ESAB DTF 180 User manual

0740 800 112 0207

Handy Tig 180 AC

Welding rectifier

Service manual

0740 800 112 0207 - 1 -

LIST OF CONTENTS

READ THIS FIRST ................................................................................................................................. 3

PRINCIPAL DIAGRAM DTF180 ............................................................................................................ 6

FUNCTION DIAGRAMM DTF180 .......................................................................................................... 7

FUNCTION DIAGRAM DTF 180, part 2 ................................................................................................. 8

FUNCTION DIAGRAMM DTF180 .......................................................................................................... 9

COMPONENT DESCRIPTION ............................................................................................................ 11

CONNECTION DIAGRAM DTF180 ..................................................................................................... 13

CONNECTION DIAGRAM DTF180, part 2 .......................................................................................... 14

CONNECTION DIAGRAM DTF180 ..................................................................................................... 15

AP00 COMPONENT POSITIONS .......................................................................................................17

AP00 CIRCUIT DIAGRAM ................................................................................................................... 17

AP01 COMPONENT POSITIONS ......................................................................................................18

AP01 COMPONENT POSITIONS ......................................................................................................19

AP01 DESCRIPTION OF OPERATION .............................................................................................. 20

AP01.1 INTERFERENCE SUPPRESSION AND START-UP CIRCUIT ........................................ 20

AP01.2 PRIMARY SMPS, PFC-PART, MOSFET DRIVERS ......................................................... 21

AP01.3 THERMAL SWITCH .......................................................................................................... 25

AP01.4 CURRENT OVERLOAD PROTECTION ........................................................................... 26

AP01.5 INTERFACE FOR TORCH BUTTON RECOGNITION, IGNITION DEVICE AND GAS VALVE

RELAY ............................................................................................................................................ 26

AP01.6 INTERFACE FOR INVERTER 2 .......................................................................................... 8

AP01.7 CURRENT SET VALUE - POTENTIOMETER I2 .............................................................. 29

AP02 COMPONENT POSITIONS ......................................................................................................30

AP02 DESCRIPTION .......................................................................................................................... 31

AP03/AP04 COMPONENT POSITIONS ............................................................................................. 32

AP03/AP04 COMPONENT POSITIONS ............................................................................................. 33

AP03 DESCRIPTION OF OPERATION .............................................................................................. 34

AP03.1 INTERFACE FOR INVERTER .......................................................................................... 34

AP03.2 INTERFACE FOR TORCH BUTTON RECOGNITION AND GAS VALVE RELAY ........... 36

AP03.3 CONNECTION TORCH BUTTON AND REMOTE CONTROL ......................................... 38

AP03.4 CONNECTION IGNITION DEVICE, SOLENOID VALVE, FAN ........................................ 39

AP04 CIRCUIT DIAGRAM .................................................................................................................. 40

AP04 COMPONENT POSITIONS .......................................................................................................40

BUS TESTER 41

1 COMPONENT POSITIONS ........................................................................................................ 41

2 CONNECTION ............................................................................................................................ 41

3 USE ............................................................................................................................................. 42

4 DISPLAYS OF THE TESTER ...................................................................................................... 42

5 CIRCUIT DIAGRAM OF THE TESTER ...................................................................................... 43

DISASSEMBLY / REASSEMBLY ........................................................................................................ 45

1 GENERAL ASSEMBLY .............................................................................................................. 45

2 ASSEMBLY GROUP AP01, CONTROL ..................................................................................... 45

3 ASSEMBLY GROUP AP02, POWER UNIT ................................................................................ 46

4 ASSEMBLY GROUP AP03, CONTROL ..................................................................................... 47

5 ASSEMBLY GROUP AP04, RECTIFIER .................................................................................... 47

6 ASSEMBLY GROUP AP05, MAINS CABLE .............................................................................. 48

7 ASSEMBLY GROUP TC01, POWER TRANSDUCER, L01, PFC-CHOKE ................................ 48

8 ASSEMBLY GROUP YV01, GAS VALVE .................................................................................. 49

9 ASSEMBLY GROUP EV01, FAN ............................................................................................... 50

10 JACKS ...................................................................................................................................... 50

STARTING UP ..................................................................................................................................... 53

1 Material ....................................................................................................................................... 53

2 Manufacturers pre-adjusted values of spareparts AP01 .. AP04 ................................................ 53

AP02 ............................................................................................................................................... 54

AP03 ............................................................................................................................................... 54

AP04 ............................................................................................................................................... 54

