ESAB EMP 285ic 1PH and 3PH User manual

MANUAL PART # 0463 620 001 © ESAB AB 2017

Valid for: serial nos. 745-xxx-xxxx, 747-xxx-xxxx

Rights

reserved

to alter specifications without

notice.

SERVICE MANUAL

EMP 285ic 1PH and 3PH

(Intentionally Blank)

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equip

ment, we urge

you to read our booklet, "Precautions and Safe Practices for Arc

Welding, Cutting, and

Gouging," Form 52-529. See:

http://www.esabna.com/eu/literature/precautions%20and%20safe%20practices%20fo

r%20arc%20welding,%20cutting%20and%20gouging.pdf

Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT

attempt to install or operate this equipment until you have read and fully understand

these instructions. If you do not fully understand these instructions, contact your supplier

for further information. Be sure to read the Safety Precautions before installing or

operating this equipment.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equip

ment, we urge

you to read our booklet, "Precautions and Safe Practices for Arc

Welding, Cutting, and

Gouging," Form 52-529. See:

http://www.esabna.com/literature/precautions%20and%20safe%20practices%20for%20a

rc%20welding,%20cutting%20and%20gouging.pdf

Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT

attempt to install or operate this equipment until you have read and fully understand

these instructions. If you do not fully understand these instructions, contact your supplier

for further information. Be sure to read the Safety Precautions before installing or

operating this equipment.

WARNING

Before use, read and understand the instruction and follow all

labels, employer’s safety practices and Safety Data Sheets.

(Intentionally Blank)

i

SECTION TABLE OF CONTENTS

Paragraph Page

SECTION 1 WELCOME TO ESAB

1.1 HOW TO USE THIS MANUAL ................................................................................... I

1.2 EQUIPMENT IDENTIFICATION ................................................................................. I

1.3

RECEIPT OF EQUIPMENT ......................................................................................... I

1.4 DESCRIPTION .......................................................................................................... I

SECTION 2 SAFETY

2.1 MEANING OF SYMBOLS ...................................................................................... 2-1

2.1.1 SAFETY GUIDANCE AND INFORMATION ............................................................ 2-1

2.1.2 SAFETY PRECAUTIONS ...................................................................................... 2-1

2.1.3 FIRES AND EXPLOSIONS .................................................................................... 2-3

2.1.4 ELECTRICAL SHOCK ........................................................................................... 2-4

2.1.5 ELECTRIC AND MAGNETIC FIELDS ..................................................................... 2-4

2.1.6 FUMES AND GASES ........................................................................................... 2-5

2.1.7 CYLINDER HANDLING ........................................................................................ 2-6

2.1.8 MOVING PARTS ................................................................................................ 2-7

2.1.9 MALFUNCTION ................................................................................................. 2-7

2.1.10 EQUIPMENT MAINTENANCE ............................................................................. 2-7

2.1.11 FALLING EQUPMENT ........................................................................................ 2-8

2.1.12 ARC RAYS .......................................................................................................... 2-8

2.1.13 NOISE ............................................................................................................... 2-8

2.1.14 USER RESPONSIBILITY ....................................................................................... 2-9

2.2 ESD (ELECTROSTATIC DISCHARGE) .................................................................... 2-11

SECTION 3 INTRODUCTION

3.1 KEY FEATURES ..................................................................................................... 3-1

3.2 EQUIPMENT ........................................................................................................ 3-1

3.2.1 EMP 285ic 1ph.................................................................................................. 3-1

3.2.2 EMP 285ic 3ph:................................................................................................. 3-2

3.3 OVERHEATING PROTECTION ............................................................................... 3-2

SECTION 4 TECHNICAL SPECIFICATIONS

4.1 EMP 285IC (1PH) SPECIFICATIONS ...................................................................... 4-1

4.2 EMP 285IC (3PH) SPECIFICATIONS ...................................................................... 4-4

SECTION 5 INSTALLATION

5.1 LOCATION ........................................................................................................... 5-1

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Paragraph Page

5.2 HIGH FREQUENCY INTERFERENCE ....................................................................... 5-2

5.2.1 User’s Responsibility......................................................................................... 5-3

5.2.2 Assessment of Area .......................................................................................... 5-3

5.3 LIFTING INSTRUCTIONS ....................................................................................... 5-4

5.4 MAIN SUPPLY...................................................................................................... 5-5

