consists of a number of function modules. Each module has a module number,

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

The modules have the following main functions:

1 User interface module

The display board that interface the weld settings with control board and display the weld parameters

(voltage and current) The interface module also helps the user to set the different parameters like

wire size selection, welding process selection, welding mode selection, inductance adjustment, Arc

force and Crater fill current and voltage adjustments.

2 Mains module

Mains filter board, mains circuit breaker and auxiliary transformer.

15 Power module

Power board including primary rectifier and IGBT transistor modules. IPS board, main transformer,

secondary inductor, secondary diode modules.

20 Control module

The control board with a microprocessor that monitors and controls the welding process.

Working principle

The mains input voltage range is three-phase 380-440VAC; ±10%; 50/60Hz at rated load. The

primary rectifier creates the DC bus voltage by rectifying the input AC voltage The primary converter of

Fabricator power sources has two power blocks which are operating in parallel to deliver the rated

load. Each power block is two switch forward converter consists of two transistor IGBTs and 2 diodes,

operating at a switching frequency of 30kHz. The transistor IGBTs are built into custom modules and

rest all are semiconductors are built into modules Each converter output is connected to a main

transformer. The main transformer output is connected to a secondary rectifier module.

FabricatorEM400i power source is rated for 310A at 100% and 400A at 60% duty cycle.

FabricatorEM500i power source is rated for 390A at 100% and 500A at 60% duty cycle.

3   INTRODUCTION

0446 574 001

- 7 -

3.2 Block diagram

4   TECHNICAL DATA

0446 574 001

- 8 -

4 TECHNICAL DATA

FabricatorEM 400i

Mains voltage 380-440V±10%, 3~50/60Hz

Primary current I

max

380 V 400 V 415 V 440 V

MIG/MAG 24 A 23 A 22 A 21 A

MMA 25 A 24 A 23 A 22 A

Setting range (DC)

MIG/MAG 30 A / 12.0 V - 400 A / 34.0 V

MMA 30 A / 21.2 V - 400 A / 36.0 V

Permissible load at MIG/MAG

60 % duty cycle 400 A / 34.0 V

100% duty cycle 310 A / 29.5 V

Permissible load at MMA

60 % duty cycle 400 A / 36.0 V

100% duty cycle 310 A / 32.4 V

Power factor at maximum current 0.93

Maximum input power at idle mode <50 W

Efficiency at maximum current 87 %

Open-circuit voltage 63.7 V

Operating temperature -10 to +40°C (14 to 104°F)

Transportation temperature -20 to +55°C (-4 to 131°F)

Dimensions l × w × h 707 × 325 × 482 mm (27.8 × 12.8 × 18.9 in.)

Weight 59 kg (130 lb)

Insulation class H

Enclosure class IP23S

Application class

FabricatorEM 500i

Mains voltage 380V to 440±10%, 3~50/60Hz

Primary current I

max

380V 400V 415V 440V

MIG/MAG 34A 33A 31A 30A

MMA 35A 34A 32A 30A

Setting range (DC)

MIG/MAG 30A / 15.5V - 500A / 39.0V

MMA 30A / 21.2V - 500A / 40.0 V

Permissible load at MIG/MAG

60% duty cycle 500A / 39.0V

100% duty cycle 390A / 33.5V

Permissible load at MMA

4   TECHNICAL DATA

0446 574 001

- 9 -

FabricatorEM 500i

60% duty cycle 500A / 40.0V

100% duty cycle 390A / 35.6V

Power factor at maximum current 0.93

Maximum input for power at idle mode <50W

Efficiency at maximum current 87%

Open circuit voltage 73.3V

Operating temperature -10 to +40°C (14 to 104°F)

Transport temperature -40 to +70°C (-40 to 158°F)

Dimensions l × w × h 707 × 325 × 482 mm (27.8 × 12.8 × 18.9 in.)

Weight 62 kg (136.6 lb)

Insulation class H

Enclosure class IP23S

Application classification

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 IP23S is intended for indoor and outdoor use; however, should not be operated in

precipitation.

Application class

The symbol indicates that the power source is designed for use in areas with increased electrical

hazard.

