ESAB | ES 300i | Service manual | ESAB ES 300i User manual

ESAB ES 300i User manual
ES 300i, ET 300i, ET 300iP
Welding power source
Service manual
0463 424 001 GB 20180627
Valid for: serial no. 627-, 643-, 719-, 721-, 725-, 742-, 815-,
825-xxx-xxxx
TABLE OF CONTENTS
1
READ THIS FIRST....................................................................................
6
2
BEFORE STARTING SERVICE................................................................
7
2.1
Service aid ..............................................................................................
7
2.2
ESAB Tools .............................................................................................
7
INTRODUCTION .......................................................................................
8
3.1
Design structure of the power source..................................................
8
3.2
Block diagram of ES 300i ......................................................................
9
3.3
Block diagram of ET 300i/ET 300iP.......................................................
10
3.4
Circuit board positions ..........................................................................
11
3.5
Left and right sides of the power source .............................................
11
WIRING DIAGRAM ...................................................................................
12
4.1
Component description .........................................................................
12
4.2
ES 300i, valid for serial no. 627-, 643-, 719-xxx-xxxx ..........................
14
4.3
ES 300i, valid for serial no. 725-, 742-xxx-xxxx ...................................
16
4.4
ES 300i, valid from serial no. 815-xxx-xxxx .........................................
18
4.5
ET 300i and ET 300iP, valid for serial no. 721-, 742-xxx-xxxx.............
20
4.6
ET 300i and ET 300iP, valid from serial no. 815-xxx-xxxx...................
22
ERROR CODES........................................................................................
24
5.1
Error code descriptions and service technician actions....................
24
5.1.1
Err 1 – Temperature fault......................................................................
24
5.1.2
Err 2 – Coolant fault .............................................................................
25
5.1.3
Err 3 – Power supply fault ....................................................................
25
5.1.4
Err 4 – Communication fault .................................................................
26
5.1.5
Err 5 – Memory fault .............................................................................
26
5.1.6
Err 6 – Timing fault ...............................................................................
27
5.1.7
Err 7 – OCV fault ..................................................................................
27
5.1.8
Err 8 – Cooler hose disconnected ........................................................
27
5.1.9
Measurement points and connectors on circuit boards ........................
28
6
TECHNICAL DATA ...................................................................................
29
7
SOFTWARE UPDATE AND CONFIGURATION.......................................
39
7.1
USB handling ..........................................................................................
39
7.1.1
Script files .............................................................................................
39
7.1.2
System software files ...........................................................................
39
7.2
Files location...........................................................................................
39
7.3
Application software update .................................................................
40
Troubleshooting application software update .......................................
40
Secondary bootloader update...............................................................
41
Troubleshooting secondary bootloader update ....................................
41
Software configuration ..........................................................................
42
Configuration of the power source according to product ordering
number .................................................................................................
42
3
4
5
7.3.1
7.4
7.4.1
7.5
7.5.1
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TABLE OF CONTENTS
8
7.5.2
VRD On/Off ..........................................................................................
42
7.5.3
Cellulosic welding process regulator ....................................................
42
7.5.4
Set time ................................................................................................
43
TROUBLESHOOTING ..............................................................................
44
8.1
Extracting power source data and status via USB flash drive ..........
44
8.1.1
Extracting welding statistics .................................................................
44
8.1.2
Extracting a service log ........................................................................
44
8.1.3
Interpreting the service log ...................................................................
44
8.1.3.1
Section 2 – db ls ................................................................................
45
8.1.3.2
Section 6 – active ..............................................................................
45
8.1.3.3
Section 7 – syslog .............................................................................
46
8.1.3.4
Section 8 – log...................................................................................
46
8.1.3.5
Section 13 – cmdProxy 10 (active)....................................................
47
8.1.3.6
Section 14 – cmdProxy 10 (log) ........................................................
47
8.1.3.7
Section 19 – cmdProxy 5 (active)......................................................
47
8.1.3.8
Section 20 – cmdProxy 5 (log) ..........................................................
47
8.1.3.9
Section 25 – cmdProxy 2 (active)......................................................
47
8.1.3.1
Section 26 – cmdProxy 2 (log) ..........................................................
0
8.2
Pre power up checks .............................................................................
47
8.2.1
Visual Inspection ..................................................................................
48
8.2.2
Input module measurements ................................................................
48
8.2.3
Power Board 15AP1 measurements ....................................................
49
8.2.4
Booster Board 27AP1 measurements ..................................................
55
8.2.5
57
8.2.7
Measurements of interconnections between Power Board 15AP1 and
Control Board 20AP1 ...........................................................................
Measurements of interconnections between Booster Board 27AP1
and Control Board 20AP1 ....................................................................
Testing the electrolytic DC bus capacitor 15C1 ....................................
8.2.8
Restoring the power source after pre power up checks .......................
59
Power up checks ....................................................................................
59
8.3.1
General.................................................................................................
59
8.3.2
Electrical test ........................................................................................
60
8.3.2.1
EMC filter board 2AP1 measurement................................................
60
8.3.2.2
Power Board 15AP1 measurements .................................................
60
8.3.2.3
Control Board 20AP1 measurements................................................
64
8.3.2.4
Booster Board 27AP1 measurements ...............................................
67
8.2.6
8.3
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58
58
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TABLE OF CONTENTS
8.3.3
68
8.3.3.1
Electrical test – TIG specific functions (applicable only to ET 300i and
ET 300iP) .............................................................................................
Torch trigger function – Control Board 20AP1 measurements ..........
8.3.3.2
HF spark generation – TIG Board 10AP1 measurements.................
70
8.3.3.3
Gas valve control...............................................................................
71
Status indications on circuit boards ....................................................
72
8.4.1
Setting panel board 1AP1 – Indication of operational status................
72
8.4.2
Control board 20AP1 – Indication of software run level .......................
73
9
DISASSEMBLY AND REASSEMBLY ......................................................
74
10
CALIBRATION OF VOLTAGE AND CURRENT.......................................
78
10.1
General USB procedure .........................................................................
78
10.2
Tooling needed .......................................................................................
78
10.3
Extracting present calibration parameters from power source .........
78
10.4
Performing measurements ....................................................................
79
10.5
Calculate new calibration parameters ..................................................
79
10.6
Downloading new calibration parameters to power source...............
80
REPLACEMENT INSTRUCTIONS ...........................................................
81
11.1
Replacing the setting knob....................................................................
81
11.2
Replacing the setting panel...................................................................
82
11.3
Replacing the encoder and the setting knob.......................................
83
11.4
Replacing the mains cable ....................................................................
84
11.5
Replacing the mains switch ..................................................................
86
11.6
Replacing the fan....................................................................................
87
11.7
Replacing the welding output terminals (ES 300i) ..............................
88
11.8
Replacing the welding output terminals (ET 300i and ET 300iP) .......
89
11.9
Replacing the current sensor................................................................
90
11.10 Replacing the front panel (ES 300i) ......................................................
91
11.11 Replacing the front panel (ET 300i and ET 300iP) ...............................
92
11.12 Replacing the EMC filter board .............................................................
93
11.13 Replacing the control board..................................................................
94
11.14 Replacing the PFC inductor ..................................................................
96
11.15 Replacing the power board ...................................................................
97
8.4
11
68
11.16 Replacing the DC bus capacitor ........................................................... 100
11.17 Replacing the booster board................................................................. 101
11.18 Replacing the thermal switch on the secondary heat sink ................ 103
11.19 Replacing the secondary rectifier diode modules .............................. 104
11.20 Replacing the output inductor module and/or the transformer
105
module.....................................................................................................
11.21 Replacing the TIG board (applicable only to ET 300i and ET 300iP) . 108
11.22 Replacing the analogue remote A/D board .......................................... 109
12
IN-SERVICE INSPECTION AND TESTING.............................................. 110
12.1
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General requirements ............................................................................ 110
© ESAB AB 2018
TABLE OF CONTENTS
13
12.2
Periodic inspection and test.................................................................. 110
12.3
Cleaning instruction............................................................................... 110
12.4
After repair, inspection and test ........................................................... 114
12.5
Visual inspection .................................................................................... 115
12.6
Electrical test .......................................................................................... 116
12.7
Functional test ........................................................................................ 117
12.8
Test report ............................................................................................... 118
SPARE PARTS AND ACCESSORIES ..................................................... 119
Rights reserved to alter specifications without notice.
0463 424 001
© ESAB AB 2018
1 READ THIS FIRST
1
READ THIS FIRST
Maintenance and repair work must be performed by an experienced person, and electrical
work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
The circuit boards are divided into numbered blocks. Component names in the wiring
diagram are listed in the component description.
Use the spare parts list as a guide to where the components are located in the equipment.
The spare parts list is published as a separate document, see the "SPARE PARTS" chapter
in this manual.
This manual contains details of design changes that have been made up to and including
June 2018.
The manual is valid for:
•
•
ES 300i with serial numbers 627-, 643-, 719-, 725-, 742-, 815-, 825-xxx-xxxx
ET 300i and ET 300iP with serial numbers 721-, 742-, 815-, 825-xxx-xxxx
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for safety and
function, of the specific set-up, lies with the integrator.
The ES 300i, ET 300i and ET 300iP are designed and tested in accordance with the
standards stated in the instruction manual. On completion of service or repair work, it is the
responsibility of the person(s) performing the work to ensure that the product still complies
with the requirements of the involved standards.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
•
•
0463 424 001
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
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© ESAB AB 2018
2 BEFORE STARTING SERVICE
2
BEFORE STARTING SERVICE
NOTE!
Follow the instructions in chapter "IN-SERVICE INSPECTION AND TESTING",
page 110 when performing service work on the equipment!
2.1
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
Antistatic service kit
2.2
ESAB Tools
Checkmaster 9000
Ordering no. 0740 505 880
Checkmaster 9000 DC - calibrated
Ordering no. 0740 505 881
0460 868 880
ESAB test box TB 1
For a list of tools needed to perform service, see section "Tooling needed", page 78.
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© ESAB AB 2018
3 INTRODUCTION
3
INTRODUCTION
ES 300i, ET 300i and ET 300iP are welding power sources intended for welding with coated
electrodes (MMA) and Live TIG welding.
3.1
Design structure of the power source
ES 300i, ET 300i and ET 300iP are inverter based power sources with multi voltage
capability which can be run on single-phase and/or three-phase electric power depending on
region. The inverter is controlled by an FPGA (Field Programmable Gate Array) at 100 kHz
switching frequency. The power source control, including the welding process, gives
directions to the FPGA through a serial interface at 10 kHz. The power source control, panel
and remote units communicate using CAN Open.
The modules have the following main functions:
1 Setting panel module
The main function is for the user to define welding process settings.
2 Input module
The main function is to convert power line input voltage to stable voltage free from
conducted disturbances as required by the EMC directive.
10 TIG module (only in ET 300i and ET 300iP)
The main function of the TIG module is to produce high voltage, high frequency pulses, thus
enabling non-contact ignition of the electric welding arc.
15 Primary module
The main function is a full bridge inverter operating at a switching frequency of 100 kHz.
IGBT transistors are used as switching elements.
16 Transformer module
The main function is to transform high voltage / low current to high current / low voltage.
19 Output inductor module
The main function is to supply the welding current. The module contains an inductor and a
current sensor.
20 Control module
This is the master of the system. The module handles the system status. It is a hub for
events/errors occurring in the system and it collects meta-data on other boards in the
system. Data can be extracted from the system using a USB flash drive connected to the
USB connector (located at the rear of the power source). The control board also contains
the FPGA which controls the inverter. From serial no. 815-xxx-xxxx the module also includes
an interface for communication with analogue remote control units.