5.5 RECOMMENDED ELECTRICAL-SUPPLY SPECIFICATIONS ...................................... 5-6

5.6 SUPPLY FROM POWER GENERATORS ................................................................. 5-7

SECTION 6 OPERATION

6.1 UNIT’S CONNECTIONS AND CONTROLS .............................................................. 6-2

6.2 CONNECTION OF WELDING AND RETURN CABLES .............................................. 6-3

6.2.1 FOR MIG/MMA PROCESS .................................................................................. 6-3

6.2.2 FOR TIG PROCESS ............................................................................................. 6-4

6.3 POLARITY CHANGE .............................................................................................. 6-4

6.4 SHIELDING GAS ................................................................................................... 6-4

6.5 VOLT-AMPERE CURVES ....................................................................................... 6-5

6.5.1 1ph VOLT-AMPERE CURVES .............................................................................. 6-5

6.5.1.1 SMAW (Stick) 120 V, 1ph ............................................................................... 6-5

6.5.1.2 SMAW (Stick) 230 V, 1ph ............................................................................... 6-5

6.5.1.3 GMAW (MIG) 120 V, 1ph ............................................................................... 6-6

6.5.1.4 GMAW (MIG) 230 V, 1ph ............................................................................... 6-6

6.5.1.5 GTAW (TIG) 120 V, 1ph .................................................................................. 6-7

6.5.1.6 GTAW (TIG) 230 V, 1ph .................................................................................. 6-7

6.5.2 3ph VOLT-AMPERE CURVES .............................................................................. 6-8

6.5.2.1 SMAW (Stick) 460 V, 3ph / SMAW (Stick) 575 V, 3ph ..................................... 6-8

6.5.2.2 GMAW (MIG) 460 V, 3ph / GMAW (MIG) 575 V, 3ph ..................................... 6-8

6.5.2.3 GTAW (TIG) 460 V, 3ph / GTAW (TIG) 575 V, 3ph ........................................... 6-9

6.6 DUTY CYCLE....................................................................................................... 6-10

6.7 REMOVING/INSTALLING BOBBIN ..................................................................... 6-13

6.8 REMOVING/INSTALLING WIRE .......................................................................... 6-15

6.8.1 REMOVING WIRE ............................................................................................ 6-16

6.8.2 INSTALLLING WIRE ......................................................................................... 6-19

6.9 WELDING WITH ALUMINUM WIRE ................................................................... 6-20

6.10 SETTING WIRE-FEED PRESSURE ......................................................................... 6-21

6.11 REMOVING/INSTALLING WIRE-FEED ROLLERS .................................................. 6-23

6.11.1 REMOVING WIRE-FEED ROLLERS .................................................................... 6-24

6.11.2 INSTALLING WIRE-FEED ROLLERS .................................................................... 6-26

6.12 REMOVING/INSTALLING/ADJUSTING WIRE-FEED GUIDES ................................ 6-28

6.12.1 OUTPUT WIRE-GUIDE REMOVAL/INSTALLATION ............................................ 6-32

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6.12.2 CENTER WIRE-GUIDE REMOVAL/INSTALLATION ............................................. 6-32

6.12.3 ADJUSTING WIRE GUIDES ............................................................................... 6-32

SECTION 7 CONTROL PANEL

7.1 HOW TO NAVIGATE ............................................................................................ 7-1

7.2 MAIN MENU ....................................................................................................... 7-1

7.3 SMIG MODE: BASIC ............................................................................................. 7-2

7.4 SMIG MODE: ADVANCED .................................................................................... 7-2

7.5 MANUAL MIG MODE: BASIC ............................................................................... 7-3

7.6 MANUAL MIG MODE: ADVANCED ...................................................................... 7-3

7.7 FLUX CORED WIRE MODE: BASIC ........................................................................ 7-4

7.8 FLUX CORED WIRE MODE: ADVANCED ............................................................... 7-4

7.9 MMA MODE: BASIC ............................................................................................ 7-5

7.10 MMA MODE: ADVANCED ................................................................................... 7-5

7.11 LIFT-TIG MODE: BASIC ........................................................................................ 7-6

7.12 LIFT-TIG MODE: ADVANCED................................................................................ 7-6

7.13 SETTINGS ............................................................................................................ 7-7

