ESAB Warrior™ 750i CC/CV User manual

Category
Welding System
Type
User manual
Service manual
0463 771 001 GB 20201222
Valid for: serial no. 038-xxx-xxxx
Warrior
750i CC/CV
TABLE OF CONTENTS
0463 771 001 © ESAB AB 2020
READ THIS FIRST
....................................................................................
4
BEFORE STARTING SERVICE
...............................................................
5
Service aid
..............................................................................................
5
ESAB Tools
.............................................................................................
5
INTRODUCTION
.......................................................................................
6
Overview
.................................................................................................
6
Design structure of the power source
..................................................
6
Working principle
...................................................................................
6
Block diagram
.........................................................................................
7
TECHNICAL DATA
...................................................................................
8
SOFTWARE UPDATE AND CONFIGURATION
.......................................
11
WIRING DIAGRAM
...................................................................................
12
Component description
.........................................................................
12
Warrior 750i CC/CV
.................................................................................
15
Position of the components
..................................................................
17
ERROR DESCRIPTION
............................................................................
20
TROUBLESHOOTING
..............................................................................
22
Pre-power-up checks
.............................................................................
22
Visual inspection................................................................................... 22
Input measurements............................................................................. 22
15BR1 bridge rectifier measurements.................................................. 23
Power board measurements ................................................................ 24
Checking the secondary rectifier diodes .............................................. 27
Input voltage selection.......................................................................... 28
Testing the electrolytic DC link capacitor board.................................... 28
Checking the VRD components ........................................................... 28
Restoring the power source after pre-power-up checks....................... 29
Power-up checks.................................................................................. 29
Restoring the power source after pre-power-up checks....................... 30
DC bus voltage monitoring ................................................................... 32
Electrical test
..........................................................................................
33
EMC filter 15EF1 .................................................................................. 33
15BR1 bridge rectifier measurements.................................................. 33
Power board 15AP1 measurements .................................................... 34
IPS board measurements..................................................................... 34
Control board measurements............................................................... 34
Advanced measurements..................................................................... 35
Gate drive board measurements....................................................... 35
Soft start ............................................................................................ 36
Preparations before soft starting ....................................................... 36
TABLE OF CONTENTS
0463 771 001 © ESAB AB 2020
Checking the power resistors R4, R5................................................ 39
Checking the IGBT gate pulses......................................................... 39
Checking the VRD............................................................................. 39
Checking the main transformer primary voltage................................ 40
Checking the welding outlet voltage.................................................. 40
Restoring the power source after soft starting................................... 41
CALIBRATION AND VALIDATION
...........................................................
42
Measurement methods and tolerances
................................................
42
Requirements specifications and standards
.......................................
42
Accuracy out of tolerance
.....................................................................
43
DISASSEMBLY AND REASSEMBLY
......................................................
44
REPLACEMENT INSTRUCTIONS
...........................................................
47
Replacing the mains cable
....................................................................
47
Replacing the control board (20AP1)
...................................................
47
Replacing the gate drive board (15AP2)
..............................................
48
Replacing the power board (15AP1)
.....................................................
49
Replacing the IPS board (15AP4)
..........................................................
50
Replacing the EMC filter (15EF1)
..........................................................
51
Replacing the VRD PCBA
......................................................................
51
Replacing the bridge rectifier and its connections
.............................
52
Replacing AC inductor
...........................................................................
52
Replacing the transformer and/or secondary inductor
......................
53
Replacing the fan
....................................................................................
56
IN-SERVICE INSPECTION AND TESTING
..............................................
57
Visual inspection in accordance with 5.1 IEC 60974-4
.......................
57
Cleaning instruction
...............................................................................
59
Labelling and report
...............................................................................
59
Maintenance and inspection procedure
...............................................
60
Test report
...............................................................................................
61
SPARE PARTS AND ACCESSORIES
.....................................................
63
Rights reserved to alter specifications without notice.
READ THIS FIRST
0463 771 001
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© ESAB AB 2020
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.
Before and after service, repair and maintenance work are performed, the safety procedure
described in the Safety test manual must be followed! The Safety test manual can be
downloaded from the Internet: manuals.esab.com
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
January 2020.
The manual is valid for:
Warrior 750i CC/CV 380 - 460 V 0445 555 880
Warrior 750i CC/CV VRD, 380 - 460 V 0445 555 882
For serial no 038-xxx-xxxx, Warrior 750i CC/CV (CE version) will fulfil the Australian standard
AS 1674.2-2003 regarding the output no load voltage for category C environment when VRD
35V is activated. Filter board 15AP3 and resistor 15R1 are needed for this and have been
added.
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 Warrior 750i CC/CV is 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
0463 771 001
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© ESAB AB 2020
BEFORE STARTING SERVICE
NOTE!