27 Secondary module
The main function is to supply the welding current. This module contains an additional board
for increasing the output voltage at low currents, to enable higher welding performance for
cellulosic electrodes.
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© ESAB AB 2018
3 INTRODUCTION
3.2
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Block diagram of ES 300i
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© ESAB AB 2018
3 INTRODUCTION
3.3
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Block diagram of ET 300i/ET 300iP
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© ESAB AB 2018
3 INTRODUCTION
3.4
Circuit board positions
*) Only in ET 300i and ET 300iP
**) From serial no. 742-xxx-xxxx
***) From serial no. 815-xxx-xxxx
3.5
Left and right sides of the power source
The graphic below shows the meaning of "left" and "right" sides of the power source as
referred to throughout this manual.
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© ESAB AB 2018
4 WIRING DIAGRAM
4
WIRING DIAGRAM
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 have names such as 20AP1 - 20AP99.
20 = module association, 1-69
AP = circuit board
1 = individual identification number, 0-99
Transistors within particular modules have identification numbers such as 15Q1 - 15Q99.
15 = module association, 1-69
Q = transistor
1 = individual identification number, 0-99
4.1
Component description
Component
Description
1
Setting panel module Wire numbers 100–199
1AP1
Setting panel board
2
Input module Wire numbers 200–299
2AP1
EMC filter board
2XS1
Connection block
2SW1
Mains switch
2L1 - 2L4
Ferrite ring cores (valid only for products with ordering no. 0445 100 880,
0445 100 883, 0445 100 900, 0445 100 903, 0445 100 920 and
0445 100 923)
10
TIG module (only in ET 300i and ET 300iP)
10AP1
TIG board (only in ET 300i and ET 300iP)
10TV1
HF TIG coil (only in ET 300i and ET 300iP)
10XS1
Cooler connector (only in ET 300i and ET 300iP)
10XS2
Torch connector (only in ET 300i and ET 300iP)
10YV1
Gas valve (only in ET 300i and ET 300iP)
15
Primary module Wire numbers 1500–1599
15AP1
Power board
15AP2
Surge protection board (from serial no. 742-xxx-xxxx)
15PM1
Power module
15PM2–15PM4 Secondary rectifier diode modules. Each module consists of two diodes.
15C1
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DC bus capacitor
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© ESAB AB 2018
4 WIRING DIAGRAM
Component
Description
15EV1
Fan
FU1
Fuse 1 A
16
Transformer module
16T1
Main transformer
16SW1
Thermal switch transformer
19
Output inductor module
19L1
Output inductor
19CS1
Current sensor
20
Control module Wire numbers 2000–2099
20AP1
Control board
20AP2
Analogue remote A/D board (from serial no. 815-xxx-xxxx)
20L1–20L2
Ferrite ring cores
20XS1
Remote connector
20XS2
USB connector
20XS3
Fan socket connector
20XP1
Fan pin connector
20C1
Capacitor
27
Secondary module Wire numbers 2700–2799
27AP1
Booster board
27SW1
Thermal switch secondary heat sink
TR41
Current transformer
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
•
•
0463 424 001
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
- 13 -
© ESAB AB 2018
4 WIRING DIAGRAM
4.2
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ES 300i, valid for serial no. 627-, 643-, 719-xxx-xxxx
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© ESAB AB 2018
4 WIRING DIAGRAM
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© ESAB AB 2018
4 WIRING DIAGRAM
4.3
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ES 300i, valid for serial no. 725-, 742-xxx-xxxx
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© ESAB AB 2018
4 WIRING DIAGRAM
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© ESAB AB 2018
4 WIRING DIAGRAM
4.4
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ES 300i, valid from serial no. 815-xxx-xxxx
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© ESAB AB 2018
4 WIRING DIAGRAM
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© ESAB AB 2018
4 WIRING DIAGRAM
4.5
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ET 300i and ET 300iP, valid for serial no. 721-, 742-xxx-xxxx
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© ESAB AB 2018
4 WIRING DIAGRAM
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© ESAB AB 2018
4 WIRING DIAGRAM
4.6
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ET 300i and ET 300iP, valid from serial no. 815-xxx-xxxx
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© ESAB AB 2018
4 WIRING DIAGRAM
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© ESAB AB 2018
5 ERROR CODES
5
ERROR CODES
The error code is used to indicate that a fault has occurred in the equipment. Errors are
indicated by the text "Err" and the error code number flashing alternately in the power
source display.
5.1
Error code descriptions and service technician actions
Suggested service technician actions for error codes are described in the sub-sections
below. Measurement points and connectors on the circuit boards, referred to in the text are to
be found in section "Measurement points and connectors on circuit boards", page 28.
5.1.1
Err 1 – Temperature fault
The temperature of the power source is too high. A LED indicating temperature fault is also
lit on the panel.
Service technician actions:
1.
2.
3.
Wait for the power source to cool down for one hour.
Connect the power source to the rated input mains supply voltage and turn the
mains power supply switch on. If the error code is still present, retrieve the service
log.
○ If the service log reads "Power module temp error", check the condition of the
flat ribbon cable between connector CN83 on the control board 20AP1 and
connector CN83 on the power board 15AP1. If needed, replace the flat ribbon
cable.
If the flat ribbon cable is OK, replace the power board (see "Replacing the
power board", page 97).
○ If the service log reads "Thermal switch or booster error", proceed as follows:
i
Turn the power source mains switch off.
ii
Check the condition of the transformer thermal switch 16SW1, by
measuring the resistance between pins X06A and X06B in
connector X06 on the booster board 27AP1.
The resistance should be ≤ 1 Ω. If the resistance is higher, replace
the transformer.
iii Check the condition of the secondary heat sink thermal
switch 27SW1, by measuring the resistance between pins X07A and
X07B in connector X07 on the booster board 27AP1.
The resistance should be ≤ 1 Ω. If the resistance is higher, replace
thermal switch 27SW1 (see "Replacing the thermal switch on the
secondary heat sink", page 103).
iv Turn the power source mains switch on.
v
Measure the 24 V power supply voltage out from the booster board
between pins X05_5 and X05_6 in connector X05 on the booster
board 27AP1.
If the voltage is < 20 V, replace flat ribbon cable 7000 (between
connector X05 on the booster board and connector CN51 on the
control board).
If the voltage is ≥ 20 V, replace the booster board (see "Replacing
the booster board", page 101).
○ If the service log is unable to read or if it contains no error codes, check the
condition of cable 2500 (between connector CN85 on the control board and
the power source USB connector 20XS2). If needed, replace cable 2500.
If cable 2500 is OK, replace the control board (see "Replacing the control
board", page 94).
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5 ERROR CODES
5.1.2
Err 2 – Coolant fault
The temperature of the coolant fluid is too high. (Only applicable to ET 300i and ET 300iP)
Service technician actions:
1.
2.
Make sure there is sufficient coolant in the cooling unit and wait until the coolant
temperature has decreased below +35 °C (+95 °F). Also make sure the
recommended duty cycle for the weld current has not been exceeded.
If the coolant temperature is below +35 °C (+95 °F) and error code Err 2 is still
displayed, troubleshoot the thermal sensor in the cooling unit (see the service
manual for the EC1000 cooling unit).
5.1.3
Err 3 – Power supply fault
The power supply to the power source is too low or too high.
Service technician actions:
1.
2.
3.
Check the condition of the customers mains supply and make sure it is within rated
input supply voltage.
Connect the power source to the rated input mains supply voltage and turn the
mains power supply switch on. If the error code is still present, retrieve the service
log.
○ If the service log reads "Phase mode changed during operation", "Input
undervoltage", "Phase error net not supported" or "DC bus error", check the
condition of the flat ribbon cable between connector CN83 on the control
board 20AP1 and connector CN83 on the power board 15AP1. If needed,
replace the flat ribbon cable.
If the flat ribbon cable is OK, replace the power board (see "Replacing the
power board", page 97).
○ If the service log reads "Undervoltage", replace the control board (see
"Replacing the control board", page 94).
○ If the service log is unable to read or if it contains no error codes, check the
condition of cable 2500 (between connector CN85 on the control board and
the power source USB connector 20XS2). If needed, replace cable 2500.
If cable 2500 is OK, replace the control board (see "Replacing the control
board", page 94).
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5 ERROR CODES
5.1.4
Err 4 – Communication fault
The communication in the power source has been disrupted.
Service technician actions:
1.
2.
Connect the power source to the rated input mains supply voltage and turn the
mains power supply switch on. If the error code is still present, retrieve the service
log.
○ If the service log reads "Slave lost contact with power source", "Master lost
contact with slave" or "CAN open bus off", check the condition of cable 100
between connector CN28 on the control board and connector J4 on the
setting panel board 1AP1. If needed, replace cable 100.
If a remote control unit is used, check the condition of cable 2030 between
connector CN29 on the control board and the power source remote control
connector 20XS1. If needed, replace cable 2030.
If cable 100 (and/or cable 2030) is OK, replace the control board (see
"Replacing the control board", page 94).
○ If the service log reads "CAN open output buffer overrun", update the system
software. If the error persists, save the service log and report the problem to
the ESAB Global Service Helpdesk.
○ If the service log is unable to read or if it contains no error codes, check the
condition of cable 2500 (between connector CN85 on the control board and
the power source USB connector 20XS2). If needed, replace cable 2500.
If cable 2500 is OK, replace the control board (see "Replacing the control
board", page 94).
5.1.5
Err 5 – Memory fault
The program memory is damaged. This fault can disable preset functions or other functions
where values are stored.
Service technician actions:
1.
Connect the power source to the rated input mains supply voltage and turn the
mains power supply switch on. If the error code is still present, retrieve the service
log.
○ If the service log reads "Failure when retrieving variables from flash or flash
empty", "Failure when storing variables to flash" or "Checksum error when
retrieving data from flash – some variables reverted to default", replace the
control board (see section "Replacing the control board", page 94).
○ If the service log reads "Failed to create all parameters defined in the type
EWduParamId", "WDU parameter configuration missing", "WDU parameter
default value out of range" or "Too many WDU parameter subscriptions",
save the service log and report the problem to the ESAB Global Service
Helpdesk.
○ If the service log is unable to read or if it contains no error codes, replace the
control board (see section "Replacing the control board", page 94). If the
error code is still present after replacing the control board, save the service
log and report the problem to the ESAB Global Service Helpdesk.
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5 ERROR CODES
5.1.6
Err 6 – Timing fault
The power source electronics are not able to execute all functions in a timely fashion.
Service technician actions:
1.
2.
Connect the power source to the rated input mains supply voltage and turn the
mains power supply switch on. If the error code is still present, retrieve the service
log.
○ If the service log reads "Servo receive communication time out" or "Process
loop max time error", replace the control board (see "Replacing the control
board", page 94).
○ If the service log is unable to read or if it contains no error codes, replace the
control board (see "Replacing the control board", page 94).
5.1.7
Err 7 – OCV fault
The Open Circuit Voltage (OCV) is too high or the electronic control of the OCV has been
disrupted.
Service technician actions:
1.
2.
Connect the power source to 400 V 3-phase and turn the mains power supply
switch on. If the error code is still present, retrieve the service log.
○ If the service log reads "Secondary voltage above limit", perform electrical
test according to section "Electrical test", page 60.
○ If the service log reads "Secondary voltage sensor lost", measure the output
voltage sense signals according to section "Measurements of
interconnections between Booster Board 27AP1 and Control Board 20AP1",
page 58.
If the output voltage sense signals check is passed and all measurement
criteria are met, replace the control board (see "Replacing the control board",
page 94).
○ If the service log is unable to read or if it contains no error codes, perform
electrical test according to section "Electrical test", page 60.
If the electrical test is passed and all measurement criteria are met, measure
the output voltage sense signals according to section "Measurements of
interconnections between Booster Board 27AP1 and Control Board 20AP1",
page 58.