5   WIRING DIAGRAM

0446 574 001

- 10 -

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, which are described in the component

descriptions on the following pages. Wire numbers and component names in the wiring diagrams

show to which module each component belongs.

Wires/cables within modules are marked 001 - 100.

Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors XS1 -

XS99 (S = socket), XP1 - XP99 (P = plug), XT1 - XT99 (T = terminal).

Circuit boards within each module are named 20AP1 - 20AP99.

20 = module association, 1-69

AP = circuit board

1 = individual identification number, 0-99

Transistors within particular modules are named 15Q1 - 15Q99.

15 = module association, 1-69

Q = transistor

1 = individual identification number, 0-99

Component Description

20AP1 Main control board

1AP1 Display board with Front Overlay

15AP1 Main Power board with IGBT's

15AP2 Fan power supply board

2AP1 Input EMC board

2AP2 Output EMC board

15T1 Transformer

2T1 Auxiliary transformer

2T2 Auxiliary transformer

2AP3, 2AP4, 2AP5 Output snubber board

FU2 Circuit breaker with cover

15L1 Inductor

15L2, 15L3 Output ferrite core

FU1 Input circuit breaker

15BR1 Input Rectifier

15EV1, 15EV2 Fan

15PM1, 15PM2, 15PM3 Secondary rectifier diode

15CS1 Secondary current sensor

XS1 Connector 7pin assy with harness

NTC_S NTC on secondary heatsink

NTC_P NTC on output inductor winding

NTC_O+ NTC on output positive terminal

NTC_O- NTC on output negative terminal

5   WIRING DIAGRAM

0446 574 001

- 11 -

5.1 Fabricator EM400i / Fabricator EM500i

5   WIRING DIAGRAM

0446 574 001

- 12 -

5.2 Position of components

Left view

5   WIRING DIAGRAM

0446 574 001

- 13 -

Right view

6   ERROR CODES

0446 574 001

- 14 -

6 ERROR CODES

Fault codes are used in order to indicate and identify a fault in the equipment.

Fault log

All faults that occur when using the welding equipment are documented as error messages in the fault

log. When the fault log is full, the oldest message will automatically erase when the next fault occurs.

6.1 Fault code description, power source

This manual describes the fault codes for the power source.

Code Description

Welding torch fault

• The torch connector may not be connected properly with wirefeeder.

• The trigger switch my be faulty.

Action:

• Turn off the switch.

• Replace the welding torch.

Output terminal over-temperature

• The OKC terminal and welding cable is not connected properly.

• The copper cross-sectional area of the output power cable is too small.

• The output cable OKC fails to meet the specification requirement.

• The fan does not work or slows down.

• NTC does not function properly.

Action:

• Verify the OKC terminal and welding cable is connected properly.

• Use cables with correct cross-sectional areas.

• Select suitable cable OKC.

• Verify the fan functions properly.

• Verify that the NTC works properly.

Abnormal input power

• The input power cable is not connected properly.

• Input power overvoltage occurs.

• Input power under voltage occurs.

• Input power phase imbalance occurs.

• The input power frequency exceeds the range

Action:

• Verify that the input cables are connected properly.

• Verify that the input power is normal.

6   ERROR CODES

0446 574 001

- 15 -

Code Description

IGBT or diode over-temperature

• The rated duty cycle is exceeded.

• The air vent of the housing is blocked.

• The radiator is covered with heavy dust.

• The fan does not work or slows down.

• The IGBT or diode current is excessively high.

• NTC does not function properly.

Action:

• Ensure that the user does not exceeds the rated duty cycle range.

• Verify that the air vent is not blocked.

• Remove dust from the radiator.

• Verify that the fan works properly.

• Verify that the main power board and output diode module are normal.

• Verify that the NTC works properly.

(1-8)

Button error

• A button is jacked up.

• A button does not rebound after being pressed.

Action:

• Check the key.

Output overcurrent

• The output is short-circuited or the current is too high.

• The output diode module is damaged.

Action:

• Verify that the output is not short-circuited.

• Verify that the output diode module is not damaged.

Input power fault

• The input power cable is not connected properly.

• Input power phase loss or phase imbalance occurs.