3 Post adjustment / check of control AP01 ..................................................................................... 55

3.1 Function test of AP01 and AP02 .............................................................................................. 55

3.2 Post-adjustment/check ............................................................................................................. 57

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4 Control AP02 ............................................................................................................................... 57

5 Control AP03, check and post-adjustment.................................................................................. 57

6 General check ............................................................................................................................. 57

MODIFICATIONS/TECHNICAL UPDATES ......................................................................................... 58

1 Weak insufficient HF-Ignition ....................................................................................................... 58

2 Welding problems for AC-current less 20 amps .......................................................................... 59

LOAD CHARACTERISTICS ................................................................................................................ 60

TECHNICAL DATA .............................................................................................................................. 61

INSTALLATION ................................................................................................................................... 63

OPERATION ........................................................................................................................................ 65

1 ELECTRODE WELDING ............................................................................................................ 67

+ Positive Electrode Polarisation ................................................................................................... 67

- Negative Electrode Polarisation ................................................................................................... 67

AC Alternating current .................................................................................................................... 67

2 TIG WELDING ............................................................................................................................ 68

TWO-STEP LIFT ARC (DC) ........................................................................................................... 70

TWO-STEP HF ............................................................................................................................... 71

FOUR-STEP LIFT ARC .................................................................................................................. 72

4-STEP-HF ..................................................................................................................................... 73

MAINTENANCE ................................................................................................................................... 74

ACCESSORIES ................................................................................................................................... 74

SPARE PARTS LIST DTF 180 ............................................................................................................ 75

ORDERING OF SPARE PARTS ......................................................................................................... 77

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READ THIS FIRST

This service manual is intended for use by technicians with electrical/electronic training to

help in connection with fault-tracing and repair.

Use the connection diagram as a form of index for the description of operation and the

component description. The circuit board is divided into numbered blocks, which are de-

scribed individually in more detail in the description of operation. All important component

names in the connection diagram are listed in the component description.

This manual contains details of all design that have been made up to and including July

2002. Rights reserved to alter specifications without notice.

NOTE! All warranty undertakings given by the supplier cease to apply if the customer at-

tempts to rectify any faults on the machine during the warranty period.

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THE DTF180 IST DESIGNED AND TESTED IN ACCORDANCE WITH

INTERNATIONAL STANDARD EN 60 974-1 (IEC 974-1).

ON COMPLETION OF SERVICE OR REPAIR WORK, IT IS THE RESPONSIBILITY OF

THE PERSON(S) ETC. PERFORMING THE WORK TO ENSURE THAT THE

PRODUCT DOES NOT DEPART FROM THE REQUIREMENTS OF THE ABOVE

STANDARD.

WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS.

TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY

PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS’ HAZARD DATA:

ELECTRIC SHOCK - Can kill

• Install and earth the welding unit in accordance with applicable standards.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet

clothing.

• Insulate yourself from earth and the workpiece.

• Ensure your working stance is safe

FUMES AND GASES - Can be dangerous to health

• Keep your head out of fumes.

• Use ventilation, extraction at the arc, or both, to keep fumes and gases from your

breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and wear

protective clothing.

• Protect bystanders with suitable screens or curtains.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable

materials nearby.

NOISE - Excessive noise can damage hearing

• Protect your ears. Use ear defenders or other hearing protection.

• Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE

INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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WARNING

This product is intended for industrial use. In a domestic environment this product

may cause radio interference. It is the users responsibility to take adequate

precautions.

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PRINCIPAL DIAGRAM DTF180

The DTF180 is a primary-switched power unit, using a power-factor-controller (PFC) in

boost topology followed by a full-bridge switched mode power supply (SMPS). A high fre-

quency transformer (TC01) isolates the mains potential from the welding potential. After

high frequency rectification (V01-V04) the polarity of the output current is controlled by an

alternating switch (V05, half-bridge topology).

Primary PFC and SMPS uses parallel-connected MOSFET on AP02 as switching ele-

ments, the polarity reversing half-bridge for the welding current uses IGBT-technology.

The switching frequency of PFC is about 70 kHz (pulse-wide-modulation), of SMPS about

102 kHz (phase-shifting-modulation). The frequency of the welding current while AC-wel-

ding is controlled to 50 Hz.

A high voltage ignition unit is used for ignition and stabilising the arc while welding. AP01

and AP03 control the power stages and ignition unit.