If the output voltage sense signals check is passed and all measurement
criteria are met, replace the control board (see "Replacing the control board",
page 94).
5.1.8
Err 8 – Cooler hose disconnected
The hose for coolant out from the cooling unit (blue connector) to the TIG torch is not
connected. (Only applicable to ET 300i and ET 300iP)
Service technician actions:
1.
2.
Make sure the hose for coolant to the TIG torch is properly connected to the
coolant output connector (blue) on the cooling unit.
If the hose for coolant to the TIG torch is properly connected and error code Err 8 is
still displayed, troubleshoot the switch for the ELP (ESAB Logic Pump) on the
cooling unit (see the service manual for the EC1000 cooling unit).
0463 424 001
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© ESAB AB 2018
5 ERROR CODES
5.1.9
Measurement points and connectors on circuit boards
Control board 20AP1
Booster board 27AP1
(bottom side of circuit board)
Power board 15AP1 (part of)
Setting panel board 1AP1
(bottom side of circuit board)
Note! The appearance of circuit boards can have minor differences to the ones presented
above dependant on circuit board version.
0463 424 001
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© ESAB AB 2018
6 TECHNICAL DATA
6
TECHNICAL DATA
ES 300i (0445 100 880)
Mains voltage
230-480 V±10%, 3~ 50/60 Hz 230 V±10%, 1~ 50/60 Hz1)
Mains supply Ssc min
4.4 MVA2), 4.1 MVA3)
No demand
Zmax
0.04 Ohm
No demand
Imax MMA
30.0 A
29.0 A
Imax TIG
21.0 A
20.0 A
Primary current
No-load power demand when in the energy-saving mode
Uin 230 V
Uin 480 V
74 W
91 W
Setting range
MMA
5 A / 20 V - 300 A / 32 V
5A / 20 V - 200 A / 28 V
TIG
5 A / 10 V - 300 A / 22 V
5A / 10 V - 200 A / 18 V
Permissible load at MMA
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at TIG
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Apparent power I2 at
maximum current
11.6 kVA2), 11.3 kVA3)
6.6 kVA
Active power I2 at maximum 11.2 kW2), 10.8 kW3)
current
6.6 kW
Power factor at maximum current
TIG
0.96
0.99
MMA
0.96
0.98
Efficiency at maximum current
MMA
89%
87%
TIG
85%
84%
VRD 35 V deactivated
48 V
48 V
VRD 35 V activated
32 V2), 34 V3)
34 V
Open-circuit voltage U0 max
Operating temperature
Transportation temperature
-10 to +40 °C (+14 to +104 °F)
-20 to +55 °C (-4 to +131 °F)
Continual sound pressure
at no-load
0463 424 001
< 70 db (A)
- 29 -
© ESAB AB 2018
6 TECHNICAL DATA
ES 300i (0445 100 880)
Dimensions l × w × h
460 × 200 × 320 mm (18.1 × 7.9 × 12.6 in.)
Weight
15 kg (33 lbs)
Insulation class transformer
F
Enclosure class
IP23
Application class
1)
1-phase available from serial number 725-xxx-xxxx
2)
Serial number 627-xxx-xxxx to 719-xxx-xxxx
3)
From serial number 725-xxx-xxxx
ES 300i (0445 100 881)
Mains voltage
220-480 V±10%, 3~ 50/60 Hz 220 V±10%, 1~ 50/60 Hz
Primary current
Imax Stick (SMAW)
32.0 A
29.0 A
Imax GTAW (TIG)
21.0 A
20.0 A
No-load power demand
when in the energy-saving
mode
91 W
91 W1), 74 W2)
Stick (SMAW)
5 A / 20 V - 300 A / 32 V
5 A / 20 V - 200 A / 28 V
GTAW (TIG)
5 A / 10 V - 300 A / 22 V
5 A / 10 V - 200 A / 18 V
Setting range
Permissible load at Stick (SMAW)
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at GTAW (TIG)
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Apparent power I2 at
maximum current
11.3 kVA
6.6 kVA
Active power I2 at maximum 10.8 kW
current
6.5 kW
Power factor at maximum current
GTAW (TIG)
0.96
0.961), 0.982)
Stick (SMAW)
0.96
0.961), 0.992)
Efficiency at maximum current
Stick (SMAW)
89%
89%1), 87%2)
GTAW (TIG)
85%
85%1), 84%2)
48 V
48 V
Open-circuit voltage U0 max
VRD 35 V deactivated
0463 424 001
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© ESAB AB 2018
6 TECHNICAL DATA
ES 300i (0445 100 881)
VRD 35 V activated
32 V1), 34 V2)
32 V1), 34 V2)
Operating temperature
+14 to +104 °F (-10 to
+40 °C)
+14 to +104 °F (-10 to
+40 °C)
Transportation temperature -4 to +131 °F (-20 to +55 °C)
-4 to +131 °F (-20 to +55 °C)
Continual sound pressure
at no-load
< 70 db (A)
< 70 db (A)
Dimensions l × w × h
18.1x7.9x12.6 in.
(460x200x320 mm)
18.1x7.9x12.6 in.
(460x200x320 mm)
Weight
33 lb (15 kg)
33 lb (15 kg)
Insulation class transformer F
F
Enclosure class
IP23
IP23
Application class
1)
Serial number 627-xxx-xxxx to 643-xxx-xxxx
2)
From serial number 719-xxx-xxxx
ES 300i (0445 100 882)
Mains voltage
220-480 V±10%, 3~ 50/60 Hz 220 V±10%, 1~ 50/60 Hz
Primary current
Imax Stick (SMAW)
32.0 A
29.0 A
Imax GTAW (TIG)
21.0 A
20.0 A
No-load power demand
when in the energy-saving
mode
91 W
91 W1), 74 W2)
Stick (SMAW)
5 A / 20 V - 300 A / 32 V
5 A / 20 V - 200 A / 32 V
GTAW (TIG)
5 A / 10 V - 300 A / 22 V
5 A / 10 V - 200 A / 18 V
Setting range
Permissible load at Stick (SMAW)
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at GTAW (TIG)
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Apparent power I2 at
maximum current
11.3 kVA
6.6 kVA
Active power I2 at maximum 10.8 kW
current
6.5 kW
Power factor at maximum current
GTAW (TIG)
0.96
0.961), 0.982)
Stick (SMAW)
0.96
0.961), 0.992)
0463 424 001
- 31 -
© ESAB AB 2018
6 TECHNICAL DATA
ES 300i (0445 100 882)
Efficiency at maximum current
Stick (SMAW)
89%
89%1), 87%2)
GTAW (TIG)
85%
85%1), 84%2)
VRD 35 V deactivated
48 V
48 V
VRD 35 V activated
32 V1), 34 V2)
32 V1), 34 V2)
Operating temperature
-10 to +40 °C (+14 to
+104 °F)
-10 to +40 °C (+14 to
+104 °F)
Open-circuit voltage U0 max
Transportation temperature -20 to +55 °C (-4 to +131 °F)
-20 to +55 °C (-4 to +131 °F)
Continual sound pressure
at no-load
< 70 db (A)
< 70 db (A)
Dimensions l × w × h
460x200x320 mm
(18.1x7.9x12.6 in.)
460x200x320 mm
(18.1x7.9x12.6 in.)
Weight
15 kg (33 lbs)
15 kg (33 lbs)
Insulation class transformer F
F
Enclosure class
IP23
IP23
Application class
1)
Serial number 627-xxx-xxxx to 643-xxx-xxxx
2)
From serial number 719-xxx-xxxx
ES 300i (0445 100 883)
Mains voltage
230-480 V±10%, 3~ 50/60 Hz 230 V±10%, 1~ 50/60 Hz1)
Mains supply Ssc min
4.4 MVA2), 4.1 MVA3)
No demand
Zmax
0.04 Ohm
No demand
Imax MMA
30.0 A
29.0 A
Imax TIG
21.0 A
20.0 A
Primary current
No-load power demand when in the energy-saving mode
Uin 230 V
Uin 480 V
74 W
87 W2), 91 W3)
Setting range
MMA
5 A / 20 V - 300 A / 32 V
5A / 20 V - 200 A / 28 V
TIG
5 A / 10 V - 300 A / 22 V
5A / 10 V - 200 A / 18 V
Permissible load at MMA
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at TIG
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
0463 424 001
- 32 -
© ESAB AB 2018
6 TECHNICAL DATA
ES 300i (0445 100 883)
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Apparent power I2 at
maximum current
11.6 kVA2), 11.3 kVA3)
6.6 kVA
Active power I2 at maximum 11.2 kW2), 10.8 kW3)
current
6.5 kW
Power factor at maximum current
MMA
0.96
0.99
TIG
0.96
0.98
Efficiency at maximum current
MMA
89%
87%
TIG
85%
84%
48 V
48 V
Open-circuit voltage U0 max
VRD 35 V deactivated
VRD 35 V activated (standard 32 V2), 34 V3)
setting at delivery)
Operating temperature
34 V
-10 to +40 °C (+14 to +104 °F)
Transportation temperature
-20 to +55 °C (-4 to +131 °F)
Continual sound pressure
at no-load
< 70 db (A)
Dimensions l × w × h
460 × 200 × 320 mm (18.1 × 7.9 × 12.6 in.)
Weight
15 kg (33 lbs)
Insulation class transformer
F
Enclosure class
IP23
Application class
1)
1-phase available from serial number 725-xxx-xxxx
2)
Serial number 627-xxx-xxxx to 719-xxx-xxxx
3)
From serial number 725-xxx-xxxx
ET 300i (0445 100 900), ET 300iP (0445 100 920)
Mains voltage
230–480 V ±10%,
3~ 50/60 Hz
230 V ±10%, 1~ 50/60 Hz
Mains supply Ssc min
4.1 MVA
No demand
Zmax
0.04 Ohm
No demand
Imax MMA
30.0 A
29.0 A
Imax TIG
22.0 A
20.0 A
Primary current
No-load power demand when in the energy-saving mode
Uin 230 V
63 W
Uin 400 V
68 W
Uin 480 V
72 W
0463 424 001
74 W
- 33 -
© ESAB AB 2018
6 TECHNICAL DATA
ET 300i (0445 100 900), ET 300iP (0445 100 920)
Setting range
MMA
5 A / 20 V - 300 A / 32 V
5 A / 20 V - 200 A / 28 V
TIG
5 A / 10 V - 300 A / 22 V
5 A / 10 V - 200 A / 18 V
Permissible load at MMA
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at TIG
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Power factor at maximum current
TIG
0.96
0.98
MMA
0.96
0.99
Apparent power I2 at
maximum current
11.6 kVA
6.6 kVA
Active power I2 at maximum 11.2 kW
current
6.6 kW
Efficiency at maximum current
TIG
83%
83%
MMA
86%
86%
Open-circuit voltage U0
max
48 V
48 V
Open-circuit voltage U0
34 V
max with VRD 35 V activated
34 V
UPK
12.4 kV
12.4 kV
Operating temperature
-10 to +40 °C (+14 to +104 °F)
Transportation temperature
-20 to +55 °C (-4 to +131 °F)
Continual sound pressure
at no-load
< 70 db (A)
Dimensions l × w × h
460 × 200 × 320 mm (18.1 × 7.9 × 12.6 in.)
