ESAB ER 1F User manual

Service manual

0463 480 001 GB 20170607

Valid for: 716-xxx-xxxx

ER 1, ER 1F

Remote controls

TABLE OF CONTENTS

0463 480 001 © ESAB AB 2017

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

BEFORE STARTING SERVICE................................................................ 4

Service aid ................................................................................................ 4

ESAB Tools ............................................................................................... 4

INTRODUCTION....................................................................................... 5

TECHNICAL DATA .................................................................................. 6

WIRING DIAGRAM................................................................................... 7

Component description ........................................................................... 7

Block diagram........................................................................................... 7

SOFTWARE .............................................................................................. 9

ERROR CODES........................................................................................ 10

Error code decriptions ............................................................................. 10

Err 4 or No response from ER1 or ER1F .............................................. 10

TROUBLESHOOTING .............................................................................. 12

Unable to set current with ER1 .............................................................. 12

Push is not detected on ER1 .................................................................. 12

LCD behaviour on ER1............................................................................ 12

Unable to increase current with ER 1F................................................... 12

Status indications on circuit boards ...................................................... 14

Remote control board 21AP1 – Indication of operational status ............ 14

DISASSEMBLY AND REASSEMBLY ...................................................... 15

ER 1 ........................................................................................................... 15

ER 1F ......................................................................................................... 17

SPARE PARTS AND ACCESSORIES ..................................................... 18

Rights reserved to alter specifications without notice.

READ THIS FIRST

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READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

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

help in connection with fault-tracing and repair.

The circuit boards are divided into numbered blocks. Component names in the wiring

diagram are listed in the component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

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

April 2017.

The manual is valid for:

• ER 1 Handheld remote control 0445 536 880 (4 pin cable) with serial number

716-xxx-xxxx

• ER 1 Handheld remote controls 0445 536 881, 0445536882 and 0445536883 (6

pin cable) with serial number 716-xxx-xxxx

• ER 1F Remote control, foot pedal 0445 550 880 (4 pin cable) with serial number

716-xxx-xxxx

• ER 1F Remote control, foot pedal 0445 550 881 and 0445550882 (6 pin cable) with

serial number 716-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 ER 1 and ER 1F 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

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BEFORE STARTING SERVICE

Service aid

ESAB can offer a number of service tools that will simplify the service.

Antistatic service kit

Ordering no. 0740 511 001

The kit makes it easier to protect sensitive

components from electrostatic discharge.

Contents:

• A conductive mat (size 610x610mm /

24×24in.)

• A 1.5 metre (3.28 ft) long ground cable

with a crocodile clip

• An adjustable wrist strap and cable with

an inbuilt protective resistor

Antistatic service kit

ESAB Tools

Checkmaster 9000

Ordering no. 0740 505 881

ESAB test box TB 1

Ordering no. 0460 868 880

INTRODUCTION

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INTRODUCTION

The remote control ER 1 can be used to control current, arc force and memory selection. The

available functions and number of memories depend on the power source the remote control

is connected to.

The foot pedal ER 1F can be used to control current. It also has a trigger function, which can

be used for weld start.

For symbols and functionality, see Instruction manual.

Wires/cables within modules are marked 100 - 6999.

Wires/cables between modules are marked 7000 - 7999.

Components outside modules are marked C1 - C99 (C=capacitor), connectors XS1 -

XS99 (S=socket), XT1 - XT99 (T=terminal).

Circuit boards within each module have names such as 20AP1 - 20AP99.

• 20 = module association, 1-69

• AP = circuit board

• 1 = individual identification number, 0-99

Transistors within particular modules have identification numbers such as 15Q1 - 15Q99.

• 15 = module association, 1-69

• Q = transistor

• 1 = individual identification number, 0-99

TECHNICAL DATA

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TECHNICAL DATA

ER 1 ER 1F

Operating voltage 12–24VDC 12–24VDC

Dimensions L×W×H 205×59×38mm±10%

(8.0×2.3×1.5in.±10%)

225×152×82mm±10%

(8.9×6.0×3.2in.±10%)

Weight unit with 5 meter

(16.4 ft) cable

475g (1.05lb) 2250g (4.96lb)

Operating temperature -20 to +60°C (-4to140°F) -20 to +60°C (-4to140°F)

Transportation temperature -40to +80°C (-40to176°F) -40to +80°C (-40to176°F)

Enclosure class IP53 IP23

WIRING DIAGRAM

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WIRING DIAGRAM

Component description

Component Description

21XS2 LCD

21XS3 Encoder

21AP1 Control board

21XS1 Remote interconnection cable

Block diagram

NOTE!

21AP1 is same but used with different configuration for remote control ER1 and

foot pedal ER1F.

ER 1

WIRING DIAGRAM

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ER 1F

SOFTWARE

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SOFTWARE

The software in ER1 and ER1F consists of three parts: system software (application

software), secondary bootloader and primary bootloader.