7.14 USER MANUAL INFORMATION ........................................................................... 7-7

7.15 ICON REFERENCE GUIDE ...................................................................................... 7-8

SECTION 8 MAINTENANCE

8.1 ROUTINE MAINTENANCE .................................................................................... 8-2

8.2 WIRE-FEEDER ASSEMBLY MAINTENANCE .......................................................... 8-2

8.2.1 WIRE-FEEDER ASSEMBLY CLEANING ................................................................. 8-2

8.3 EMP-UNIT POWER-SIDE MAINTENANCE ............................................................. 8-5

8.4 TORCH LINER MAINTENANCE ............................................................................. 8-5

8.4.1 TORCH LINER CLEANING ................................................................................... 8-5

SECTION 9 TROUBLESHOOTING 3-PHASE UNIT

9.1 POWER-SUPPLY SIDE THEORY OF OPERATION ................................................... 9-1

9.1.1 Structure of the Power-Supply Side .................................................................. 9-2

9.1.2 Design structure of the Power Supply Circuit .................................................... 9-3

9.1.3 Working Principle of the Power Supply Side Sub-Assemblies ............................ 9-3

9.2 PRELIMINARY FUNCTIONAL CHECKS ................................................................... 9-5

9.3 SUBASSEMBLY DESCRIPTION, LOCATION, TEST POINTS, REMOVAL ................... 9-7

9.3.1 Access into the Power Side ............................................................................... 9-7

9.3.2 User Interface (UI) ............................................................................................ 9-7

9.3.2.1 UI Disassembly .............................................................................................. 9-9

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9.3.2.2 User Interface (UI) Software-Displayed Fault Codes ..................................... 9-10

9.4 POWER-SUPPLY SIDE INTERNAL LED (LIGHT EMITTING DIODE) DIAGNOSTICS . 9-11

9.4.1 Main Power Switch, SW1 ................................................................................ 9-11

9.4.2 EMI Filter Board ............................................................................................. 9-13

9.4.2.1 EMI Filter Board Disassembly....................................................................... 9-15

9.4.3 Main Power Board .......................................................................................... 9-15

9.4.3.1 Main Power Board Disassembly ................................................................... 9-18

9.4.4 Internal Power Supply (IPS) Board .................................................................. 9-20

9.4.4.1 IPS Board Disassembly ................................................................................. 9-22

9.4.5 Control Board ................................................................................................. 9-23

9.4.5.1 DIP Switch Settings ...................................................................................... 9-25

9.4.5.2 Control Board Disassembly .......................................................................... 9-28

9.4.6 Main Transformer .......................................................................................... 9-28

9.4.7 Output Diode Assembly .................................................................................. 9-30

9.4.7.1 Output Diode Board Disassembly ................................................................ 9-32

9.4.8 Output Inductor ............................................................................................. 9-32

9.4.9 Current Sensor ............................................................................................... 9-34

9.4.10 Cooling Fans ................................................................................................... 9-35

9.4.11 Gas Valves ...................................................................................................... 9-36

9.5 FUNCTIONAL TEST PROCEDURES ...................................................................... 9-37

9.5.1 Initial Set up conditions .................................................................................. 9-37

9.6 POWER UP TEST ................................................................................................ 9-38

9.6.1 POWER-UP TEST PROBLEMS ........................................................................... 9-40

9.7 SMAW PROCESS TEST ....................................................................................... 9-42

9.7.1 SMAW Process Test: LED status ...................................................................... 9-42

9.7.2 SMAW PROCESS TEST PROBLEMS ................................................................... 9-43

9.8 GTAW LIFT TIG PROCESS TEST .......................................................................... 9-44

9.8.1 GTAW LIFT TIG Process Test: LED status ......................................................... 9-44

9.8.2 GTAW LIFT TIG PROCESS TEST PROBLEMS ...................................................... 9-45

9.9 GMAW MIG PROCESS TEST ............................................................................... 9-46

9.9.1 GMAW Process Test: LED status ..................................................................... 9-46

9.9.2 GMAW PROCESS TEST PROBLEMS .................................................................. 9-47

9.10 COMPONENT, SUB-ASSEMBLY TESTS................................................................ 9-49

9.10.1 Power Cord/Plug, Power Switch, and EMI Board Test ..................................... 9-49

9.10.2 Primary Rectifier Test ..................................................................................... 9-51

9.10.2.1 BR1, BR2 Test Procedure ............................................................................. 9-53

9.10.3 IPS Board Test ................................................................................................ 9-55