Weight with cooler
without cooler
26.6 kg (58.6 lb)
16.8 kg (37.0 lb)
Isolation class transformer
F
Enclosure class
IP23
Application class
ET 300i (0445 100 903), ET 300iP (0445 100 923)
Mains voltage
230–480 V ±10%,
3~ 50/60 Hz
230 V ±10%, 1~ 50/60 Hz
Mains supply Ssc min
4.1 MVA
No demand
0463 424 001
- 34 -
© ESAB AB 2018
6 TECHNICAL DATA
ET 300i (0445 100 903), ET 300iP (0445 100 923)
Zmax
0.04 Ohm
No demand
Imax MMA
30.0 A
29.0 A
Imax TIG
22 A
20.0 A
Primary current
No-load power demand when in the energy-saving mode
Uin 230 V
63 W
Uin 400 V
68 W
Uin 480 V
72 W
74 W
Setting range
MMA
5 A / 20 V - 300 A / 32 V
5 A / 20 V - 200 A / 28 V
TIG
5 A / 10 V - 300 A / 22 V
5 A / 10 V - 200 A / 18 V
Permissible load at MMA
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at TIG
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Power factor at maximum current
TIG
0.96
0.98
MMA
0.96
0.99
Apparent power I2 at
maximum current
11.6 kVA
6.6 kVA
Active power I2 at maximum 11.2 kW
current
6.6 kW
Efficiency at maximum current
TIG
83%
83%
MMA
86%
86%
VRD 35 V deactivated
48 V
48 V
VRD 35 V activated
34 V
34 V
UPK
12.4 kV
12.4 kV
Open-circuit voltage U0 max
Operating temperature
Transportation temperature
-10 to +40 °C (+14 to +104 °F)
-20 to +55 °C (-4 to +131 °F)
Continual sound pressure
at no-load
Dimensions l × w × h
0463 424 001
< 70 db (A)
460 × 200 × 320 mm (18.1 × 7.9 × 12.6 in.)
- 35 -
© ESAB AB 2018
6 TECHNICAL DATA
ET 300i (0445 100 903), ET 300iP (0445 100 923)
Weight with cooler
without cooler
26.6 kg (58.6 lb)
16.8 kg (37.0 lb)
Isolation class transformer
F
Enclosure class
IP23
Application class
ET 300iP (0445 100 921)
Mains voltage
220–480 V ±10%,
3~ 50/60 Hz
220 V ±10%, 1~ 50/60 Hz
Imax Stick (SMAW)
30.0 A
30.0 A
Imax GTAW (TIG)
22.0 A
20.0 A
Primary current
No-load power demand when in the energy-saving mode
Uin 220 V
63 W
Uin 400 V
68 W
Uin 480 V
72 W
74 W
Setting range
Stick (SMAW)
5 A / 20 V - 300 A / 32 V
5 A / 20 V - 200 A / 28 V
GTAW (TIG)
5 A / 10 V - 300 A / 22 V
5 A / 10 V - 200 A / 18 V
Permissible load at Stick (SMAW)
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at GTAW (TIG)
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Power factor at maximum current
GTAW (TIG)
0.96
0.98
Stick (SMAW)
0.96
0.99
Apparent power I2 at
maximum current
11.6 kVA
6.6 kVA
Active power I2 at maximum 11.2 kW
current
6.6 kW
Efficiency at maximum current
GTAW (TIG)
83%
83%
Stick (SMAW)
86%
86%
Open-circuit voltage U0
max
48 V
48 V
0463 424 001
- 36 -
© ESAB AB 2018
6 TECHNICAL DATA
ET 300iP (0445 100 921)
Open-circuit voltage U0
34 V
max with VRD 35 V activated
34 V
UPK
12.4 kV
12.4 kV
Operating temperature
+14 to +104 °F (-10 to +40 °C)
Transportation temperature
-4 to +131 °F (-20 to +55 °C)
Continual sound pressure
at no-load
< 70 db (A)
Dimensions l × w × h
18.1 × 7.9 × 12.6 in. (460 × 200 × 320 mm)
Weight with cooler
without cooler
58.6 lb (26.6 kg)
37.0 lb (16.8 kg)
Isolation class transformer
F
Enclosure class
IP23
Application class
ET 300iP (0445 100 922)
Mains voltage
220–480 V ±10%,
3~ 50/60 Hz
220 V ±10%, 1~ 50/60 Hz
Imax Stick (SMAW)
30.0 A
30.0 A
Imax GTAW (TIG)
22.0 A
20.0 A
Primary current
No-load power demand when in the energy-saving mode
Uin 230 V
63 W
Uin 400 V
68 W
Uin 480 V
72 W
74 W
Setting range
Stick (SMAW)
5 A / 20 V - 300 A / 32 V
5 A / 20 V - 200 A / 28 V
GTAW (TIG)
5 A / 10 V - 300 A / 22 V
5 A / 10 V - 200 A / 18 V
Permissible load at Stick (SMAW)
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at GTAW (TIG)
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Power factor at maximum current
GTAW (TIG)
0.96
0.98
Stick (SMAW)
0.96
0.99
Apparent power I2 at
maximum current
11.6 kVA
6.6 kVA
0463 424 001
- 37 -
© ESAB AB 2018
6 TECHNICAL DATA
ET 300iP (0445 100 922)
Active power I2 at maximum 11.2 kW
current
6.6 kW
Efficiency at maximum current
GTAW (TIG)
83%
83%
Stick (SMAW)
86%
86%
Open-circuit voltage U0
max
48 V
48 V
Open-circuit voltage U0
34 V
max with VRD 35 V activated
34 V
UPK
12.4 kV
Operating temperature
Transportation temperature
12.4 kV
-10 to +40 °C (+14 to +104 °F)
-20 to +55 °C (-4 to +131 °F)
Continual sound pressure
at no-load
Dimensions l × w × h
< 70 db (A)
460 × 200 × 320 mm (18.1 × 7.9 × 12.6 in.)
Weight with cooler
without cooler
26.6 kg (58.6 lb)
16.8 kg (37.0 lb)
Isolation class transformer
F
Enclosure class
IP23
Application class
Mains supply, Ssc 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.
0463 424 001
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© ESAB AB 2018
7 SOFTWARE UPDATE AND CONFIGURATION
7
SOFTWARE UPDATE AND CONFIGURATION
The software in the power source consists of three parts, system software (application
software), secondary bootloader and primary bootloader.
7.1
USB handling
USB is used for software update, configuration and for extracting service log.
The amount of files saved on a USB flash drive used for software update, configuration and
retrieving service log, should be limited! It is possible to have other files on the same USB
drive but our recommendation is to only keep script files, system software files and log
files on the drive. There may only be one script file or one system software on the USB
drive. The power source will ignore all other file types. The script file or system software file
must be stored in the root catalogue of the USB drive.
7.1.1
Script files
Script files are used to demand the power source to do something, i.e. to configure or to
retrieve a service log. A script file must always be renamed "sparc.script" when it is saved to
the USB drive.
7.1.2
System software files
This section is valid for files used for application software update and secondary bootloader
update. A software update file must always be renamed “sparc.fcf” when it is saved to the
USB drive.
7.2
Files location
All system software files and script files are accessible to download through a link on each
country/regions local partner login site.
0463 424 001
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© ESAB AB 2018
7 SOFTWARE UPDATE AND CONFIGURATION
7.3
Application software update
Before starting the software update, make sure the following are available:
•
•
•
a USB flash drive
the correct system software file
the appropriate configuration file for the power source model and variant
The system software file will make sure that the power source (including the setting panel)
and connected digital accessories (e.g. remote or pedal) are updated. To ensure
compatibility, make sure that any accessory that is used together with the power source is
connected to the power source before updating the software. If several accessories are to
be used together with the power source but cannot be connected to the power source at the
same time, you have to repeat the update procedure for each accessory. Regardless of
which software versions that are installed in the power source and the accessories, the
system software update will ensure that the power source and all connected devices are
updated to the same new software version.
1.
2.
3.
4.
Copy the system software file (filename.fcf) to the USB drive.
Rename the file sparc.fcf.
Insert the USB flash drive into the power source USB connector.
The software update starts and three LED segments (---) start scrolling across the
power source display. The software update takes approximately one minute. When
the update is completed, the power source automatically restarts and the new
system software version is presented in the display. To confirm that the update
process is finalized, the text "USB" flashes in the display for a moment, after which
the text "USB" is shown with fixed light.
Remove the USB flash drive.
If there are several accessories used in the system, for instance two different remote control
units, perform the update procedure described above one time with each accessory
connected.
NOTE!
After update has been performed, it is recommended to configure the power
source using the latest version of the appropriate script file (see section
"Software configuration", page 42).
7.3.1
Troubleshooting application software update
Issue
Actions
The software update does
not start, i.e. the display
does not turn black and no
LED segments appear.
1.
2.
3.
Remove the USB flash drive.
Make sure the system software file is named
sparc.fcf.
Insert the USB flash drive again.
The software update still
does not start, although the
actions above have been
performed.
1.
2.
3.
4.
Remove the USB flash drive.
Turn the power source off.
Insert the USB flash drive again.
Turn the power source on again.
The power source does not
restart automatically when
the update is completed.
1.
If the power source has not restarted automatically
approximately one minute after the update process
started, shut the power source down manually.
Remove the USB flash drive.
Turn the power source on again.
2.
3.
0463 424 001
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© ESAB AB 2018
7 SOFTWARE UPDATE AND CONFIGURATION
7.4
Secondary bootloader update
The procedure in this section should only be performed if the procedure according to section
"Application software update", page 40 is not working. Make sure you have a USB flash
drive and the correct secondary bootloader software file available, before starting the
procedure. The secondary bootloader software file will make sure that the power source
(including the setting panel) and connected digital accessories (e.g. remote or pedal) are
updated. To ensure compatibility, make sure that any accessory that is used together with
the power source is connected to the power source before updating the software. If several
accessories are to be used together with the power source but cannot be connected to the
power source at the same time, you have to repeat the update procedure for each
accessory. Regardless of which software versions that are installed in the power source and
the accessories, the system software update will ensure that the power source and all
connected devices are updated to the same new software version.
1.
2.
3.
4.
Copy the bootloader software file (filename.fcf) to the USB drive.
Rename the file sparc.fcf.
Insert the USB flash drive into the power source USB connector.
The software update starts and three LED segments (---) start scrolling across the
power source display. The software update takes approximately one minute. When
the update is completed, the power source automatically restarts and the new
system software version is presented in the display. To confirm that the update
process is finalized, the text "USB" flashes in the display for a moment, after which
the text "USB" is shown with fixed light.
Remove the USB flash drive.
If there are several accessories used in the system, for instance two different remote control
units, perform the update procedure described above one time with each accessory
connected.
After performing the procedure above, update the application software according to section
"Application software update", page 40.
NOTE!
You do not need to re-configure the power source after updating secondary
bootloader, since configuration parameters are stored in a permanent memory.
7.4.1
Troubleshooting secondary bootloader update
Issue
Actions
The software update does
not start, i.e. the display
does not turn black and no
LED segments appear.
1.
2.
3.
Remove the USB flash drive.
Make sure the bootloader software file is named
sparc.fcf.
Insert the USB flash drive again.
The software update still
does not start, although the
actions above have been
performed.
1.
2.
3.
4.
Remove the USB flash drive.
Turn the power source off.
Insert the USB flash drive again.
Turn the power source on again.
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Issue
Actions
The power source does not
restart automatically when
the update is completed.
1.
2.
3.
The power source still does
not start, although all
actions above have been
performed.
7.5
1.
If the power source has not restarted automatically
approximately one minute after the update process
started, shut the power source down manually.
Remove the USB flash drive.
Turn the power source on again.
Load the application system software, by performing
the procedure according to section "Application
software update", page 40.
Software configuration
Each power source has a certain software configuration at delivery from factory. The power
source can also be configured in field. The following options are available for field
configuration:
•
•
•
VRD On/Off
Cellulosic welding process regulator
Set time
7.5.1
1.
2.
3.
4.
5.
6.