The software is updated using the USB port on the power source. For information about

software update, see power source service manual.

ERROR CODES

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ERROR CODES

Error code decriptions

The error code is used to indicate that a fault has occurred in the equipment. Errors are

indicated by the text "Err" and the error code number flashing alternately in the power source

display.

For error codes, see power source service manual. Additional error codes and suggested

service technician actions for error codes are described in the sub-sections below.

Err 4 or No response from ER1 or ER1F

No response from the remote control ER1, foot pedal ER1F or Err 4 on power source.

Service technician actions:

1. Check if cable has a 4 pin or 6 pin connector. Follow the adequate instructions

depending on the cable.

2. Check if the cable is cut or damaged.

3. Check the continuity in the cable.

4 pin cable configuration Connector

numbering

Color Connector Function On PCBA

Black 1 0 V CN1, MTA156 Pin 1

Red 2 +12 V CN1, MTA156 Pin 2

Blue 3 CAN L CN8, Pin 1

White 4 CAN H CN8, Pin 2

Shield Metal cup Shield ER1: To cable mounting plate

ER1F: To PCBA mounting

plate

6 pin cable configuration Connector

numbering

Color Connector Function On PCBA

Black 2 0 V CN1, MTA156 Pin 1

Red/Grey 1 +12 V CN1, MTA156 Pin 2

Blue 3 CAN L CN8, Pin 1

White 4 CAN H CN8, Pin 2

Shield Metal cup Shield ER1: To cable mounting plate

ER1F: To PCBA mounting

plate

Test points for measurements

Test point number Value (in V DC)

TP35, TP2 11.25 V ≤ V ≤ 11.85 V

TP1 4.5 V ≤ V ≤ 5.5 V

TP6 3.13 ≤ V ≤ 3.47

ER 1F: TP12 2.75 ≤ V ≤ 2.90

ERROR CODES

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TROUBLESHOOTING

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TROUBLESHOOTING

See also section “Err 4 or No response from ER1 or ER1F”, page10.

Unable to set current with ER1

1. Rotate the encoder wheel knob. Check

for any obstacle in the wheel path.

2. Check the cable 21XS3 from encoder to

control PCBA. Check if continuity exists

based on color coding.

3. If the cable and the encoder are intact,

replace control board.

Test point Value in idle state When encoder wheel knob is rotated

Red ±3.3 ±0.3 VDC Changes to 0 V and returns to 3.3 V

Blue ±3.3 ±0.3 VDC Changes to 0 V and returns to 3.3 V

Push is not detected on ER1

1. Check if the rubber button is intact.

2. If rubber button is intact, replace the overlay and rubber assembly. Check for

functionality.

Action Measure Requirement

Press the switch Voltage at TP7 wrt. TP3 (GND) 0.3 ±0.3 VDC

Release the switch Voltage at TP7 wrt. TP3 (GND) 3.2 ±0.3 VDC

3. If the issue still persists replace the control board 21AP1.

LCD behaviour on ER1

LCD shows strange images or blank spaces, back light does not glow or any other

malfunctioning state.

1. Replace with a new LCD.

2. Restart the power source and check functionality of remote control.

3. If issue is still not resolved, replace the control board 21AP1.

Unable to increase current with ER 1F

Unable to increase current by pressing the foot pedal ER 1F. Stays at 5 on display.

1. Press the foot control and check for any obstacle in the path. Proceed with next step if

path is clear.

The trigger does not work

1. Check if the micro switch trigger is mechanically stable. If not, replace the complete

unit.

2. Check the voltage at the test points. If the values deviate replace 21AP1.

TROUBLESHOOTING

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# Action On connector On test point Requirement

1 Press the trigger

microswitch.

CN5.1 w.r.t CN5.2 Voltage at TP7 wrt.

TP3 (GND)

0.3±0.3VDC

2 Release the trigger

microswitch.

CN5.1 w.r.t CN5.2 Voltage at TP7 wrt.

TP3 (GND)

3.2±0.3VDC

POT does not work

1. Check if the POT rotates smoothly. If not, replace the unit housing.

2. Check if the cable 21XS2 is intact by checking the continuity. If not intact, replace

21XS2.

3. Check the voltage at the test points. If the values deviate replace 21AP1.

# Action On connector On PCBA Requirement

1 Foot pedal in fully

released state.

CN9.2 w.r.t CN5.2 Voltage at TP9 wrt.

TP3 (GND)

0.29±0.3VDC

2 Foot pedal in fully

pressed state.

CN9.2 w.r.t CN5.2 Voltage at TP9 wrt.

TP3 (GND)

3.27±0.3VDC

TROUBLESHOOTING

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Status indications on circuit boards

Remote control board 21AP1 – Indication of operational status

The LED D4 on the remote control board is used to indicate the operational status of the

board according to the table below.

LED D4 Operational status

Off

The remote control board is disconnected or the power supply is turned off.

Green

The remote control works as expected and has an established communication

path with the power source control board.