9.10.4 Main Power Board Test .................................................................................. 9-57

9.10.5 Control Board Test ......................................................................................... 9-61

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Paragraph Page

9.10.6 UI Board Test .................................................................................................. 9-65

9.10.7 D67-D69/D174-D177 Output Diode Board Test .............................................. 9-67

9.10.7.1 Output Diode Board External Test ............................................................... 9-67

9.10.7.2 Output Diode Board Internal Test ................................................................ 9-68

9.10.8 Current Sensor Test ........................................................................................ 9-69

9.10.9 Remote Control Trigger Test ........................................................................... 9-70

SECTION 10 TROUBLESHOOTING 1-PHASE UNIT

10.1 1-PHASE UNIT: POWER-SUPPLY SIDE OPERATION ............................................ 10-1

10.1.1 Structure of the Power-Supply Side ................................................................ 10-1

10.1.2 1-Phase Unit: Design structure of the Power Supply Circuit ............................ 10-2

10.1.3 1-Phase Unit: Working Principle of the Power Supply Side Sub-Assemblies .... 10-3

10.2 PRELIMINARY FUNCTIONAL CHECKS ................................................................. 10-5

10.3 SUBASSEMBLY DESCRIPTION, LOCATION, TEST POINTS, REMOVAL ................. 10-8

10.3.1 User Interface (UI) .......................................................................................... 10-8

10.3.1.1 UI Disassembly ............................................................................................ 10-9

10.3.1.2 User Interface (UI) Software-Displayed Fault Codes ................................... 10-10

10.3.2 Main Power Switch, SW1 .............................................................................. 10-11

10.3.3 Main Power Board ........................................................................................ 10-12

10.3.3.1 Main Power Board Disassembly ................................................................. 10-16

10.3.4 Control Board ............................................................................................... 10-18

10.3.4.1 DIP Switch Settings .................................................................................... 10-20

10.3.4.2 Control Board Disassembly ........................................................................ 10-23

10.3.5 Main Transformer ........................................................................................ 10-23

10.3.6 Output Diode Assembly ................................................................................ 10-25

10.3.6.1 Output Diode Board Disassembly .............................................................. 10-26

10.3.7 Output Inductor ........................................................................................... 10-27

10.3.8 Current Sensor ............................................................................................. 10-29

10.3.9 Cooling Fans ................................................................................................. 10-30

10.3.10 Gas Valves .................................................................................................... 10-31

10.4 FUNCTIONAL TEST PROCEDURES .................................................................... 10-32

10.4.1 Power-UP Procedure .................................................................................... 10-32

10.4.1.1 Power-Up Faults ........................................................................................ 10-34

10.4.2 SMAW Process Test ...................................................................................... 10-36

10.4.2.1 SMAW Process Test: LED status ................................................................. 10-36

10.4.2.2 SMAW Process Test Problems ................................................................... 10-37

10.4.3 GTAW LIFT TIG Process Test ......................................................................... 10-38

10.4.3.1 GTAW LIFT TIG Process Test: LED status .................................................... 10-38

10.4.3.2 GTAW LIFT TIG Process Test Problems ....................................................... 10-39

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10.4.4 GMAW MIG Process Test .............................................................................. 10-40

10.4.4.1 GMAW Process Test Problems ................................................................... 10-41

10.5 COMPONENT, SUB-ASSEMBLY TESTS.............................................................. 10-43

10.5.1 Initial Set up conditions ................................................................................ 10-43

10.5.2 MAIN POWER CABLE/PLUG Test ................................................................... 10-44

10.5.3 SW1, ON/OFF SWITCH Test ........................................................................... 10-45

10.5.4 VR1, VARISTOR on POWER BOARD Test ........................................................ 10-46

10.5.5 BR1/BR2, BRIDGE RECTIFIERS ON POWER-BOARD ........................................ 10-47

10.5.6 PTC1 (R79)/RELAY (RY1) CONTACTS IN PARALLEL ON POWER BOARD Test ... 10-47

10.5.7 D49, D50 DIODES/Q19, Q21/C35-38 on POWER BOARD Test ....................... 10-48

10.5.8 Q3, Q4, Q6; Q7 SWITCHING TRANSISTORS on POWER BOARD Test ................ 10-50

10.5.9 D67-D69/D174-D177 Output Diode Board Test ............................................ 10-52

10.5.9.1 Output Diode Board External Test ............................................................. 10-52

10.5.9.2 Output Diode Board Internal Test .............................................................. 10-53

10.5.10 Main Power Board Test ................................................................................ 10-54

10.5.11 Control Board Test ....................................................................................... 10-56

10.5.12 UI Board Test ................................................................................................ 10-60

