ESAB Warrior™ 750i CC/CV 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

- 4 -

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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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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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

- 7 -

Block diagram

TECHNICAL DATA

0463 771 001

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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

- 9 -

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

- 10 -

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

- 11 -

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

- 12 -

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

- 13 -

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

- 14 -

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

- 15 -

Warrior 750i CC/CV

WIRING DIAGRAM

0463 771 001

- 16 -

WIRING DIAGRAM

0463 771 001

- 17 -

Position of the components

Left view

WIRING DIAGRAM

0463 771 001

- 18 -

Right view

WIRING DIAGRAM

0463 771 001

- 19 -

Right view, power modules

ERROR DESCRIPTION

0463 771 001

- 20 -

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

ESAB Warrior™ 750i CC/CV User manual

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