Configuration of the power source according to product ordering number
Download the correct script file according to the product ordering number on the
rating plate (e.g. if the ordering number is 0445 100 883, download script file
445100883.zip).
Unzip the script file, rename it “sparc.script” and copy it to a USB flash drive.
Insert the USB flash drive into the power source USB port.
Restart the power source.
The text "USB" is flashing in the power source display.
When the text "USB" is presented with fixed light, remove the USB flash drive.
Restart the power source again.
The configuration of all the nodes in the power source is now completed.
7.5.2
VRD On/Off
On power sources with ordering numbers 0445 100 883, 0445 100 903 and 0445 100 923,
the VRD functionality is activated (configuration On) by default from the factory. On all other
product variants, the VRD functionality is deactivated (configuration Off) by default.
7.5.3
Cellulosic welding process regulator
There are two regulators for cellulosic welding included in the power source, "KCO" and
"KC". Power sources with ordering numbers 0445 100 880, 0445 100 882 and 0445 100 883
are pre-configured to use KCO. Power sources with ordering numbers 0445 100 881 are
pre-configured to use KC. The two regulators differ in welding characteristics. KCO has a
higher arc energy and is suitable for root welding and vertical down welding. All product
variants can be configured to use any of the two regulators.
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7.5.4
Set time
The time of the power source control board can be set, by editing the script file, specifying
the preferred date and time.
1.
2.
3.
Open the correct script file in a text editor:
gettime
settime 2016-07-05 8:40:00
gettime
Edit the date and time (2016-07-05 8:40:00) specifying the preferred values.
Continue by performing the procedure according to section "Configuration of the
power source according to product ordering number", page 42.
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8
TROUBLESHOOTING
8.1
Extracting power source data and status via USB flash drive
Data and status of the power source (and connected accessories) can be extracted through
USB. This can be helpful when troubleshooting.
8.1.1
Extracting welding statistics
It is possible to extract welding statistics by inserting an empty USB flash drive in the power
source USB port. The statistics contain number of welds, average current on these welds
and total welding time. The statistics are continuously saved in the control board permanent
memory.
8.1.2
Extracting a service log
A log with data and status of the power source can be retrieved using a script file and a USB
flash drive. Recommended programs for reading the service log are Microsoft Word and
Microsoft WordPad. A service log is extracted as folows:
1.
2.
Copy the correct script file to a USB flash drive and name it sparc.script.
Insert the USB flash drive into the power source USB port.
The text "USB" is flashing in the power source display.
When the log is completed, the text "USB" is shown with fixed light in the display.
When the text "USB" is presented with fixed light, remove the USB flash drive. The
USB flash drive now contains a log named esabdata.txt.
3.
8.1.3
Interpreting the service log
The service log is divided into sections. In the first sections you can see the configuration
data and the status for the master, i.e. the control board. Next you can see the data and the
status for the setting panel, the remote/pedal and the cooling unit.
Section Command
Description
1
gettime
Retrieves the time for the control board
2
db ls
Lists the configuration for the node for the control board
3
version
Retrieves software version in the control board
4
version pccm Retrieves FPGA code version in the control board
5
version boot
Retrieves the version of primary and secondary boot loader in the
control board
6
active
Lists all currently active errors, which may or may not block usage.
This list contains both errors from the control board and from any
other connected board in the system, e.g. a panel and a remote
control or a pedal.
7
syslog
Lists all events which has occurred in the system. This list contains
both events in the control board and events sent from any other
connected board in the system
8
log
Lists all events in the control board
9
cmdProxy 10 Retrieves the time for the panel board (CAN Open node #10)
(gettime)
10
cmdProxy 10 Lists the configuration for the panel board
(db ls)
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Section Command
Description
11
cmdProxy 10 Retrieves software version in the panel board
(version)
12
cmdProxy 10 Retrieves the version of primary and secondary boot loader in the
(version boot) panel board
13
cmdProxy 10 Lists all currently active errors, which may or may not block any
(active)
usage. This list contain both errors in the panel and errors which
are distributed to the other boards in the system
14
cmdProxy 10 Lists all events in the panel board
(log)
15
cmdProxy 5
(gettime)
Retrieves the time for the remote/pedal board (CAN Open node #5)
16
cmdProxy 5
(db ls)
Lists the configuration for the remote/pedal board
17
cmdProxy 5
(version)
Retrieves software version in the remote/pedal board
18
cmdProxy 5 Retrieves the version of primary and secondary boot loader in the
(version boot) remote/pedal board
19
cmdProxy 5
(active)
Lists all currently active errors, which may or may not block any
usage. This list contain both errors in the remote/pedal and errors
which are distributed to the other boards in the system
20
cmdProxy 5
(log)
Lists all events in the remote/pedal board
21
cmdProxy 2
(gettime)
Retrieves the time for the cooler board (CAN Open node #2)
22
cmdProxy 2
(db ls)
Lists the configuration for the cooler board
23
cmdProxy 2
(version)
Retrieves software version in the cooler board
24
cmdProxy 2 Retrieves the version of primary and secondary boot loader in the
(version boot) cooler board
25
cmdProxy 2
(active)
Lists all currently active errors, which may or may not block any
usage. This list contain both errors in the cooler and errors which
are distributed to the other boards in the system
26
cmdProxy 2
(log)
Lists all events in the cooler board
8.1.3.1
Section 2 – db ls
This command lists the configuration as available in the node. The configuration parameters
are grouped together according to their use. All power block configuration parameters are
placed in the PowerBlockConfig-group, data related to the PCBA is grouped in
HardwareData etc.
8.1.3.2
Section 6 – active
The scope indicates whether the error originates from the local node or from another node
in the system. Errors are never stored persistently. However the event in which an error
occurred is stored, but in the log and the syslog.
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8.1.3.3
Section 7 – syslog
The system log contains events which affect the system in some way. The events are listed
in the reverse chronological order, i.e. the newest event is presented first and the oldest
event is presented last. Each line contains the following metadata of the event:
Metadata header Explanation
Idx
Index in the buffer (0, 1, 2, …)
Time
The time at which the power source received notification that the event
has occurred. This may be slightly different from the time when the event
first occurred in the originating node.
Severity
This is an indication of how severe the event is. Events are only logged if
the severity is FAILURE or higher. The different severities are (in
increasing severity); DEBUG, INFORMATIONAL, NOTICE, WARNING,
FAILURE, CRITICAL, ALERT and EMERGENCY.
Error
This is the public error number which may be presented on the panel or
remote. Typically this error code is of the form “over temperature” or
“communication problems”.
ID.Sub
This tuple of values indicate which internal event identifier and event
sub-identifier actually resulted in the error. This tuple enables finding
which software or hardware component which actually triggered the
error.
Act/Clr
If "ACT", this means that a new error is active. If "clr" this means that a
previously activated error has been cleared.
Data
This field may contain 32 bits of data provided from the event originator.
Node@nodetime This field identifies the node which issues the event and at which node
time the event occurred.
Description
8.1.3.4
This is a description of the event.
Section 8 – log
This listing contains an extract of the log for the power source. This log contains events
which occur locally on each node.
Metadata value
Explanation
[YYYY-mm-dd hh:mm:ss]
Time when the event occurred
DEBUG, INFORMATIONAL, This is an indication of how severe the event is.
NOTICE, WARNING,
FAILURE, CRITICAL,
ALERT and EMERGENCY.
Id:
This identifier indicates which internal event identifier
triggered the event.
Sub:
This identifier indicates which event sub-identifier triggered
the event.
Ext id:
This is the public error number which may be presented on
the panel or remote. Typically this error code is of the form
"over temperature" or "communication problems".
Description
This is a description of the event.
Data
This field may contain 32 bits of data provided from the event
originator.
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8.1.3.5
Section 13 – cmdProxy 10 (active)
The scope indicates whether the error originates from the local node or from another node
in the system. Errors are never stored persistently. However the event in which an error
occurred is stored, but in the log and the syslog.
8.1.3.6
Section 14 – cmdProxy 10 (log)
This listing contains an extract of the log for the panel. This log contains events which occur
locally on each node. For explanations of metadata values, see "Section 8 – log", page
46.
8.1.3.7
Section 19 – cmdProxy 5 (active)
The scope indicates whether the error originates from the local node or from another node
in the system. Errors are never stored persistently. However the event in which an error
occurred is stored, but in the log and the syslog.
8.1.3.8
Section 20 – cmdProxy 5 (log)
This listing contains an extract of the log for the remote control. This log contains events
which occur locally on each node. For explanations of metadata values, see "Section 8 –
log", page 46.
8.1.3.9
Section 25 – cmdProxy 2 (active)
The scope indicates whether the error originates from the local node or from another node
in the system. Errors are never stored persistently. However the event in which an error
occurred is stored, but in the log and the syslog.
8.1.3.10
Section 26 – cmdProxy 2 (log)
This listing contains an extract of the log for the cooling unit. This log contains events which
occur locally on each node. For explanations of metadata values, see "Section 8 – log",
page 46.
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8.2
Pre power up checks
WARNING!
Make sure the power source is disconnected from the mains supply and wait at
least 30 seconds for the DC bus capacitor to discharge before removing any of
the power source panels!
Then remove the power source left side panel according to chapter
"DISASSEMBLY AND REASSEMBLY", page 74 and measure the voltage
between the "+" and "-" screws of the capacitor, using a multimeter. If the voltage
between the "+" and "-" screws of the capacitor is not < 20 V, wait further until
the voltage is below 20 V!
8.2.1
Visual Inspection
Examine the power source for any visible signs of damage. Especially check:
1.
2.
Printed circuit boards for burned varistors or other components
Cables and connectors
8.2.2
Input module measurements
Perform the following measurements, using a multimeter set to resistance test setting:
1.
2.
Turn the mains switch on and measure the resistance, for all phases, between the
mains plug and the input socket CN21 on Power Board 15AP1:
○ Mains plug R – CN21.1: < 1 Ω
○ Mains plug S – CN21.2: < 1 Ω
○ Mains plug T – CN21.3: < 1 Ω
Measure the resistance between the in phases CN21.1, CN21.2 and CN21.3 of the
power board socket CN21. The resistance should be > 100 kΩ between all phases.
If the measurement specification for any of the measurements is not met, check the mains
switch and the EMC filter board. Replace any faulty components according to instructions in
chapter "REPLACEMENT INSTRUCTIONS", page 81.
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8.2.3
Power Board 15AP1 measurements
Measurements for Power Board 15AP1 are presented in detail on the following pages.
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1.
Using a multimeter set to diode test setting, measure the input rectifier bridge as
follows:
a) The input phases to DC_bus_rtn on DC_bus capacitor:
i
With the positive test probe on DC_Bus_rtn ("-" on DC_bus capacitor
15C1) and the negative test probe on CN21.1, check for one diode
voltage drop (0.4 - 0.6 V).
ii
With the positive test probe on DC_Bus_rtn ("-" on DC_bus capacitor
15C1) and the negative test probe on CN21.2, check for one diode
voltage drop (0.4 - 0.6 V).
iii With the positive test probe on DC_Bus_rtn ("-" on DC_bus capacitor
15C1) and the negative test probe on CN21.3, check for one diode
voltage drop (0.4 - 0.6 V).
b)
The input phases to rectified DC bus on pin CN12:
i
With the positive test probe on CN21.1 and the negative test probe on
CN12, check for one diode voltage drop (0.4 - 0.6 V).
ii
With the positive test probe on CN21.2 and the negative test probe on
CN12, check for one diode voltage drop (0.4 - 0.6 V).
iii With the positive test probe on CN21.3 and the negative test probe on
CN12, check for one diode voltage drop (0.4 - 0.6 V).