10.5.13 Current Sensor Test ...................................................................................... 10-62

10.5.14 Remote Control Trigger Test ......................................................................... 10-63

10.6 CALIBRATION (FOR BOTH 3 PH AND 1 PH) ...................................................... 10-64

SECTION 11 ORDERING SPARE PARTS

11.1 SPARE PARTS .................................................................................................... 11-1

11.2 WEAR PARTS ..................................................................................................... 11-3

11.3 ACCESSORIES .................................................................................................... 11-4

11.4 REPLACEMENTS PARTS ..................................................................................... 11-5

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viii

SECTION LIST OF FIGURES

Figure Page

Figure 2-1. Danger and Warning Symbols ............................................................................ 2-1

Figure 5-1. Minimum Safe Clearances .................................................................................. 5-1

Figure 5-2. Lifting Illustrated ................................................................................................ 5-4

Figure 5-3. Sloping Ground .................................................................................................. 5-4

Figure 5-4. Rating plate (1) with supply connection data ..................................................... 5-6

Figure 6-1. Front & Rear Views: Model EMP 285ic ............................................................... 6-2

Figure 6-2. Function of User Interface Control Dials............................................................. 6-3

Figure 6-3. SMAW (Stick) 120 V, 1ph ................................................................................... 6-5

Figure 6-4. SMAW (Stick) 230 V, 1ph ................................................................................... 6-5

Figure 6-5. GMAW (MIG), 120 V, 1 ph.................................................................................. 6-6

Figure 6-6. GMAW (MIG) 230 V, 1ph ................................................................................... 6-6

Figure 6-7. GTAW (TIG) 120 V, 1ph ...................................................................................... 6-7

Figure 6-8. GTAW (TIG) 230 V, 1ph ...................................................................................... 6-7

Figure 6-9. SMAW (Stick) 460 V, 3ph / SMAW (Stick) 575 V, 3ph ......................................... 6-8

Figure 6-10. GMAW (MIG) 460 V, 3ph / GMAW (MIG) 575 V, 3ph ....................................... 6-8

Figure 6-11 GTAW (TIG) 460 V, 3ph / GTAW (TIG) 575 V, 3ph .............................................. 6-9

Figure 6-12. Example of 40 % Duty Cycle ........................................................................... 6-10

Figure 6-13. Example of 50 % Duty Cycle ........................................................................... 6-10

Figure 6-14. Plotting Duty Cycle for 120 V, 1ph AC ............................................................. 6-11

Figure 6-15. Plotting Duty Cycle for 230 V, 1ph AC ............................................................. 6-11

Figure 6-16 Plotting Duty Cycle for 460 V or 575 V, 3ph AC ............................................... 6-12

Figure 6-17 Tightening the Bobbin Locking Nut (A) for 100 mm (4 in.) .............................. 6-13

Figure 6-18. Tightening the Bobbin Locking Nut (A) for 200 mm (8 in.), 300 mm (12 in.) ... 6-14

Figure 6-19. View of Wire-Bobbin-Side .............................................................................. 6-15

Figure 6-20. Wire-Bobbin Side Exposed View..................................................................... 6-16

Figure 6-21. Wire-Feed Mechanism ................................................................................... 6-17

Figure 6-22. Holding Knob for Torch Adapter ..................................................................... 6-18

Figure 6-23. Check Feed-Roller for Slip, Indicating no Over-pressure ................................. 6-21

Figure 6-24. Checking for Proper Feed-Roller Pressure ...................................................... 6-22

Figure 6-25. Location of Wire-Feed Rollers and Pressure Rollers........................................ 6-23

Figure 6-26. Wire-Feed Mechanism ................................................................................... 6-24

Figure 6-27. Drive Gear with Woodruff Key on Motor Shaft............................................... 6-25

ix

SECTION LIST OF FIGURES

Figure Page

Figure 6-28. Feed Roller Removal and Installation ............................................................. 6-25

Figure 6-29. Wire-Feed Rollers Offered in Multiple Sizes ................................................... 6-26