Follow the instructions in chapter "IN-SERVICE INSPECTION AND TESTING",
page57 when performing service work on the equipment!
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 610×610mm /
24×24in.)
A 1.5m (3.28ft) long ground cable with
a crocodile clip
An adjustable wrist strap and cable with
a built-in protective resistor
ESAB Tools
Tool Ordering number
ESAB test box TB1 0460 868 880
Tool-Service kit W750i 0446 599 880
Checkmaster 9000 0740 505 880
Checkmaster 9000 DC 0740 505 881
NOTE!
The Checkmaster load bank is obsolete and not for new orders.
Recommended measuring devices
For general measurements: Fluke175, Fluke177, Fluke179 or any other multimeter
with equal performance
For safety test: Fluke1503, Fluke1507, Fluke1577, Fluke1587 or any other
multimeter with equal performance
Required equipment for soft start
Tool-Service kit W750i (0446 599 880)
Oscilloscope (50 MHz - 100 MHz, 1 - 2 GSa/s)
Differential probe (1.4 kV, 100 MHz)
Multimeter ( 0-600 V AC/DC)
Va (Power supply 1) - 24 V DC, 5 A
Vb (Power supply 2) - 40-60 V DC, 5 A
Auxiliary transformer - Secondary 42 V AC
INTRODUCTION
0463 771 001
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© ESAB AB 2020
INTRODUCTION
Overview
The Warrior 750i CC/CV is a welding power source intended for GMAW welding, as well as
for welding with powder filled cored wire (FCAW-S), for GTAW welding, for welding with
coated electrodes (SMAW) and arc air gouging.
Design structure of the power source
The Warrior 750i CC/CV power source is transistor-controlled, operating on the inverter
principle. It consists of a number of function modules. Each module has a module number,
which is always included as the first part of the name/identification of components in the
module. The modules have the following main functions:
1-User interface module
The display board that interface the weld settings with control board and display the weld
parameters (voltage and current).
2 - Mains module
Mains filter board, primary inductor, mains switch, auxiliary transformer.
15 - Power module
Power board including primary rectifier and IGBT transistor modules. IPS board main
transformer, secondary inductor, secondary diode modules.
20 - Control module
The control board, with a microprocessor, that monitors and controls the welding process.
Working principle
The mains input voltage range is three-phase 380±10% to 460±10% VAC at rated load.
The auxiliary transformer 2T1 has multiple primary connections and has to be correctly
connected depending on the mains voltage. The primary rectifier creates the DC bus voltage
by rectifying the input AC voltage.
The primary inverter of the Warrior 750i CC/CV power source has two inverter blocks which
are operating in parallel to deliver the rated load. Each inverter is a 4-transistor IGBT
fullbridge, operating at a switching frequency of 22 kHz. All power semiconductors are built
into modules.
Each inverter output is connected to a main transformer with 7:1 turn ratio. The main
transformer output is connected to a secondary rectifier which contains two diode modules.
Warrior 750i CC/CV power source is rated 750A/44VDC at 100% and 820A/44VDC at
60% duty cycle.
INTRODUCTION
0463 771 001
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© ESAB AB 2020
Block diagram
TECHNICAL DATA
0463 771 001
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© ESAB AB 2020
TECHNICAL DATA
Warrior 750i CC/CV
Working voltage 380 – 460V,±10%,3~50/60 Hz
Mains supply S
scmin
5.4 MVA
Mains supply Z
max
0.0319 ohm
Primary current 380 V 400 V 415V 440V 460 V
I
max.
GMAW - MIG 70A 66A 64A 60A 58A
I
max.
GTAW - TIG 55A 52A 50A 47A 45A
I
max.
SMAW - MMA 70A 66A 64A 60A 58A
I
max.