• DSP is not powered on.

• No program is written into DSP or DSP is damaged.

• Communication open circuit exists.

Action:

• Verify that the input cables are connected properly.

• Verify that the input power is normal.

• Verify that the wire inching control board connection is normal.

• Verify that the display board connection is normal.

• Verify that the wire inching control board works properly.

6   ERROR CODES

0446 574 001

- 16 -

Code Description

Output overvoltage

• The input voltage is too high.

• The main transformer is damaged or defective.

• The output cables are not connected correctly.

Action:

• Verify that the input voltage is normal.

• Verify that the main transformer is not damaged.

• Verify that the output cables are connected correctly.

Primary side overcurrent

• IGBT is damaged.

• The primary side diode is damaged.

• The main transformer is damaged.

• The secondary output diode module is damaged.

Action:

• Verify that the main power board is not damaged.

• Verify that the main transformer is not damaged.

• Verify that the output diode module is not damaged.

E10

Primary side overvoltage

• The input power is insufficient.

• The input voltage is too high.

Action:

• Verify that the input power is normal.

• Verify that the input voltage is normal.

E11

Current Hall connector disconnection

• The current Hall connector is disconnected.

Action:

• Verify that the connector is connected.

E12

Disconnection of the input voltage detection connector

• The input voltage detection connector is not connected or the ring terminal of the

connection cable is not connected.

• The input voltage detection cable is damaged.

Action:

• Verify that the input voltage detection connector is connected and the ring

terminal of the connection cable is connected.

• Verify that the input voltage detection cable is normal.

E20

PCB not registered

• The PCB is not compatible.

Action:

• Purchase the compatible PCB recommended by ESAB.

7   TROUBLESHOOTING

0446 574 001

- 17 -

7 TROUBLESHOOTING

7.1 Pre power-up checks

WARNING!

Make sure the power source is disconnected from the mains supply and wait at least 4

minutes for the DC bus capacitors to discharge before removing any of the power source

panels!

Remove the power source right side panel according to Section 9  "DISASSEMBLY AND

REASSEMBLY", page 26 and measure the voltage between the CON8 "+" and CON9 "-"

screws of the capacitors, using a multimeter. If the voltage between the "+" and "-" screws

of the capacitor is not less than 20 V, wait further until the voltage is below 20 V!

7.1.1 Visual inspection

Examine the power source for any visible signs of damage. Check:

1. Printed circuit boards for burned varistors or other components

2. Cables and connectors

7.1.2 Input measurements

Perform the following measurements, using a multimeter set to resistance test setting:

1. Turn the mains on and measure the resistance, for all phases, between the mains plug and the

CN4-CN6 terminals on the input EMC board 2AP1:

• Mains plug L1–CN4 on the EMC board 2AP1: less than 1 Ω

• Mains plug L2–CN5 on the EMC board 2AP1: less than 1 Ω

• Mains plug L3–CN6 on the EMC board 2AP1: less than 1 Ω

7   TROUBLESHOOTING

0446 574 001

- 18 -

2. Measure the resistance between the phases L1, L2 and L3 on the input EMC board, the resistance

should be:

• CN4 – CN5: Approximately 184.5 Ω

• CN4 – CN6: Approximately 178.5 Ω

• CN5 – CN6: Approximately 6.3 Ω

If the measurement specification for any of the measurements is not met, check the mains switch

and the EMC filter board. Replace any faulty components according to instructions in Section 10 

"REPLACEMENT INSTRUCTIONS", page 29

7.1.3 Power board 15AP1 measurements

1. Using a multimeter set to diode test setting, measure the input rectifier bridge as follows:

• The input phases to HV_GND on 15BR1 rectifier:

1. With the positive test probe on A ("-" on power board) and the negative test probe on

HV_GND, check for one diode voltage drop (0.3 - 0.5V).

2. With the positive test probe on B ("-" on power board) and the negative test probe on

HV_GND, check for one diode voltage drop (0.3 - 0.5V).

3. With the positive test probe on C ("-" on power board) and the negative test probe on

HV_GND, check for one diode voltage drop (0.3 - 0.5V).