Figure 6-30. Location of Wire-Guides and Their Set Screws ............................................... 6-29

Figure 6-31. Wire Guides ................................................................................................... 6-30

Figure 6-32. Wire-Feed Mechanism ................................................................................... 6-31

Figure 6-33. Verify Clearance of Both Guide Tubes ............................................................ 6-33

Figure 8-1. Tension Arm & Wire-Feed Cover on Wire-Feed Assembly .................................. 8-3

Figure 9-1. EMP 3-Phase Unit’s Power Supply Side .............................................................. 9-1

Figure 9-2. 3-Phase Power Supply Side Assemblies .............................................................. 9-2

Figure 9-3. 3-Phase Power Supply Circuit Functional Block Diagram .................................... 9-4

Figure 9-4. Power-Side Cover Removal ................................................................................ 9-7

Figure 9-5. User Interface (UI) ............................................................................................. 9-8

Figure 9-6. Connector Location on UI board ........................................................................ 9-8

Figure 9-7. UI Structure ....................................................................................................... 9-9

Figure 9-8. Location of Mounting Screws for UI ................................................................... 9-9

Figure 9-9. Main Power Switch, SW1, Functional Location ................................................. 9-11

Figure 9-10. Main Power Switch, SW!, Connection Labels.................................................. 9-12

Figure 9-11. Main Power Switch, SW1, 3 ph....................................................................... 9-12

Figure 9-12. Location of EMI Filter Board ........................................................................... 9-13

Figure 9-13. EMI Filter Board Map ..................................................................................... 9-14

Figure 9-14. EMI Filter Functional Location ........................................................................ 9-14

Figure 9-15. EMI Board Disassembly .................................................................................. 9-15

Figure 9-16. Location of Main Power Board ....................................................................... 9-16

Figure 9-17. Location of Primary Rectifier, BR1, BR2 .......................................................... 9-16

Figure 9-18. Main Power Board Map ................................................................................. 9-17

Figure 9-19. Main Power Board (3ph) Functional Location................................................. 9-18

Figure 9-20. Heat Sink Support Bracket ............................................................................. 9-19

Figure 9-21. Main Power Supply Board Disassembly .......................................................... 9-19

Figure 9-22. Location of Internal Power Supply (IPS) Board ............................................... 9-20

Figure 9-23. Internal Power Supply (IPS) Board Map .......................................................... 9-21

Figure 9-24. IPS Board Functional Location ........................................................................ 9-22

Figure 9-25. IPS Board Disassembly ................................................................................... 9-22

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SECTION LIST OF FIGURES

Figure Page

Figure 9-26. Location of Control Board .............................................................................. 9-23

Figure 9-27. Control Board LED Locations .......................................................................... 9-24

Figure 9-28. DIP Switch Settings on Control Board ............................................................. 9-25

Figure 9-29. Control Board Functional Location ................................................................. 9-26

Figure 9-30. Control Board Connector Locations................................................................ 9-27

Figure 9-31. Control Board Disassembly ............................................................................ 9-28

Figure 9-32. Location of Main Transformer ........................................................................ 9-29

Figure 9-33. Main Transformer Functional Location .......................................................... 9-29

Figure 9-34. Location of Output Diode Assembly ............................................................... 9-30

Figure 9-35. Map of Output Diode Board ........................................................................... 9-31

Figure 9-36. Output Diode Assembly Functional Location .................................................. 9-31

Figure 9-37. Output Diode Board Disassembly ................................................................... 9-32

Figure 9-38. Location of Output Inductor ........................................................................... 9-33

Figure 9-39. Output Inductor Functional Location ............................................................. 9-33

Figure 9-40. Location of Current Sensor ............................................................................. 9-34

Figure 9-41. Current Sensor Functional Location ............................................................... 9-34

Figure 9-42. Location of Cooling Fans ................................................................................ 9-35

Figure 9-43. Cooling Fans Functional Location ................................................................... 9-35

Figure 9-44. Gas Valves...................................................................................................... 9-36

Figure 9-45. Power-Side Cover Removal ............................................................................ 9-37

Figure 9-46. Control Board LED Locations .......................................................................... 9-39

Figure 9-47. Test Points for Control Board CN10 ................................................................ 9-47

Figure 9-48. Test Points for Control Board CN13 ................................................................ 9-48