Gouging 70A 66A 64A 60A 58A
No load power in energy-saving
mode 6.5min. after welding
32W
Setting range for all modes
GMAW - MIG flat characteristic
GTAW - TIG drooping charcteristic
SMAW - MMA drooping characteristic
Gouging
16A/15V–820 A/44V
10A/10V–820A/34V
15A/15V–820A/44V
100A/18V–820A/44V
Permissible load at GMAW
60% duty cycle
100% duty cycle
820A/44V
750A/44V
Permissible load at GTAW
60% duty cycle
100% duty cycle
820A/34V
750A/34V
Permissible load at SMAW
60% duty cycle
100% duty cycle
820A/44V
750A/44V
Gouging
35% duty cycle
60% duty cycle
100% duty cycle
850 A / 44 V
820A/44V
750A/44V
Power factor at maximum current
GMAW
0.91
GTAW
SMAW
Gouging
Efficiency at maximum current
TECHNICAL DATA
0463 771 001
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© ESAB AB 2020
Warrior 750i CC/CV
GMAW
91%
GTAW
SMAW
Gouging
Open-circuit voltage with VRD
function (RMS/Peak)
25/33 VDC
Open-circuit voltage without VRD
function (RMS/Peak)
63/89VDC
Operating temperature 14to104 °F (-10to40°C)
Transport temperature -4to131 °F (-20to55 °C)
Constant sound pressure when
idling <70 dB (A)
Dimensions l × w × h 33.5×16.3×25.1in. (850×415×637mm)
Weight (welding power source) 213.8 lb (101kg)
Insulation class H
Enclosure class IP23
Application class
Recommended maximum current values for connection cables set
At an ambient temperature of +25°C and normal 10 minutes cycle:
Cable area
Duty cycle
Voltage loss/10m100% 60% 35%
50 mm
2
280A 310A 370A 0.35V/100A
70 mm
2
350A 400A 480A 0.25V/100A
95 mm
2
430A 500A 600A 0.19V/100A
120 mm
2
500A 580A 720A 0.15V/100A
Please use additional cables in parallel, if the current carrying capacity of the cable,
presented in the table, is exceeded.
At an ambient temperature of +40°C and normal 10 minutes cycle:
Cable area
Duty cycle
Voltage loss/10m100% 60% 35%
50 mm
2
250A 270A 320A 0.37V/100A
70 mm
2
310A 350A 420A 0.27V/100A
95 mm
2
370A 430A 520A 0.20V/100A
120 mm
2
430A 510A 620A 0.16V/100A
Please use additional cables in parallel, if the current carrying capacity of the cable,
presented in the table, is exceeded.
NOTE!
It is advised to use two pieces of 95 mm
2
in parallel if working under full load.
Recommended fuse sizes and minimum cable area Warrior 750i CC/CV
TECHNICAL DATA
0463 771 001
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© ESAB AB 2020
Warrior 750i CC/CV
Mains voltage 380V, 3~ 50/60Hz 400V, 3~ 50/60Hz
Mains cable area
4x16mm
2
4x16mm
2
Phase current I
eff
65A 62A
Fuse
anti-surge
type C MCB
80A 80A
Warrior 750i CC/CV
Mains voltage 415V, 3~ 50/60Hz 440V, 3~ 50/60Hz
Mains cable area
4x16mm
2
4x12mm
2
Phase current I
eff
60 A 56A
Fuse
anti-surge
type C MCB
63A 63A
Warrior 750i CC/CV
Mains voltage 460V, 3~ 50/60Hz
Mains cable area
4x12mm
2
Phase current I
eff
54A
Fuse
anti-surge
type C MCB
63A
NOTE!
Maintain a minimum of 5 meters mains cable.
Mains supply, S
sc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
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.
SOFTWARE UPDATE AND CONFIGURATION
0463 771 001
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© ESAB AB 2020
SOFTWARE UPDATE AND CONFIGURATION
Before starting the software update, make sure the following are available:
STM32CubeProgrammer release v2.3.0
TTL-232R-3V3 (Make: FTDI) – serial interface cable (5V red wire, removed from the
connector).
1. Change the jumper from CN14-1, CN 14-2 to CN14-2, CN 14-3 on the control board to
change from Application mode to Boot mode.
2. Restart the power supply. It will enter Boot mode.
3. Connect the serial interface cable to the USART pins CN11.
4. Use the STM programmer and set the following:
Select the Port and Press Connect
Baud rate – 115200
Parity - None
Data bits – 8
Stop bits – 1
5. Select the Open file tab, and select the target.bin or target.hex
6. • Press Download to write the software in the microcontroller.
7. Change back the jumper from CN14-2, CN 14-3 to CN14-1, CN 14-2 (Application
mode).
8. Restart the system.
WIRING DIAGRAM
0463 771 001
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© ESAB AB 2020
WIRING DIAGRAM
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
The power source consists of a number of function modules. The circuit board and
component names and the wire numbers in the wiring diagram, show to which module each
board/component/wire belongs. The function modules, circuit boards and components are
listed in the component description below.
Wires/cables within modules are marked 100 - 6999.
Wires/cables between modules are marked 7000 - 7999.
Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors
XS1 - XS99 (S = socket), XT1 - XT99 (T = terminal).
Circuit boards within each module are named 20AP1 - 20AP99.
20 = module association, 1-69
AP = circuit board
1 = individual identification number, 0-99
Transistors within particular modules are named 15PM1 - 15PM99.
