ESAB 162i User manual

Brand: ESAB

Model: 162i

Category: Welding System

Type: User manual

This manual is also suitable for

HandyArc 132i DV. 142i

ESAB 162i is a welding power source designed for use in manual metal arc welding processes. It is suitable for welding a wide range of metals, including steel, stainless steel, and aluminum. The device features a number of advanced features that make it easy to use and deliver high-quality welds. These features include:

Automatic voltage adjustment, which ensures that the correct voltage is always applied to the arc, regardless of the input voltage.
Thermal overload protection, which helps to prevent the device from overheating and failing.
A built-in fan, which helps to keep the device cool during operation.

Automatic voltage adjustment, which ensures that the correct voltage is always applied to the arc, regardless of the input voltage.
Thermal overload protection, which helps to prevent the device from overheating and failing.
A built-in fan, which helps to keep the device cool during operation.

HandyArc 132i DV,

142i, 162i

Service manual

0463 768 001 GB 20201222

Ordering no. Product Notes

743463 HandyArc 132iDV Brazil

618674 HandyArc 132iDV Colombia

90180760004 HandyArc 132iDV Mexico

743464 HandyArc 142i Brazil

743525 HandyArc 142i Argentina

4610210150 HandyArc 200i India

734006 HandyArc 142i Russia

743465 HandyArc 162i Brazil

743526 HandyArc 162i Argentina

618672 HandyArc 162i Peru

90180650019 HandyArc 162i Mexico

734008 HandyArc 162i Russia

TABLE OF CONTENTS

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1 READ THIS FIRST

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

2 BEFORE STARTING SERVICE

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

3 INTRODUCTION

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

3.1 Welding equipment

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

3.2 Schematic diagram

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

4 WIRING DIAGRAM

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

4.1 Component description

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

5 TECHNICAL DATA

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

6 TROUBLESHOOTING

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

6.1 Fault tracing

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

6.2 Visual inspection

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

6.3 Components testing

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

6.4 Restoring the power source after pre power up checks

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

6.5 Power up checks

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

6.6 Power on tests

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

6.7 Advanced measurements

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

7 IN-SERVICE INSPECTION AND TESTING

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

7.1 General requirements

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

7.2 Periodic inspection and test

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

7.3 Cleaning instruction

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

7.4 After repair, inspection and test

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

7.5 Visual inspection

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

7.6 Electrical test

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

7.7 Functional test

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

7.8 Test report

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

8 SPARE PARTS AND ACCESSORIES

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

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.

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

November2020.

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 HandyArc 132i DV, HandyArc 142i, and HandyArc 162i 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 Section 7  "IN-SERVICE INSPECTION AND TESTING",

page 31 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

Tool Ordering number

ESAB test box TB1 0460 868 880

Checkmaster 9000

Checkmaster 9000 DC

Or resistive load with equal performance

Recommended measuring devices

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

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

3   INTRODUCTION

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3 INTRODUCTION

The HandyArc 132i DV, 142i and 162i are power sources intended for MMA (Manual Metal Arc)

welding.

3.1 Welding equipment

1 Status indicator 5 Power switch

2 Current adjusting knob 6 Plastic rear panel

3 Thermal protection indicator 7 Negative OKC connector

4 Power cable 8 Positive OKC connector

WARNING!

Loose connections at the solder terminal can cause overheating and cause the male plug

to merge into the OKC terminal.

Main supply

The power source (only HandyArc 132i DV) will automatically adjust to the supplied input voltage

which is 127/220V AC, whereas HandyArc142i and162i are 220V AC. Make sure that it is protected

by the correct fuse rating. A protective ground connection must be installed correctly, in accordance

with regulations.

1. Rating plate with supply connection data.

3   INTRODUCTION

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Rating plates of HandyArc 132i DV, 142i and 162i

Rating plates are located on the bottom of the power source.

3   INTRODUCTION

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3.2 Schematic diagram

Schematic diagram of HandyArc 132i DV, 142i and 162i

Parts Functions

START PROTECTION CONTROL To avoid equipment breakdown, the power source measures the

mains voltage when the power switch is turned ON. To protect

the power source, check that the mains voltage is correct

according to the rating (120/230 V AC) before switching on the

power source.

RECTIFY AND FILTER Transfer the power from AC into DC.

INVERTER Increases the frequency (43 kHz) and transfers the power from

DC into AC.

DECREASE VOLTAGE Changes the high voltage into lower to get high energy.

SECOND TIME RECTIFY Transfer the power from AC into DC.

CONTROL CIRCUIT Estimates the PWM signal and controls the entire process.

DRIVING CIRCUIT Controls the switch for inverter circuit.

AUXILIARY POWER SUPPLY Supply power for CONTROL CIRCUIT and DRIVING CIRCUIT.

FEEDBACK CIRCUIT Gets sampling from the output, sends feedback to CONTROL

CIRCUIT.

4   WIRING DIAGRAM

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4 WIRING DIAGRAM

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic sensitive

devices.

• Use proper static-proof bags and boxes.

The power source consists of a number of function modules. The function modules, circuit boards and

components are listed in the component description below.

Wiring diagram components

Input rectifier and filter circuit

Primary rectifier - HandyArc

132i DV

Converts AC to DC.

Primary rectifier -

HandyArc142i and 162i

Converts AC to DC.

Electrolytic capacitor Smooths the DC voltage.

Inverter circuit

IGBT Converts low frequency DC to

43kHz high frequency AC.

4   WIRING DIAGRAM

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Main transformer Converts HF high voltage to HF

low voltage power.

Secondary rectifier

Secondary rectifier diode

(FRD)

Converts HF AC to DC power.

NOTE!

