ESAB Arc 151i A33 User manual

Caddy®

Service manual

0740 800 185 GB 20181205

Valid for: serial no. 803-, 828-, 927-, 747-, 840-xxx-xxxx

Arc 151i A33        

Arc 201i A33

TABLE OF CONTENTS

0740 800 185 © ESAB AB 2018

READ THIS FIRST.................................................................................... 4

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

WIRING DIAGRAM................................................................................... 6

Component description ......................................................................... 6

Arc 151i A33, valid for serial no. 803-, 828 and 927-xxx-xxxx ............ 8

Arc 151i A33, valid for serial no. 747 and 840-xxx-xxxx ..................... 10

Arc 201i A33, valid for serial no. 803-, 828 and 927-xxx-xxxx ............ 12

Arc 201i A33, valid for serial no. 747 and 840-xxx-xxxx ..................... 14

TECHNICAL DATA ................................................................................... 16

Valid for serial no. 803-, 828-, 927-xxx-xxxx......................................... 16

Valid for serial no. 747-, 840-xxx-xxxx .................................................. 17

DESCRIPTION OF OPERATION.............................................................. 19

1 MMC module ........................................................................................ 19

2AP1 Power supply board ..................................................................... 19

2AP1:1 Interference suppressor circuit ................................................ 20

2AP1:2 Primary circuit.......................................................................... 21

2AP1:3 Secondary circuit ..................................................................... 22

2AP1 Component positions.................................................................. 23

15AP1 Power board................................................................................ 26

Charging circuit .................................................................................... 27

Power factor corrector (PFC)................................................................ 27

Gate driver stages ................................................................................ 27

Switching circuit.................................................................................... 27

Supply to 2AP1..................................................................................... 28

15AP1 Component positions................................................................ 28

15AP2 Secondary board ........................................................................ 28

15AP2 Component positions................................................................ 29

20AP1 Control board.............................................................................. 29

20AP1:1 Power supply ......................................................................... 30

20AP1:2 Control panel interface circuits .............................................. 31

20AP1:3 Remote control input ............................................................. 31

20AP1:4 Pulse width modulator ........................................................... 32

20AP1:5 Temperature monitoring......................................................... 32

20AP1:6 Shunt and current control amplifier........................................ 33

20AP1:7 Arc voltage feedback ............................................................. 33

20AP1:8 TIG functions ......................................................................... 34

20AP1:9 Welding process control ........................................................ 34

20AP1:10 Power-up starting sequence................................................ 35

20AP1 Component positions................................................................ 36

FAULT CODES ......................................................................................... 38

TABLE OF CONTENTS

0740 800 185 © ESAB AB 2018

SERVICE INSTRUCTIONS....................................................................... 39

What is ESD? .......................................................................................... 39

Service aid .............................................................................................. 39

Checking the semiconductor module of 15AP1 .................................. 41

Checking rectifier and freewheel diodes ............................................. 42

Checking the gate pulses ...................................................................... 43

Soft starting ............................................................................................ 45

Mounting components on the heat sink............................................... 47

SPARE PARTS ......................................................................................... 49

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.

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" chapter

in this manual.

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

November 2017.

The manual is valid for:

• Arc 151i A33 with serial no. 803-xxx-xxxx, 828-xxx-xxxx, 927-xxx-xxxx, 747-xxx-xxxx

and 840-xxx-xxxx

• Arc 201i A33 with serial no. 803-xxx-xxxx, 828-xxx-xxxx, 927-xxx-xxxx, 747-xxx-xxxx

and 840-xxx-xxxx

The Arc 151i and Arc 201i are designed and tested in accordance with international

and European standards IEC/EN 60974. 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 above standard.

INTRODUCTION

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INTRODUCTION

Design structure of the power source

Block diagram of the Arc 151i and Arc 201i

The power source is transistor-controlled, operating on the inverter principle. It consists of a

number of function modules, as shown in the block diagram above. Each module has a

module number, which is included as the first part of the name/identification of components in

the module.