If any of the measurements show an open or short circuit, the rectifier bridge is defect
and the power board needs to be replaced (see section "Replacing the power board",
page 97).
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2.
Using a multimeter set to diode test setting, measure the full bridge as follows:
a) Disconnect transformer cable 1611D from connection point CN17 on the power
board.
NOTE!
Be careful so that the spacer between the cable 1611D cable eye
and connection point CN17 is not lost!
b)
c)
d)
e)
With the positive test probe on DC_Bus_rtn ("-" on DC_bus capacitor 15C1)
and the negative test probe on CN17, check for one diode voltage drop (0.3 0.5 V).
With the positive test probe on DC_Bus_rtn ("-" on DC_bus capacitor 15C1)
and the negative test probe on CN18, check for one diode voltage drop (0.3 0.5 V).
With the positive test probe on CN17 and the negative test probe on DC_Bus
("+" on DC_bus capacitor 15C1), check for one diode voltage drop (0.3 - 0.5 V).
With the positive test probe on CN18 and the negative test probe on DC_Bus
("+" on DC_bus capacitor 15C1), check for one diode voltage drop (0.3 - 0.5 V).
If any of the measurements show an open or short circuit, the full bridge is defect and
the power board needs to be replaced (see section "Replacing the power board",
page 97).
NOTE!
When reconnecting the transformer cable 1611D, do not forget to put back
the spacer between the cable eye and connection point CN17!
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3.
4.
Using a multimeter set to resistance test setting, measure the PFC buck switch as
follows:
a) Remove the control board according to section "Replacing the control board",
page 94.
b) Disconnect the PFC inductor cables from connection points CN13 and CN15 on
the power board.
c) With the negative test probe on CN12 and the positive test probe on CN13,
measure the resistance. The resistance should be > 100 kΩ.
d) With the negative test probe on CN12 and the positive test probe on CN15,
measure the resistance. The resistance should be > 100 kΩ.
If any of the measurements show a short circuit, the power module is defect and the
power board needs to be replaced (see section "Replacing the power board", page
97).
Using a multimeter set to diode test setting, measure the PFC buck freewheeling
diode as follows:
a) Remove the control board according to section "Replacing the control board",
page 94.
b) Disconnect the PFC inductor cables from connection points CN13 and CN15 on
the power board.
c) With the positive test probe on DC_bus_rtn ("-" on DC_bus capacitor 15C1)
and the negative test probe on CN13, check for one diode voltage drop (0.3 0.5 V).
d) With the positive test probe on DC_bus_rtn ("-" on DC_bus capacitor 15C1)
and the negative test probe on CN15, check for one diode voltage drop (0.3 0.5 V).
If any of the measurements show an open or short circuit, the power module is defect
and the power board needs to be replaced (see section "Replacing the power board",
page 97).
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5.
Using a multimeter set to resistance test setting, measure the PFC boost switch as
follows:
a) Remove the control board according to section "Replacing the control board",
page 94.
b) Disconnect the PFC inductor cables from connection points CN13 and CN15 on
the power board.
c) With the positive test probe on DC_bus_rtn ("-" on DC_bus capacitor 15C1)
and the negative test probe on CN13, measure the resistance. The resistance
should be > 100 kΩ.
d) With the positive test probe on DC_bus_rtn ("-" on DC_bus capacitor 15C1)
and the negative test probe on CN15, measure the resistance. The resistance
should be > 100 kΩ.
If any of the measurements show a short circuit, the power module is defect and the
power board needs to be replaced (see section "Replacing the power board", page
97).
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6.
7.
Using a multimeter set to diode test setting, measure the PFC booster diode as
follows:
a) Remove the control board according to section "Replacing the control board",
page 94.
b) Disconnect the PFC inductor cables from connection points CN14 and CN16 on
the power board.
c) With the negative test probe on DC_Bus ("+" on DC_bus capacitor 15C1) and
the positive test probe on CN14, check for one diode voltage drop (0.3 - 0.5 V).
d) With the negative test probe on DC_Bus ("+" on DC_bus capacitor 15C1) and
the positive test probe on CN16, check for one diode voltage drop (0.3 - 0.5 V).
If any of the measurements show an open or short circuit, the power module is defect
and the power board needs to be replaced (see section "Replacing the power board",
page 97).
Using a multimeter set to resistance test setting, measure the resistance over the fuse
FU1.
If the measurement shows an open circuit, replace the fuse.
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8.2.4
Booster Board 27AP1 measurements
To be able to troubleshoot the booster diodes on the booster board, remove the power
source right side panel according to chapter "DISASSEMBLY AND REASSEMBLY", page
74.
Measurements for Booster Board 27AP1 are presented in detail below.
1.
Using a multimeter set to diode test setting, measure the forward voltage drop over
the output rectifier diode in the following way: With the positive test probe on the
negative welding output terminal and the negative test probe on the positive welding
output terminal, check for one diode voltage drop (0.3 - 0.5 V).
If the measurement shows an open or short circuit, one or several of the rectifier
diodes are defect and need to be replaced (see section "Replacing the secondary
rectifier diode modules", page 104).
NOTE!
Always replace all rectifier diode modules at the same time!
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2.
3.
Using a multimeter set to resistance test setting, measure the resistance between the
welding output terminals in the following way: With the positive test probe on the
positive welding output terminal and the negative test probe on the negative welding
output terminal, check for a resistance of 4 - 5 kΩ.
If the measurement shows an open or short circuit, the booster board is defect and
needs to be replaced (see section "Replacing the booster board", page 101).
Perform the following measurements, using a multimeter set to diode test setting:
a) Booster MOSFET body diode:
i
With the negative test probe on the drain of diode V16 (on the booster
board) and the positive test probe on the positive welding output
terminal, check for one diode voltage drop (0.3 - 0.5 V).
ii
With the negative test probe on the drain of diode V26 (on the booster
board) and the positive test probe on the positive welding output
terminal, check for one diode voltage drop (0.3 - 0.5 V).
b) Booster diode:
i
With the negative test probe on the drain of diode V16 (on the booster
board) and the positive test probe on the negative welding output
terminal, check for one diode voltage drop (0.3 - 0.5 V).
ii
With the negative test probe on the drain of diode V26 (on the booster
board) and the positive test probe on the negative welding output
terminal, check for one diode voltage drop (0.3 - 0.5 V).
If any of the measurements show an open or short circuit, the booster board is defect
and needs to be replaced (see section "Replacing the booster board", page 101).
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8.2.5
Measurements of interconnections between Power Board 15AP1 and Control
Board 20AP1
Using a multimeter set to resistance test setting, measure the supply from the primary
current transformer as follows:
1.
2.
3.
4.
5.
Remove the control board according to section "Replacing the control board",
page 94.
Measure the resistance between pins CN83_2 and CN83_4 at connector CN83 on
the power board.
The resistance should be ≤ 1 Ω. If the resistance is higher, replace the power board
(see section "Replacing the power board", page 97).
Reconnect the flat ribbon cable to connector CN83 on the power board and
measure the resistance between pins CN83_2 and CN83_4 in the flat ribbon
cable connector (disconnected from the control board).
The resistance should be ≤ 1 Ω. If the resistance is higher, replace the flat ribbon
cable.
Reinstall the control board (see section "Replacing the control board", page 94
for details).
Measure the resistance between pins CN83_2 and CN83_4 at connector CN83 on
the control board.
The resistance should be ≤ 1 Ω. If the resistance is higher, replace the control
board (see section "Replacing the control board", page 94).
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8.2.6
Measurements of interconnections between Booster Board 27AP1 and Control
Board 20AP1
Using a multimeter set to resistance test setting, measure the output voltage sense signals
as follows:
1.
2.
Measure the resistance between the positive welding output terminal and capacitor
C318 on the control board.
The resistance should be in the interval 60 - 70 kΩ.
Measure the resistance between the negative welding output terminal and
capacitor C302 on the control board.
The resistance should be in the interval 60 - 70 kΩ.
If the measurement specification for any of the measurements is not met, check the
condition of the flat ribbon cable between the control board (connector CN51) and the
booster board (connector X05). If needed, replace the flat ribbon cable.
If the flat ribbon cable is OK, replace the booster board (see "Replacing the booster board",
page 101).
8.2.7
Testing the electrolytic DC bus capacitor 15C1
NOTE!
In order to be able to test the DC bus capacitor as described below, the power
board has to be removed (see section "Replacing the power board", page
97).
Measure the capacitance between the positive (+) and the negative (-) pole of the
electrolytic DC bus capacitor 15C1, using a capacitance meter. The capacitance should be
in the interval 1200 - 1500 µF.
If no capacitance meter is available, measure the resistance between the positive (+) and
the negative (-) pole of the capacitor. The resistance should be > 100 kΩ.
If the measurement specification is not met, replace the capacitor.
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8.2.8
Restoring the power source after pre power up checks
NOTE!
After having completed all pre power up checks, restore the power source
carefully as follows:
1.
2.
3.
Reconnect the PFC inductor cables to connection points CN13 and
CN15 on the power board (if not already reconnected, for details see
section "Replacing the PFC inductor", page 96).
Reconnect transformer cable 1611D to connection point CN17 on the
power board (if not already reconnected, for details see section
"Replacing the power board", page 97.
Reinstall the control board (if not already reinstalled, for details see
section "Replacing the control board", page 94). Check that all
cables and connectors are located correctly.
8.3
Power up checks
8.3.1
General
After having performed pre power up checks according to the instructions in the previous
pages and restored the power source according to section "Restoring the power source
after pre power up checks", page 59, you can perform power up check as follows:
1.
2.
Connect the power source to the rated input mains supply voltage and turn the
mains power supply switch on.
○ If the power source starts and the setting panel is working:
i
Check if an error code is presented in the display.
ii
Connect a USB flash drive to the power source USB connector and
retrieve the service log.
iii Based on the presented error code and the service log, perform the
adequate actions according to chapter "ERROR CODES", page
24.
iv If the fault is still not located, perform test according to section
"Electrical test", page 60.
○ If the power source does not start, perform test according to section
"Electrical test", page 60.
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8.3.2
Electrical test
8.3.2.1
EMC filter board 2AP1 measurement
1.
Measure the phase to phase RMS voltage between all phases in the mains
connectors L1, L2 and L3 on the EMC filter board 2AP1.
If there is no voltage, replace the mains switch.
NOTE!
The voltages presented in the illustration below are only examples, since
the actual voltages will vary depending on which input mains supply voltage
the power source is connected to.
8.3.2.2
1.
Power Board 15AP1 measurements
Measure the phase to phase RMS voltage between all phases in the mains connector
CN21 on the power board 15AP1.
If there is no voltage, replace the EMC filter board 2AP1.
NOTE!
The voltages presented in the illustration below are only examples, since
the actual voltages will vary depending on which input mains supply voltage
the power source is connected to.
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2.
Measure the DC_bus voltage between the plus and minus connections for the
electrolytic DC bus capacitor 15C1. The voltage should be 440 ±10 V.
If the measurement specification is not met, replace the power board 15AP1.
3.
Measure the DC_bus voltage between pins 1 and 3 of connector CN41 on the power
board 15AP1. The voltage should be 440 ±10 V.
If the measurement specification is not met, replace the fuse FU1.
4.
Measure the 24V_Weld voltage over capacitor C417 on the power board 15AP1. The
voltage should be 25 ±2 V.
If the measurement specification is not met, replace the power board.
5.
Measure the 24V_PE voltage over capacitor C419 on the power board 15AP1. The
voltage should be 25 ±2 V.
If the measurement specification is not met, replace the power board.
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6.
Measure the 12V_CAN2 voltage over capacitor C418 on the power board 15AP1. The
voltage should be 13 ±3 V.
If the measurement specification is not met, replace the power board.
7.