Figure 9-49 Test Points on IPS Board for Continuity to Plug Blades ................................... 9-50

Figure 9-50. Test Point Schematic for Continuity ............................................................... 9-50

Figure 9-51. Location of BR 1 and BR 2 on Main Power Board ........................................... 9-51

Figure 9-52. Pin Identification for BR1, BR2 ....................................................................... 9-52

Figure 9-53. Schematic of BR1 or BR2 ................................................................................ 9-53

Figure 9-54. Terminal Identification of BR 1, BR 2 .............................................................. 9-54

Figure 9-55. IPS Board Test Points ..................................................................................... 9-56

Figure 9-56. Location of VR1 on Main Power Board ........................................................... 9-57

Figure 9-57. Test Points for Rl79, RY1 ................................................................................ 9-58

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SECTION LIST OF FIGURES

Figure Page

Figure 9-58. Test Points for C70, C72, C400 ....................................................................... 9-59

Figure 9-59. Test Points for Q3, Q4, Q6, Q7 ....................................................................... 9-60

Figure 9-60. SW2 Switch Positions ..................................................................................... 9-61

Figure 9-61. Test Points for Control Board CN19 ................................................................ 9-62

Figure 9-62. Test Points for Control Board CN17 ................................................................ 9-62

Figure 9-63. Test Points for Control Board CN18 ................................................................ 9-63

Figure 9-64. Test Points for Control Board CN13 ................................................................ 9-63

Figure 9-65. CN10 Test Points ............................................................................................ 9-64

Figure 9-66. Pinout of CN6 on Control Board ..................................................................... 9-66

Figure 9-67. UI CN3 to Control Board CN6 Connector Locations ........................................ 9-66

Figure 9-68. Reference Figure for Steps 1 & 2 .................................................................... 9-67

Figure 9-69. Diode Output Test Procedure Illustrated ........................................................ 9-68

Figure 9-70. CN18 Test Points ............................................................................................ 9-69

Figure 9-71. Remote Control Connector, J1 Pinout Diagram .............................................. 9-70

Figure 10-1. EMP 1-Phase Unit’s Power Supply Side .......................................................... 10-1

Figure 10-2. 1-Phase Power Supply Side Assemblies .......................................................... 10-2

Figure 10-3. 1-Phase Power Supply Circuit Functional Block Diagram 1 ph ........................ 10-4

Figure 10-4. User Interface (UI) ......................................................................................... 10-8

Figure 10-5. Connector Location on UI board .................................................................... 10-8

Figure 10-6. UI Structure ................................................................................................... 10-9

Figure 10-7. Location of Mounting Screws for UI ............................................................... 10-9

Figure 10-8. Location of Main Power Switch, SW1 ........................................................... 10-11

Figure 10-9. Main Power Switch, SW1, Functional Location ............................................. 10-11

Figure 10-10. Main Power Switch, SW1 ........................................................................... 10-12

Figure 10-11. Location of BR1, BR2 and Main Power Board ............................................. 10-13

Figure 10-12. Location of Select Components .................................................................. 10-14

Figure 10-13. 1 ph Main Power Board Map ..................................................................... 10-15

Figure 10-14. Main Power Board (1ph) Functional Location ............................................. 10-16

Figure 10-15. Location of Left, Baffle Support Bracket ..................................................... 10-16

Figure 10-16. 1 ph Main Power Supply Board Fastener Locations ..................................... 10-17

Figure 10-17. Location of Control Board .......................................................................... 10-18

Figure 10-18. Control Board LED Locations ...................................................................... 10-19

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SECTION LIST OF FIGURES

Figure Page

Figure 10-19. DIP Switch Settings on Control Board ......................................................... 10-20

Figure 10-20. Control Board Functional Location ............................................................. 10-21

Figure 10-21. Control Board Connector Locations ............................................................ 10-22

Figure 10-22. Control Board Disassembly ........................................................................ 10-23

Figure 10-23. Location of Main Transformer .................................................................... 10-24

Figure 10-24. Main Transformer Functional Location....................................................... 10-24

Figure 10-25. Location of Output Diode Assembly ........................................................... 10-25

Figure 10-26. Output Diode Assembly Functional Location .............................................. 10-25

Figure 10-27. Map of Output Diode Board ....................................................................... 10-26

Figure 10-28. Output Diode Board Disassembly ............................................................... 10-27