The modules have the following main functions:

1 MMC module

Control panel and display board.

2 Mains module

Mains switch, mains interference suppressor and power supply board.

15 Power module

This module is a single forward converter, operating at a switching frequency of 65 kHz.

All power semiconductors are built into modules.

20 Processor board module (controller module)

This is the controller board, 20AP1, that monitors and controls the power source. The micro

processor of the board comprises the welding data unit.

WIRING DIAGRAM

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WIRING DIAGRAM

The power source is based on a number of function modules. These are described in the

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

wiring diagram show to which module each component belongs.

Circuit boards within each module have names such as 15AP1 - 15AP99.

15 = module association, 1-69

AP = circuit board

1 = individual identification number, 0-99

Components within modules are named in a similar way.

Component description

1 MMC module: control panel and display board, see "1 MMC module", page19.

2 Mains module.

2AP1 Power supply board, see "2AP1 Power supply board", page19.

2L1-2L9 Ferrite ring cores.

2QF1 Mains switch.

2XS1 Flat pin sockets. Important: to obtain a proper electric connection, the complete

cord set must be replaced if the sockets have to be replaced.

15 Power module.

15AP1 Power board, see "15AP1 Power board", page26.

15AP2 Secondary board, see "15AP2 Secondary board", page28.

15C1 Smoothing capacitor, 1000 uF.

15D1 Diode module with rectifier and freewheel diodes.

15EV1 Fan.

15L1 Inductor.

15L2 PFC Inductor (Power Factor Corrector)

15RS1 Shunt. 60 mV at 100 A.

15ST1 Thermal switch, fitted in the winding of main transformer 15TM1. See "20AP1:5

Temperature monitoring", page32.

15ST2 Thermal switch, fitted on the heat sink. See "20AP1:5 Temperature monitoring",

page32.

15TM1 Main transformer.

20AP1 Controller circuit board. See "20AP1 Control board", page29.

20L1 Ferrite ring core.

WIRING DIAGRAM

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CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

WIRING DIAGRAM

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Arc 151i A33, valid for serial no. 803-, 828 and 927-xxx-xxxx

WIRING DIAGRAM

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WIRING DIAGRAM

0740 800 185

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Arc 151i A33, valid for serial no. 747 and 840-xxx-xxxx

WIRING DIAGRAM

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WIRING DIAGRAM

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Arc 201i A33, valid for serial no. 803-, 828 and 927-xxx-xxxx

WIRING DIAGRAM

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WIRING DIAGRAM

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Arc 201i A33, valid for serial no. 747 and 840-xxx-xxxx

WIRING DIAGRAM

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TECHNICAL DATA

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TECHNICAL DATA

Valid for serial no. 803-, 828-, 927-xxx-xxxx

Arc 151i Arc 201i

Mains voltage 230 V, 1 ~ 50/60 Hz 230 V, 1 ~ 50/60 Hz

Primary current

I

max

TIG 13.8 A 24.1 A

I

max

MMA 21.3 A 24.9 A

Mains supply Z

max

0.35 ohm Z

max

0.30 ohm

No-load power 30 W 30 W

Voltage/current range, MMA

A31 8 A /20 V - 150 A /26 V -

A33 4 A /20 V - 150 A /26 V 4 A /20 V - 170 A /26.8 V

Voltage/current range TIG 3 - 150 A 3 - 220 A

Permissible load at MMA

25% duty cycle 150 A / 26.0 V 170 A / 26.8 V

60% duty cycle 100 A / 24.0 V 130 A / 25.2 V

100% duty cycle 90 A / 23.6 V 110 A / 24.4 V

Permissible load at TIG

20% duty cycle - 220 A / 18.8 V

25% duty cycle 150 A / 16.0 V -

60% duty cycle 120 A / 14.8 V 150 A / 16.0 V

100% duty cycle 110 A / 14.4 V 110 A / 15.6 V

Power factor at maximum

current

0.99 0.99

Efficiency at maximum current 80% 81%

Open-circuit voltage

A31 without VRD function

1)