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FUNCTION DIAGRAMM DTF180

first version (valid for machines til serial no. 751-229-0012)

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FUNCTION DIAGRAM DTF 180, part 2

first version

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FUNCTION DIAGRAMM DTF180

second version (valid for machines from serial no. 751-229-0012 on)

0740 800 112 0207 - 10 -

FUNCTION DIAGRAM DTF180, part 2

second version

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COMPONENT DESCRIPTION

This component description refers to the connection diagram on the following pages.

AP00 E-Assembly, HD30 power filter, Interference suppression circuit board, con-

nector to mains voltage cable

AP01 control HD30ST, consists of partial circuit boards AP01-1 HD30STU and

AP01-2 HD30STO. It contents:

• all front operating elements and displays

• interference suppression and start-up circuit

• PFC-control

• primary switch mode power supply for internal supply

• clock generation, potential separation, MOSFET-drivers, phase-shift-

modulator

• functional management and function storage

• process sequence control

• logic and control for secondary inverter

AP02 control HD30PR, it contains:

• cooled mains rectifier, mains electrolytic capacitors

• cooled power MOSFET's and boost diode for PFC-stage

• cooled power MOSFET's for mains full-bridge

• gate network for MOSFET's

AP03 inverter circuit board HD30WRZ (first version), it contains:

• potential separation and control-driver for IGBT inverter

• connection area and protection circuit for IGBT

• thermal switch recording, shunt and voltage recording

• torch button recording

• high-voltage ignition unit

• solenoid valve control

• connector for remote control

AP03 inverter circuit board HD41WRZ (second version), it contains:

• potential separation and control-driver for IGBT inverter

• connection area and protection circuit for IGBT

• thermal switch recording, shunt and voltage recording

• torch button recording

• high-voltage ignition unit

• solenoid valve control

• connector for remote control

• connector to mains voltage cable

• power filter

• Interference suppression circuit board

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AP04 rectifier board HD41GR, it contains:

• connection area and protection circuit for rectifier modules

V01..V04 rectifier modules, each module contains two parallel rectifier diodes

V05 IGBT-half bridge, 300A/600V

TC01 High frequency power transformer

TC02 current sensor transformer 200:1

TC03 HF - choke

L01 interference suppression choke with protective conductor

L02 interference suppression for exterior conductor

L03 Choke, boost inductor (PFC)

X... connectors

XS01 mains cable 3*1.5

XS02,03 socket for TIG torch, workpiece cable

XS05 remote regulator socket, Burndy, complete

YV01 solenoid valve, 230V AC

EV01 fan, 230V AC

QF01 main switch 0/1 DTF180

RP01 potentiometer 10k, linear, on AP01-2, for welding current I1

RP02 potentiometer 10k 300° linear, for welding current I2

RP03 potentiometer 50k, linear, on AP01-2, for current slope (TIG) and I1 start

time (MMA)

RP04 potentiometer, part of remote control device

SA01 torch button, DTF180

SA02 second torch button connected on AP03 for special function, not used on

DTF180

SA03 start button for remote control, part of remote control device

SA04 welding mode button on AP1-2 (front panel)

SA05 selector switch TIG / MMA

ST01 thermal switch, opening, 80°C

ST02 thermal switch, opening, 70°C

ST03 thermal switch, opening, 90°C

0740 800 112 0207 - 13 -

CONNECTION DIAGRAM DTF180

(first version)

0740 800 112 0207 - 14 -

CONNECTION DIAGRAM DTF180, part 2

(first version)

0740 800 112 0207 - 15 -

CONNECTION DIAGRAM DTF180

(second version)

0740 800 112 0207 - 16 -

CONNECTION DIAGRAM DTF180, part 2

(second version)

0740 800 112 0207 - 17 -

AP00 COMPONENT POSITIONS

AP00 is connected to mains voltage

and works as an interference suppres-

sion filter. Mains cable XS01 is con-

nected on PE, N, L of X1. X9 and X8

connects the mains voltage to mains

switch QF01.

WARNING! The circuit and its parts are connecteed to mains voltage potential.

AP00 CIRCUIT DIAGRAM

WARNING! The circuit and its parts are connecteed to mains voltage potential.

In case of replacement of single components it is important for security and electroma-

gnetical compability to use only original parts.

Note: pc-board AP00 is only used in the first version of the DTF 180. In the second ver-

sion of the DTF 180, the mains filter was implemented on to the new pc-board AP03

(HD41WRZ).

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AP01 COMPONENT POSITIONS

(first version)

0740 800 112 0207 - 19 -

AP01 COMPONENT POSITIONS

(second version)

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ESAB DTF 180 User manual

ESAB DTF 180 User manual

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