IGBT and Secondary rectifier diode (FRD) look similar. Read the descriptions carefully

before you do repair to make sure you do not use the wrong part.

4   WIRING DIAGRAM

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HandyArc 132i DV

4   WIRING DIAGRAM

0463 768 001

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HandyArc 142i and 162i

4   WIRING DIAGRAM

0463 768 001

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4.1 Component description

HandyArc 132i DV

1 Secondary rectifier diode (FRD) 3 Main transformer

2 Control panel PCB

4   WIRING DIAGRAM

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1 Connection line 3 Fan

2 Main PCB 4 IGBT

HandyArc 142i and 162i

1 Panel control PCB 2 Main transformer

4   WIRING DIAGRAM

0463 768 001

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1 Main PCB 3 Fan

2 IGBT

4   WIRING DIAGRAM

0463 768 001

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Inverter with integrated control PCB, HandyArc 132i DV

1 IGBT heat sink 6 Auxiliary transformer

2 Drive transformer 7 NTC connector

3 Capacitors 8 Connector between Main PCB and Panel

control PCB

4 Main relay 9 Main transformer

5 Fan connector

1 IGBT 4 Main transformer

2 IGBT heatsink 5 Secondary rectifier diode (FRD)

3 Secondary rectifier diode (FRD) heatsink

4   WIRING DIAGRAM

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Inverter with integrated control PCB, HandyArc 142i and 162i

1 Rectifier bridge 5 NTC connector

2 Fan connector 6 Panel control PCB connector

3 Main relay 7 Switch power transformer

4 Drive transformer 8 Main transformer

1 IGBT 3 IGBT heatsink

2 Rectifier bridge

5   TECHNICAL DATA

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5 TECHNICAL DATA

HandyArc 132i DV HandyArc 142i HandyArc 162i

Mains voltage

127 V +/-10%

1~50/60 Hz

220 V +/-10%

1~50/60 Hz

220 V +/-10%

1~50/60 Hz

127 V +/-10%

1~50/60 Hz

Mains frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz

Primary current I

max

20-90 A 20-130 A 20-140 A 20-160 A

Permissible load at SMAW

100% duty cycle 40 A/21.6 V 58 A/22.3 V 62.6 A/22.2 V 72 A/22.9 V

60% duty cycle 52 A/22.1 V 75 A/23 V 81 A/23.2 V 92 A/23.7 V

20% duty cycle 90 A/23.6 V 130 A/25.2 V 140 A/25.6 V 160 A/26.4 V

Power factor at

maximum current

0.82 0.77 0.77 0.77

Efficiency at

maximum current

82% 82% 83% 83%

Open circuit

voltage

75 V 65 V 75 V 75 V

Apparent power 3.56 kVA 5.5 kVA 5.94 kVA 7.04 kVA

Consumed power 2.8 kW 4.2 kW 4.7 kW 5.5 kW

Maximum effective

current

12.5 A 11 A 12.1 A 14.3 A

Maximum rated

current

28 A 25 A 27 A 32 A

Dimensions

l × w × h

300 × 115 × 232 mm (11.8×4.5×9.1in.)

Weight 3.5 kg 3.7 kg

Recommended

transformer

≥ 5.4 kVA ≥ 8.3 kVA ≥ 9 kVA ≥10.5 kVA

Recommended

circuit breaker

(type B)

≥30 A ≥30 A ≥30 A ≥35 A

Operating

temperature

-10 to 40 °C (+14 to +104°F)

Enclosure class IP 21S

Application class

Duty cycle

According to the IEC 60974-1 standard, the duty cycle is the relationship between the welding period

(Open Arc) in a period of 10 minutes. To explain, the time period used by the IEC standard (10

minutes) is used in the following example. Suppose a welding source is designed to operate at a duty

cycle of 15% to 90 amps. This means that the equipment was built to supply the welding current (90A)

for 1.5 minutes, that is, the arc welding time, every 10 minutes (15% of 10 minutes is 1.5 minutes) .

During the other 8.5 minutes of the 10-minute period, the welding source must remain on and cool.

5   TECHNICAL DATA

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Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid

objects or water.

Equipment marked IP21S is intended for indoor use.

Application class

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

hazard.

6   TROUBLESHOOTING

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6 TROUBLESHOOTING

6.1 Fault tracing

Pre power up checks

WARNING!

Make sure the power source is disconnected from the mains supply and wait at least 5

minutes for the DC bus capacitor to discharge before removing the power source cover!

Then remove the power source cover and measure the voltage between the "+" and "-"

DC-Bus capacitors soldering pads, using a multimeter. If the voltage between the "+" and

"-" DC-Bus capacitors soldering pads, is not < 20 V, wait further until the voltage is below

20 V!

6.2 Visual inspection

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

1. Printed circuit boards for burned varistors or other components

2. Cables and connectors

6.3 Components testing

Primary diode bridge

Use a multimeter set to diode test setting.

Connect the negative probe to DC+ and positive probe to DC-, it should read 0.85 ±0.2 V. Keep the

negative probe at the DC+ and connect the positive probe to each of the AC pins, it should read

0.47V±0.05 V.

Connect positive probe to DC -, and negative probe to each of the AC pins, it should read

0.47V±0.05 V.

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ESAB 162i User manual

Brand: ESAB

Model: 162i

Category: Welding System

Type: User manual

This manual is also suitable for

HandyArc 132i DV. 142i

Automatic voltage adjustment, which ensures that the correct voltage is always applied to the arc, regardless of the input voltage.
Thermal overload protection, which helps to prevent the device from overheating and failing.
A built-in fan, which helps to keep the device cool during operation.

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ESAB 162i User manual

This manual is also suitable for

ESAB 162i User manual

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