58 - 72 V -

A33 VRD function deactivated

2)

55 - 60 V 55 - 60 V

VRD function activated

2)

< 35 V < 35 V

Operating temperature -10 °C - +40 °C -10 °C - +40 °C

Transportation temperature -20 °C - +55 °C -20 °C - +55 °C

Constant A-weighted sound

pressure

< 70 dB < 70 dB

Dimensions, l x b x h 418 x 188 x 208 mm 418 x 188 x 208 mm

Weight

with A31 7.9 kg -

with A33 8.1 kg 8.3 kg

Enclosure class IP 23 IP 23

Application class

TECHNICAL DATA

0740 800 185

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Valid for serial no. 747-, 840-xxx-xxxx

Arc 151i Arc 201i

Mains voltage 230 V, 1 ~ 50/60 Hz 230 V, 1 ~ 50/60 Hz

Primary current:

I

max

TIG 13.8 A 24.1 A

I

max

MMA 21.3 A 24.9 A

No-load power 30 W 32 W

Voltage/current range, MMA:

A31 8 A / 20 V - 150 A / 26 V -

A33 4 A / 20 V - 150 A / 26 V 4 A / 20 V - 170 A / 26.8 V

Voltage/current range TIG 3A / 10V - 150 A / 16V 3A / 10V - 220A / 18V

Permissible load at MMA:

25% duty cycle 150 A / 26.0 V 170 A / 26.8 V

60% duty cycle 100 A / 24.0 V 130 A / 25.2 V

100% duty cycle 90 A / 23.6 V 110 A / 24.4 V

Permissible load at TIG:

20% duty cycle - 220 A / 18.8 V

25% duty cycle 150 A / 16.0 V -

60% duty cycle 120 A / 14.8 V 150 A / 16.0 V

100% duty cycle 110 A / 14.4 V 110 A / 14.4 V

Power factor at maximum current 0.99 0.99

Efficiency at maximum current 80% 81%

Open-circuit voltage:

A31 without VRD function

1)

58 - 72 V -

A33 VRD function deactivated

2)

56 V 56 V

VRD function activated

2)

23 V 22 V

Operating temperature -10 °C - +40 °C -10 °C - +40 °C

Transportation temperature -20 °C - +55 °C -20 °C - +55 °C

Constant A-weighted sound

pressure

< 70 dB < 70 dB

Dimensions (l × b × h) 418 × 188 × 208 mm 418 × 188 × 208 mm

Weight:

with A31 7.9 kg -

with A33 8.1 kg 8.3 kg

Enclosure class IP 23 IP 23

Application class

1) Valid for power sources without VRD specification on the rating plate.

2) Valid for power sources with VRD specification on the rating plate. The VRD function is

explained in the instruction manual for the control panel.

Mains supply, Z

max

TECHNICAL DATA

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Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

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 IP23 is intended for indoor and outdoor use.

Application class

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

electrical hazard.

DESCRIPTION OF OPERATION

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DESCRIPTION OF OPERATION

This description of operation describes the function of circuit boards and other components in

the equipment. It is divided into sections, numbered to correspond to the circuit board

numbers and divisions into function blocks.

1 MMC module

The MMC module consists of an operator's control panel and a display board.

The control panel is used for setting and displaying welding data. The welding data are

stored by the control board of the power source.

The control panel is described in separate instruction and service manuals.

A33 intended for MMA- and DC TIG welding without pulsing.

Pushbuttons are used for parameter selection and a knob for parameter settings.

2AP1 Power supply board

The power supply board filters the mains voltage and generates internal supply voltages for

the equipment.

There are several different versions of the power supply board. The difference between the

versions can be seen in section "2AP1 Component positions", page23.

DESCRIPTION OF OPERATION

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2AP1:1 Interference suppressor circuit

WARNING!

Dangerous voltage - mains voltage

The mains voltage is filtered by the power supply board. Power board 15AP1 rectifies the

mains voltage.

Serial no. 803-, 828-, 927-xxx-xxxx

Serial no. 747-, 840-xxx-xxxx

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