Red (fixed) The software has found that an error has occurred. This error may be either

local to the remote control or a system-wide error.

Note! These type of error does not include the communication interface since

that is separately indicated.

Red

(1Hzflash)

No communication path has been established or some other error has occurred

in the communication system.

DISASSEMBLY AND REASSEMBLY

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DISASSEMBLY AND REASSEMBLY

ER 1

DANGER!

Disconnect the power supply when engaged in electrical enclosures and electric

motors. Work with high voltage upon contact may result in death.

Remove the back cover

1. Remove the five screws (1).

2. Remove the back cover of the remote control (2).

3. The back cover houses the magnets and strap. If replacing with a new back cover,

check if the magnets are assembled and if it has a strap.

To replace magnets, place the back cover on a metal surface and remove the screws.

Remove the interconnection cable

4. Remove the two screws (3).

5. Remove the connectors.

6. Place the aluminium tape on the cable below the metal plate.

DISASSEMBLY AND REASSEMBLY

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Remove the encoder assembly

7. Remove the two screws to access the encoder assembly. Note the direction of the

encoder bearing part.

Remove the circuit board

8. Disconnect the cable to the LCD.

9. Remove the three screws holding the circuit board and remove the board.

If needed, replace the LCD on the front cover.

Reassemble the remote control in the reverse order using the correct tightening torques

according to the illustrations.

DISASSEMBLY AND REASSEMBLY

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ER 1F

1. Press the two spring latches (1) to release the top cover.

2. Press and release the cable gland (2). The PCBA and connectors are covered by an

IP protection sheet.

3. Remove the connectors (3).

4. Remove the screw connecting the shield of cable to the metal plate used for mounting

the PCBA (4).

5. Replace the cable.

6. Insert the connectors (3).

7. Ensure that the IP protection sheet is covering the PCBA and connectors.

8. Replace the top cover.

SPARE PARTS AND ACCESSORIES

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SPARE PARTS AND ACCESSORIES

For spare parts, see the spare parts list for the product. For accessories, see the instruction

manual for the product. These documents can be downloaded from the Internet:

www.esab.com

Document type File name Product

Spare parts list 0059 576 990 MTA1CAN, M110PCAN, AT1CAN,

AT1CFCAN, M1, AT1, AT1CF, RA12,

RA23, RAT1, FS002CAN, FS002,

T1FootCAN, ER1, ER1F

Instruction manual 0463 471 * ER 1, ER 1F

SPARE PARTS AND ACCESSORIES

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ESAB subsidiaries and representative offices

www.esab.com

Europe

AUSTRIA

ESAB Ges.m.b.H

Vienna-Liesing

Tel: +43 1 888 25 11

Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.

Heist-op-den-Berg

Tel: +32 15 25 79 30

Fax: +32 15 25 79 44

BULGARIA

ESAB Kft Representative Office

Sofia

Tel: +359 2 974 42 88

Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.

Vamberk

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Herlev

Tel: +45 36 30 01 11

Fax: +45 36 30 40 03

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

Andover

Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel: +33 1 30 75 55 00

Fax: +33 1 30 75 55 24

GERMANY

ESAB Welding & Cutting GmbH

Langenfeld

Tel: +49 2173 3945-0

Fax: +49 2173 3945-218

HUNGARY

ESAB Kft

Budapest

Tel: +36 1 20 44 182

Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A.

Bareggio (Mi)

Tel: +39 02 97 96 8.1

Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V.

Amersfoort

Tel: +31 33 422 35 55

Fax: +31 33 422 35 44

NORWAY

AS ESAB

Larvik

Tel: +47 33 12 10 00

Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o.

Katowice

Tel: +48 32 351 11 00

Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 8 310 960

Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL

Bucharest

Tel: +40 316 900 600

Fax: +40 316 900 601

RUSSIA

LLC ESAB

Moscow

Tel: +7 (495) 663 20 08

Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel: +421 7 44 88 24 26

Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A.

San Fernando de Henares

(MADRID)

Tel: +34 91 878 3600

Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB

Gothenburg

Tel: +46 31 50 95 00

Fax: +46 31 50 92 22

ESAB International AB

Gothenburg

Tel: +46 31 50 90 00

Fax: +46 31 50 93 60

SWITZERLAND

ESAB Europe GmbH

Baar

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC

Kiev

Tel: +38 (044) 501 23 24

Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem-MG

Tel: +55 31 2191 4333

Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 0220

Fax: +1 905 670 4879

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting

Products

Florence, SC

Tel: +1 843 669 4411

Fax: +1 843 664 5748

Asia/Pacific

AUSTRALIA

ESAB South Pacific

Archerfield BC QLD 4108

Tel: +61 1300 372 228

Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 2326 3000

Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 45 670 7073

Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd

USJ

Tel: +603 8023 7835

Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 6861 43 22

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt

Dokki-Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting

Ltd

Durbanvill 7570 - Cape Town

Tel: +27 (0)21 975 8924

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

ESAB ER 1F, ER 1 User manual

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