Figure 10-29. Location of Output Inductor ....................................................................... 10-28

Figure 10-30. Output Inductor Functional Location.......................................................... 10-28

Figure 10-31. Location of Current Sensor ......................................................................... 10-29

Figure 10-32. Current Sensor Functional Location ........................................................... 10-29

Figure 10-33. Location of Cooling Fans ............................................................................ 10-30

Figure 10-34. Cooling Fans Functional Location ............................................................... 10-31

Figure 10-35. Gas Valves .................................................................................................. 10-31

Figure 10-36. Control Board LED Locations ...................................................................... 10-33

Figure 10-37. Test Points for Control Board CN10 ............................................................ 10-41

Figure 10-38. Test Points for Control Board CN13 ............................................................ 10-42

Figure 10-39. Reference Figure for Steps 1a, 1b, 1c ......................................................... 10-44

Figure 10-40. Reference Figure for SW1, ON/OFF SWITCH ............................................... 10-45

Figure 10-41. Reference Figure for VR1 ........................................................................... 10-46

Figure 10-42. Reference Figure for PTC1/RV1 .................................................................. 10-47

Figure 10-43. Reference Figure for D49, D50 DIODES/Q19, Q21/C35-38 .......................... 10-49

Figure 10-44. Reference Figure for Q3, Q4, Q6; Q7 .......................................................... 10-51

Figure 10-45. Reference Figure for D67-D69/D174-D177 ................................................. 10-52

Figure 10-46. Diode Output Test Procedure Illustrated .................................................... 10-53

Figure 10-47. Reference Figure for Main Power Board Test ............................................. 10-54

Figure 10-48. Reference for Step 3a and 3b ..................................................................... 10-55

Figure 10-49. SW2 Switch Positions ................................................................................. 10-56

Figure 10-50. Test Points for Control Board CN19 ............................................................ 10-57

xiii

SECTION LIST OF FIGURES

Figure Page

Figure 10-51. Test Points for Control Board CN13 ............................................................ 10-57

Figure 10-52. CN 10 Test Voltage Measurement .............................................................. 10-58

Figure 10-53. Test Points for Control Board CN17 ............................................................ 10-58

Figure 10-54. Test Points for Control Board CN18 ............................................................ 10-59

Figure 10-55. Pinout of CN6 on Control Board ................................................................. 10-61

Figure 10-56. UI CN3 to Control Board CN6 Connector Locations ..................................... 10-61

Figure 10-57. CN 18 Test Measurements ......................................................................... 10-62

Figure 10-58. Remote Control Connector, J1 Pinout Diagram .......................................... 10-63

Figure 11-1. Unit-Part Example .......................................................................................... 11-2

Figure 11-2. Wire-Feed Assembly, Wear-Parts ................................................................... 11-3

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xv

SECTION LIST OF TABLES

Table Page

Table 4-1. Specifications for EMP 285ic 1ph ........................................................................ 4-1

Table 4-2. Specifications for EMP 285ic 3ph ........................................................................ 4-4

Table 5-1. Recommended Electrical-Supply Specifications: 1 ph, 50/60 Hz .......................... 5-6

Table 5-2. Recommended Electrical-Supply Specifications 3 ph, 50/60 Hz ........................ 5-7

Table 8-1. Maintenance Schedule During Normal Conditions .............................................. 8-2

Table 9-1. 3-Phase Power Supply Side Assemblies ............................................................... 9-2

Table 9-2. Table of Faults ..................................................................................................... 9-5

Table 9-3. UI Fault Codes ................................................................................................... 9-10

Table 9-4. Control Board LED Meanings ............................................................................. 9-25

Table 9-5. BR1, BR2 Test Procedure ................................................................................... 9-54

Table 10-1. 1-Phase Power Supply Side Assemblies ........................................................... 10-2

Table 10-2. Table of Faults ................................................................................................. 10-5

Table 10-3. UI Fault Codes ............................................................................................... 10-10

Table 10-4. Control Board LED Meanings ......................................................................... 10-20

Table 11-1. Unit Part Numbers .......................................................................................... 11-2

Table 11-2. Reference for Figure 10-2 Wire-Feed Assembly, Wear-Parts ........................... 11-3

Table 11-3. Accessories ..................................................................................................... 11-4

Table 11-4. Replacement Part # ......................................................................................... 11-5

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ESAB EMP 285ic 1PH and 3PH User manual

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