• The input phases to rectified DC_LINK+ on pin 15BR1 rectifier:

1. With the positive test probe on DC_LINK+ and the negative test probe on A ("+" on power

board), check for one diode voltage drop (0.3 - 0.5V).

2. With the positive test probe on DC_LINK+ and the negative test probe on B ("+" on power

board), check for one diode voltage drop (0.3 - 0.5V).

3. With the positive test probe on DC_LINK+ and the negative test probe on C ("+" on power

board), check for one diode voltage drop (0.3 - 0.5V).

7   TROUBLESHOOTING

0446 574 001

- 19 -

If any of the measurements show an open or short circuit, the rectifier bridge is defect and needs to

be replaced (see Section 10.4  "Replacing the secondary rectifier diode modules", page 31).

2. Using a multimeter set to diode test setting, measure the full bridge as follows:

1. Disconnect transformer cable from connection point CON10, CON11, CON12 and CON13 on

the power board.

2. With the positive test probe on HV_GND ("-" on CON9BUS- of the power board) and the

negative test probe on CON10P+, check for one diode voltage drop (0.3 - 0.5V).

3. With the positive test probe on HV_GND ("-" on CON9BUS- of the power board) and the

negative test probe on CON11P-, check for one diode voltage drop (0.3 - 0.5V).

4. With the positive test probe on CON10 P+ and the negative test probe on DC_LINK+ ("+" on

CON8BUS+of the power board), check for one diode voltage drop (0.3 - 0.5V).

5. With the positive test probe on CON11 P- and the negative test probe on DC_LINK+ ("+" on

CON8BUS+ of the power board), check for one diode voltage drop (0.3 - 0.5V).

6. With the positive test probe on HV_GND ("-" on CON9BUS- of the power board) and the

negative test probe on CON12P+, check for one diode voltage drop (0.3 - 0.5V).

7. With the positive test probe on HV_GND ("-" on CON9BUS- of the power board) and the

negative test probe on CON13P-, check for one diode voltage drop (0.3 - 0.5V).

8. With the positive test probe on CON12 P+ and the negative test probe on DC_LINK+ ("+" on

CON8BUS+of the power board), check for one diode voltage drop (0.3 - 0.5V).

9. With the positive test probe on CON13 P- and the negative test probe on DC_LINK+ ("+" on

CON8BUS+ of the power board), check for one diode voltage drop (0.3 - 0.5V).

If any of the measurements show an open or short circuit, the full bridge is defect and the power

board needs to be replaced. If there are no open or short circuits, reconnect the transformer cable.

7   TROUBLESHOOTING

0446 574 001

- 20 -

7.1.3.1 Checking the secondary rectifier diode modules

Use a diode tester to check the secondary rectifier diodes. There are three diode modules and each

module contains one diodes. All the diodes are connected in parallel. A copper bar connects all

anodes (S1, S2). The diodes have to be disconnected from either the copper bar or the cathode (S3,

S4) cables to be checked individually.

Measure between the connections of the secondary rectifier modules:

1. Measure S1 - S3. Required value, approximately (0.3 - 0.5V).

2. Measure S3 - S1. Required value, open circuit.

3. Measure S2 - S4. Required value, approximately (0.3 - 0.5V).

4. Measure S4 - S2. Required value, open circuit.

NOTE!

It might take a few seconds to reach the required values due to capacitors in the connected

circuits.

7.1.3.2 Restoring the power source after pre power up checks

WARNING!

After having performed pre power up checks according to the instructions above, make

sure all cables and connectors are reconnected!

Particularly check that:

• Transformer cable has been reconnected to connector S1 on the power board 15AP1.

• Any broken fuses are replaced.

• The secondary rectifier diodes have been reconnected in the correct way.

• Cable BUS+ has been reconnected to connector CON8 on the power board 15AP1.

Page is loading ...

ESAB Fabricator EM 400i User manual

Brand: ESAB

Model: Fabricator EM 400i

Category: Welding System

Type: User manual

This manual is also suitable for

Fabricator EM 500i

Download PDF

report

ESAB Fabricator EM 400i User manual

This manual is also suitable for

ESAB Fabricator EM 400i User manual

Related papers

Other documents