15 = module association, 1-69
PM = transistor
1 = individual identification number, 0-99
Component description
Component Description
15AP1 Power board
15AP2 Gate drive board
15AP3 VRD filter board
15AP4 Internal power supply board
15R1 Resistor in VRD filter board
15BR1 Bridge rectifier bridge, 3 phase
15C1, 15C2, 15C3 Capacitors 0.1 micro farad
15CS1, 15CS2 Secondary current sensor, Ratio 1:2000
15EV1, 15EV2 Fan, 24VDC
15L1, 15L2 Secondary inductor
15PM1, 15PM2, 15PM3, 15PM4 IGBT power transistor modules. Each
module consists of two transistors and
two freewheel diodes.
WIRING DIAGRAM
0463 771 001
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© ESAB AB 2020
Component Description
15PM6, 15PM7, 15PM8, 15PM9 Secondary rectifier diode modules. Each
module consists of two diodes.
15ST1 Thermal switch, Primary heat sink top
15ST2 Thermal switch, Primary heat sink bottom
15ST3 Thermal switch, Secondary heat sink
15T1, 15T2 HF transformer, Turns ratio 7:1
1AP1 MMC module
20AP1 Control board
15EF1 EMC filter
2L2 Input inductor
2QF1 Input control switch
2QF2 Voltage selector switch
2T1 Auxiliary transformer, with multiple input
windings
Input voltage windings:
380V
400V
415V
440V
460V
Output voltages:
20V (Secondary)
40V (Secondary)
42V (Secondary)
FU1 10A circuit breaker
FU3 20A circuit breaker
R4, R5 Pre-charge resistor, 10 watts, 12 ohm each
XT1, XT2, XT3 Input terminals
1S1 Electrode selection, three positions
1R1 Potentiometer 10kilohm, Inductance/Arc
force
1G1 Encoder/Current knob
1S3 Process selection, five positions
XS1 Remote connector (12 pin)
XS2 Wire feeder connector (19-Pin)
XS3 Cooler connector (12 Pin)
WIRING DIAGRAM
0463 771 001
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© ESAB AB 2020
Component Description
15L3-L4,15L5-L6
15L7-L8, 15L9-L10
15L11-L12,15L13-L14
15L15-L16,15L17-L18
Ferrite cores
2L1 Input cable ferrite core
WIRING DIAGRAM
0463 771 001
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© ESAB AB 2020
Warrior 750i CC/CV
WIRING DIAGRAM
0463 771 001
- 16 -
© ESAB AB 2020
WIRING DIAGRAM
0463 771 001
- 17 -
© ESAB AB 2020
Position of the components
Left view
WIRING DIAGRAM
0463 771 001
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© ESAB AB 2020
Right view
WIRING DIAGRAM
0463 771 001
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© ESAB AB 2020
Right view, power modules
ERROR DESCRIPTION
0463 771 001
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© ESAB AB 2020
ERROR DESCRIPTION
Errors in the power source can be displayed on the front panel as:
a message "Err" on the front panel display (Errors 1 and 3)
an illuminated temperature LED (Error 2)
NOTE!
Errors 1, 2 and 3 are indicated in exactly the same way. It is not possible to
distinguish between them on the display.
1 DC bus over/under voltage or high DC bus ripple voltage
Welding is stopped. The fault is reset after power off/on.
The DC bus voltage is, or has been, too high or too low. The overvoltage limit is 800V for CE variant
and 1000V for CSA. The undervoltage limit is 320 V for both of the variants.
If any phase is missing or disconnected, the welding output will be limited to 190A, 28V.
1. Turn off the mains power supply to reset the unit.
2. Check the mains voltage (all 3 phases) is OK.
3. Check the DC bus capacitors C52-C59.
4. Check the Capacitor board 15AP2.
5. Check the connection between the Power board 15AP1 and the Capacitor board 15AP2.
6. Check the primary rectifier 15BR1.
7. Check the 20VAC supply voltage.
8. Check the fuse S1 on the Power board 15AP1. If the fuse blows frequently replace the Power
board 15AP1.
9. Check the precharge power resistors R4, R5, R304, R305 on Power board 15AP1. Replace the
Power board if the resistors are defect.
2 Temperature error
Welding is stopped. The fault is automatically reset when temperature is within limits.
Thermal switch 15ST2 is open because the temperature on the primary heat sink has exceeded 82°C,
and/or thermal switch 15ST3 is open because the temperature on the secondary heat sink has
exceeded 82°C.
1. Wait until the heat sinks of the power source have cooled off. Check the fan 15EV1 and the air
filter. Check if the heat sinks are dirty and if they are, clean them.
2. Check the thermal switches 15ST2, 15ST3.
3. Check the connections between the thermal switches and the Power board 15AP1.
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ESAB Warrior™ 750i CC/CV User manual

Category
Welding System
Type
User manual

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