Disconnect the flat ribbon cable from connector CN83 on the control board 20AP1.
Measure the 24V_Weld voltage between pins 8 (Weld_rtn) and 9 (24V_Weld) in the
flat ribbon cable connector (disconnected from the control board). The voltage should
be 25 ±2 V.
If the measurement specification is not met, replace the involved flat ribbon cable.
8.
Disconnect the flat ribbon cable from connector CN82 on the control board 20AP1.
Measure the 24V_PE voltage between pins 6 (PE_rtn) and 7 (24V_PE) in the flat
ribbon cable connector (disconnected from the control board). The voltage should be
25 ±2 V.
If the measurement specification is not met, replace the involved flat ribbon cable.
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9.
With the flat ribbon cable still disconnected from connector CN82 on the control board,
measure the 24V_PE voltage between pins 6 (PE_rtn) and 10 (24V_PE_ext) in the
flat ribbon cable connector. The voltage should be 25 ±2 V.
If the measurement specification is not met, replace the involved flat ribbon cable.
10. With the flat ribbon cable still disconnected from connector CN83 on the control board,
measure the 12VCAN2 voltage between pins 20 (12VCAN2_rtn) and 19 (12VCAN2)
in the flat ribbon cable connector. The voltage should be 13 ±3 V.
If the measurement specification is not met, replace the involved flat ribbon cable.
11. After having completed all power board measurements described above, reconnect all
flat ribbon cables.
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8.3.2.3
1.
Control Board 20AP1 measurements
Measure the 24V_Weld voltage between pin 2 of connector CN23 (24V_Weld) and pin
1 of connector CN22 (24V_Weld_rtn). The voltage should be 25 ±2 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
NOTE!
In power sources ET 300i and ET 300iP, connector CN23 is a 5 pole
connector but pin 2 of the connector is still connected to "24V_Weld", which
means that measurement between these pins should meet the specification
given above.
2.
Measure the 24V_PE voltage between pins 1 (24V_PE) and 5 (PE_rtn) of connector
CN28 on the control board 20AP1. The voltage should be 25 ±2 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
3.
Measure the 24V_PE_out voltage between pins 1 (24V_PE_out) and 5 (PE_rtn) of
connector CN27 on the control board 20AP1. The voltage should be 25 ±2 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
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4.
Measure the 12V_CAN2 voltage between pins 1 (12V_CAN2) and 2 (12V_CAN_rtn)
of connector CN29 on the control board 20AP1. The voltage should be 13 ±3 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
5.
Measure the 5V_USB voltage between pins 1 (5V_USB) and 5 (USB_rtn) of
connector CN85 on the control board 20AP1. The voltage should be 5.5 ±1.0 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
6.
Measure the 3V3_STM voltage between pins 3 (3V3_STM) and 1 (Weld_rtn) of
connector CN22 on the control board 20AP1. The voltage should be 3.3 ±0.3 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
7.
Measure the 3V3_IO_Weld voltage between pins 3 (3V3_IO_Weld) and 1 (Weld_rtn)
of connector CN43 on the control board 20AP1. The voltage should be 3.3 ±0.3 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
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8.
Measure the secondary current sensor supply voltage between pin 1 of connector
CN52 (C_SENSOR_POWER+) and pin 1 of connector CN43 (Weld_rtn). The voltage
should be 15 ±0.5 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
9.
Measure the secondary current sensor supply voltage between pin 3 of connector
CN52 (C_SENSOR_POWER-) and pin 1 of connector CN43 (Weld_rtn). The voltage
should be -14 ±0.5 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
10. Measure the secondary current sensor output signal between pin 2 of connector CN52
(CS_INPUT) and pin 1 of connector CN43 (Weld_rtn). The voltage should be
0 ±0.01 V.
If the measurement specification is not met, replace the secondary current sensor
(see section "Replacing the current sensor", page 90).
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8.3.2.4
Booster Board 27AP1 measurements
1.
Measure the +24V voltage between pins 5 and 6 of connector X05 on the booster
Board. The voltage should be 24 ±2 V.
If the measurement specification is not met, replace flat ribbon cable 7000 (between
connector CN51 on the control board and connector X05 on the booster board).
2.
Measure the +15V_DRV voltage between point X10 and pin 6 of the DC/DC converter
A01 on the booster Board. The voltage should be 15 ±1 V.
If the measurement specification is not met, replace the booster board (see section
"Replacing the booster board", page 101).
3.
If the power source display is still not lit up, despite the fact that all actions above have
been performed, check the condition of the cable to the setting panel. If needed,
replace the cable.
If the power source display is not lit up and the cable to the setting panel is OK,
replace the setting panel (see section "Replacing the setting panel", page 82).
4.
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8.3.3
Electrical test – TIG specific functions (applicable only to ET 300i and ET 300iP)
The subsections below present troubleshooting of TIG specific functions that are only
available in power sources ET 300i and ET 300iP.
8.3.3.1
Torch trigger function – Control Board 20AP1 measurements
Equipment
•
•
Multimeter
Oscilloscope
1.
Without pushing the TIG trigger on the torch and with the positive test probe on
pin 1 of connector CN21 on the control board 20AP1 and the negative test probe on
pin 2, measure the voltage. The voltage should be in the interval 10–20 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
2.
Push the TIG trigger on the torch (or short-circuit the torch connector 10XS2 on the
power source) and with the positive test probe on pin 1 of connector CN21 on the
control board 20AP1 and the negative test probe on pin 2, measure the torch trigger
voltage. The voltage should be < 1 V.
If the measurement specification is not met, replace the TIG trigger harness.
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3.
Push the TIG trigger on the torch (or short-circuit the torch connector 10XS2 on the
power source) and, using an oscilloscope with the positive test probe on pin 1 of
connector CN23 on the control board 20AP1 and the negative test probe on pin 2,
measure the TIG HF trigger voltage. The voltage should vary according to the signal
chart below. The high voltage level should be 25 ±2 V.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
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8.3.3.2
HF spark generation – TIG Board 10AP1 measurements
Equipment
•
•
Multimeter
Oscilloscope with test probes rated for high voltage
If the HF spark does not work at HF start, perform the following measurements:
1.
Measure the 24V_PE voltage between TP13 (24 V) and TP12 (0 V) on the TIG
Board 10AP1. The voltage should be 25 ±2 V.
If the measurement specification is not met, check the condition of cable 7070
between connector CN23 on the control board and connector CN01 on the TIG
board. If needed, replace the cable.
2.
Push the TIG trigger on the torch and, using an oscilloscope with the positive test
probe on TP10 on the TIG Board 10AP1 and the negative test probe on TP12,
measure the voltage. The voltage should be 660 ±30 V and vary according to the
signal chart below.
WARNING!
High voltage! Make sure the test probes used are rated for high voltage!
If the measurement specification is not met, replace the TIG board (see
"Replacing the TIG board (applicable only to ET 300i and ET 300iP)", page 108).
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8.3.3.3
Gas valve control
Equipment
•
1.
Oscilloscope
Push the TIG trigger on the torch and, using an oscilloscope with the positive test
probe on pin 1 of connector CN25 on the control board 20AP1 and the negative
test probe on pin 3, measure the gas valve voltage. The voltage should vary
according to the signal chart below.
If the measurement specification is not met, replace the control board (see section
"Replacing the control board", page 94).
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8.4
Status indications on circuit boards
On some circuit boards in the power source there are LEDs (light-emitting diodes) used to
indicate the status of each board. The meanings of the different indications are explained in
the sub-sections below.
8.4.1
Setting panel board 1AP1 – Indication of operational status
LED D54 on the setting panel board is used to indicate the operational status of the board
according to the table below.
LED D54 Operational status
Off
The setting panel board is disconnected or the power supply is turned off.
Green
The setting panel works as expected and has an established communication
path with the power source control board.
Red (fixed) The software has found that an error has occurred. This error may be either
local to the setting panel or a system-wide error.
Note! These type of error does not include the communication interface since
that is separately indicated.
Red
(1 Hz flash) No communication path has been established or some other error has occurred
in the communication system.
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8.4.2
Control board 20AP1 – Indication of software run level
The LED pairs D229/D230 and D231/D232 on the control board are are used to indicate the
current software run level of the board. The meanings of the different indications are
explained in the table below.
The LEDs not described below are not in use.
D229/D230 D231/D232 Software run level
Off
Off
There is no supply voltage to the control board.
Off
Green
Application start up
Green
(fixed)
Green
(fixed)
Application running ok, Idle run state
Green
Green
(1 Hz flash) (1 Hz flash) Application running ok, Interactive run state, i.e. the user may
interact with the equipment
Green
Green
(3 Hz flash) (3 Hz flash)
Green
Application running ok, Processing run state
Red
Application error (recoverable)
Red
Red
Application error (non-recoverable). Power off or reset is required.
Off
Red
Application in test or debug mode
Red
Green
Application shut down
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9 DISASSEMBLY AND REASSEMBLY
9
1.
DISASSEMBLY AND REASSEMBLY
Disconnect the power source from the mains supply.
WARNING!
Wait at least 30 seconds for the DC bus capacitor to discharge, before
starting the disassembly.
2.
Remove the screws holding the power source side panels (four screws in the left side
panel and four screws in the right side panel). Remove the side panels.
3.
To make sure the DC bus capacitor is discharged, measure the voltage between the
"+" and "-" screws of the capacitor, using a multimeter. The "+" and "-" screws are
accessible from the left side of the power source once the left side panel has been
removed. The voltage should be < 20 V when the capacitor is discharged.
WARNING!
Always wait until the voltage is below 20 V between the "+" and "-" screws
of the capacitor, before continuing the disassembly.
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4.
Remove the four screws holding the top panel. Use a thin screwdriver or similar to
loosen the snap fittings and remove the top panel.
5.
Remove the two screws located at the bottom of the rear panel. Use a thin screwdriver
or similar to loosen the snap fittings and detach the rear panel.
NOTE!
You only need to detach the rear panel if you are going to change the
mains switch, the output inductor or the transformer module.
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6.
After having finished the required service work inside the power source, reattach the
power source panels in the reverse order.
NOTE!
To be able to reattach the rear panel, you have to loosen the strain relief
screw for the mains cable.
When tightening the strain relief screw again, make sure approximately
1 cm of the cable isolation is inside the strain relief block. If the cable is
inserted too far, risk of blocking the fan exists. If the cable is not inserted far
enough, the strain relief block might not fix the cable isolation thoroughly.
NOTE!
When reattaching the top panel, the "F" marking underneath the top panel
should point towards the front of the power source.
NOTE!
When reattaching the right side panel, make sure the IP shield on the
inside of the panel is in the correct position. The IP shield should be angled
approximately 90° into the power source, so that it is positioned between
the welding outlet connector and the transformer outlets.
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7.
Tighten the screws using the correct tightening torque according to the illustration
below.
NOTE!
Do not forget to reattach and tighten the screws holding the rear panel
(2 screws) and top panel (4 screws).
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10 CALIBRATION OF VOLTAGE AND CURRENT
10
CALIBRATION OF VOLTAGE AND CURRENT
Calibration of voltage and current is done after replacing the current sensor, the control board
or the booster board.
The calibration of the power source is a four step process. It consists of:
1.
2.
3.
4.
extracting present calibration parameter from the power source
performing measurements of the power source under load
calculating new calibration parameters
loading the new parameters to the power source
NOTE!
Power source with ordering number 0445 100 881 or 0445 100 882 is not
equipped with a display showing welding voltage. In this case the
calibration parameters for voltage is loaded back ( "Downloading new
calibration parameters to power source", page 80, step 1).
10.1
General USB procedure
The following procedure is used several times during calibration:
1.
Insert the USB flash drive into the power source USB connector.
To confirm that the power source has read the USB flash drive, the text "USB"
flashes in the display for a moment, after which the text "USB" is shown steadily lit.
Remove the USB flash drive from the USB connector.
2.
10.2
•
•
•
•
•
•
•
•
Tooling needed
A resistive load bank capable of dissipating the load of 300 A at 32 V adjustable to a
load of 5 A at 10 V. One alternative is Checkmaster 9000 from ESAB (ordering number
0740 505 880).
A computer with USB connector, text editor (Notepad++, WordPad or similar) and Excel
spreadsheet software.
An empty USB memory stick.
A precision current measurement instrument, DC average (or use instrumentation on
Checkmaster 9000).
A precision voltage measurement instrument, DC average (or use Checkmaster 9000)
The file: Manual calibration.xlsx
The file: manual_calibration_readback.script.txt
All system software files and script files are accessible to download through a link on
each country/regions local partner login site.
10.3
1.
2.
3.
4.
5.
6.
Extracting present calibration parameters from power source
Turn the power source on.
Copy the file manual_calibration_readback.script.txt to the empty USB
memory stick.
Rename the file on the USB memory stick to sparc.script.
Insert the USB memory stick in the power source after it has completed the startup
sequence.
"USB" will start flashing in the power source panel.
When "USB" is steadily lit in the panel, remove the USB memory stick from the power
source.
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10.4
1.
2.
3.
4.
5.
6.
7.
8.
9.
Performing measurements
Select the MMA weld process on the power source. Set the arc force or soft/crisp
value to 0. Set the hot start value to 0. Make sure the cellulosic mode is NOT
activated.
Change the set current to a low current value: 5 A.
Connect a load to get a low voltage, approximately 5 V.
Note the reference values measured with the external instruments: current Ilow2 and
voltage Ulow2.
Note the at equipment displayed values: current Ilow1 and voltage Ulow1.
Change the set current to a high current value close to 300 A and load to
approximately 32 V.
Note the reference values measured with the external instruments: current Ihigh2 and
voltage Uhigh2.
Note the at equipment displayed values: current Ihigh1 and voltage Uhigh1.
Turn the current down, and disconnect the load.
10.5
Calculate new calibration parameters
1.
Insert the USB memory stick in the computer and open the file sparc_out.txt. The
file content should look similar to:
2.
3.
Open the file Manual calibration.xlsx.
Update the fields “Previous calibration data” with the values from the file
sparc_out.txt.
4.
Enter the displayed values from the power source and the corresponding reference
values from the external instrument for current and voltage. Enter the values for both
the low and high load measurement point.
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5.
New calibration parameters are generated in cell A24. Select the cell and copy the
information.
10.6
1.
Downloading new calibration parameters to power source
For power source with ordering number 0445 100 881 or 0445 100 882: Create a
new text document and paste the values generated in cell A24 into it. Replace the
values for voltage with the extracted values from sparc_out.txt (see "Calculate
new calibration parameters", page 79, step 1).
For power source with ordering number 0445 100 880, 0445 100 883,
0445 100 900, 0445 100 901, 0445 100 902, 0445 100 903, 0445 100 904,
0445 100 920, 0445 100 921, 0445 100 922 or 0445 100 923: Create a new text
document and paste the new parameters generated in cell A24 into it.
2.
Remove the first and last line containing only a “.
Make sure there is an empty line at the end of the file.
3.
4.
5.
6.
Save the file with the name sparc.script to an empty USB memory stick.
Insert the USB memory in the power source.
"USB" will start flashing in the power source panel.
When "USB" is steadily lit in the panel, remove the USB memory stick from the power
source.
Restart the power source to make the new calibration parameters apply.
7.
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11 REPLACEMENT INSTRUCTIONS
11
REPLACEMENT INSTRUCTIONS
WARNING!
Before performing any of the service work described in this chapter, make sure
the power source is disconnected from the mains supply and that the DC bus
capacitor is discharged (for details see chapter "DISASSEMBLY AND
REASSEMBLY", page 74).
NOTE!
When reassembling the power source after any service work described in this
chapter, make sure all IP shields, EMC shield plates, insulation sheets, foams
and hoses and other IP protection devices are accurately restored according to
the instructions! These parts are important for personal safety and for the welding
power source to operate accurately and not getting overheated during various
conditions.
11.1
1.
2.
3.
Replacing the setting knob
Remove the setting knob cap.
Remove the nut and washer on the setting knob and remove the knob.
Attach the new knob and fasten in the reverse order.
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11 REPLACEMENT INSTRUCTIONS
11.2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Replacing the setting panel
Remove the power source side panels and top panel, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Detach the setting panel by bending using a thin screwdriver by the two tabs at top
of the panel.
Disconnect the setting panel cable and remove the panel.
Clean the surface of the front panel where the setting panel adhesive foam should
be attached.
Connect the setting panel cable, including the earth connection cable, to the new
setting panel.
Remove the protective film from the adhesive foam on the new setting panel.
Put the top of the new setting panel in the correct position and carefully attach the
panel bending it downwards.
The illustration above shows an example of setting panel. However this instruction
applies to all panel variants.
If needed, configure the power source. When ordering a new setting panel or a
panel board kit as a spare part, the default configuration is as follows:
○ Panel type: Full functionality panel (default configuration in product variants
with ordering numbers 0445 100 880 and 0445 100 883)
If another configuration than the default configuration is needed, configure the
power source according to section "Software configuration", page 42.
Reattach the side panels and the top panel, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11.3
1.
2.
3.
4.
5.
6.
Replacing the encoder and the setting knob
Remove the setting panel according section "Replacing the setting panel", page
82.
Remove the setting knob according to section "Replacing the setting knob", page
81.
Remove the nut and washer holding the encoder.
Disconnect the encoder cable from the setting panel board. Remove the encoder.
Attach the new encoder to the setting panel, using the nut and washer, and
connect the encoder cable.
Remove the old adhesive foam from the setting panel. Clean the surface of the
setting panel and the front panel thoroughly. Attach the new adhesive foam to the
setting panel.
NOTE!
To enable any condensation water to drain out of the setting panel, the
slit in the adhesive foam must be positioned downwards.
7.
8.
9.
Put the top of the setting panel in the correct position and carefully attach the panel
bending it downwards (for details, see "Replacing the setting panel", page 82).
Attach the new setting knob (see "Replacing the setting knob", page 81).
Reattach the side panels and the top panel, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11.4
1.
2.
3.
4.
5.
Replacing the mains cable
Remove the right side panel according to chapter "DISASSEMBLY AND
REASSEMBLY", page 74.
Loosen the strain relief screw (A) for the mains cable.
Disconnect the old mains cable wires from the connection block (B) and the earth
connection point (C). Cut the cable ties (D) and remove the cable.
To simplify the installation, remove the fan including the surrounding foam.
Strip the new mains cable according to the specification in the graphic (E).
NOTE!
Make sure the mains cable complies with applicable regulations! For
information of minimum mains cable area, see the instruction manual.
6.
Insert the cable with about 1 cm (0.4 in.) of isolation inside the strain relief block.
Tighten the strain relief screw (A) to a torque of 1.5 - 2 Nm (13.3 - 17.7 in. lb).
NOTE!
If the cable is inserted too far, risk of blocking the fan exists. If the cable is
not inserted far enough, the strain relief block might not fix the cable
isolation thoroughly.
7.
Reinsert the fan including the surrounding foam.
NOTE!
Make sure the fan is inserted in the correct direction. The arrow
symbols (G) on the side of the fan show the air flow and the rotation
directions.
8.
9.
Fasten the wires, using two cable ties (D).
Applicable only to products with ordering numbers 0445 100 880, 0445 100 883,
0445 100 900, 0445 100 903, 0445 100 920 and 0445 100 923: Install the two ferrite
cores (F). The earth connection wire should pass through the ferrite cores two times.
10. Connect the earth connection wire (C). A toothed washer should be located closest to
the heat sink. Tighten the screw to a torque of 6 ±0.6 Nm (53.1 ±5.3 in. lb).
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11. Connect all phases to the connection block (B) and tighten the screws to a torque of
1 ±0.2 Nm (8.85 ±1.8 in. lb). When using the power source in a single-phase electric
power system, connection block position L3 is not used.
NOTE!
Different variants of the power source are certified for different mains
voltages! Always refer to the rating plate for specification of the specific
power source in use!
WARNING!
In 1-phase operation, the L3 terminal is powered, even though not
connected. Make sure the L3 terminal is disconnected!
12. Reattach the right side panel to the power source, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11 REPLACEMENT INSTRUCTIONS
11.5
1.
2.
3.
4.
5.
6.
7.
8.
Replacing the mains switch
Remove the power source side and top panels and also detach the rear panel,
according to instructions in chapter "DISASSEMBLY AND REASSEMBLY", page
74.
Remove the fan including the surrounding foam (for details see section "Replacing
the fan", page 87).
Remove the screw for the mains switch knob and remove the knob, including the
expandable mounting socket.
Remove the two screws for the mains switch and remove the switch.
Disconnect the incoming wires (211, 212 and 213) and the outgoing wires (221,
222 and 223) from the mains switch.
Connect and attach the new mains switch in the reverse order, using the correct
tightening torques according to the illustration.
Reinsert the fan according to instructions in section "Replacing the fan", page
87.
Reattach the power source panels according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11 REPLACEMENT INSTRUCTIONS
11.6
1.
2.
3.
4.
5.
Replacing the fan
Remove the right side panel from the power source, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Disconnect the mains cable wires from the connection block and the earth
connection point.
Disconnect the fan cables.
Remove the fan including the surrounding foam.
Insert the new fan and connect the cables.
NOTE!
Make sure the fan is inserted in the correct direction. The arrow symbols
on the side of the fan show the air flow and the rotation directions.
Make sure the fan cables are twisted. The cables should be twisted at
least five turns.
6.
7.
Reconnect the mains cable wires according to instructions in section "Replacing
the mains cable", page 84.
Reattach the right side panel to the power source, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
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11.7
1.
2.
3.
4.
5.
6.
Replacing the welding output terminals (ES 300i)
Remove the power source side panels, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
Remove the screws connecting the copper bars to the welding outlets.
Remove the nuts and washers and remove the welding output terminals.
Attach the new welding terminals and fasten the nuts and washers, using the
correct tightening torque according to the illustration.
Reattach the copper bars to the welding outlets using the screws. Fasten the
screws to the correct tightening torque according to the illustration.
Reattach the power source side panels, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11.8
1.
2.
3.
4.
5.
Replacing the welding output terminals (ET 300i and ET 300iP)
Remove the power source side panels, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
Remove the screw connecting the copper bar to the right welding outlet and the
screw connecting the HF coil cable to the left welding outlet.
Remove the nuts and washers and remove the welding output terminals.
Attach the new welding terminals and fasten the nuts and washers, using the
correct tightening torque according to the illustration.
Reconnect the copper bar to the right welding outlet and the HF coil cable to the
left welding outlet. Tighten the screws using the correct tightening torque according
to the illustration.
NOTE!
To prevent stray current, make sure the insulating sleeve is located
correctly! The insulating sleeve should be threaded onto the plastic
surrounding the welding terminal and secured using a cable tie. At the
other end of the insulating sleeve, at least 10 mm of the cable isolation
should be inside the insulating sleeve.
6.
Reattach the power source side panels, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11.9
1.
2.
3.
4.
5.
6.
Replacing the current sensor
Remove the power source side panels and top panel, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Remove the screws connecting the copper bars to the welding outlets and detach
the front panel (for details see section "Replacing the front panel (ES 300i)", page
91).
Disconnect cables 1531, 1532 and 1533 from the current sensor.
Remove the two screws at the bottom of the current sensor.
Remove the screw and nut connecting cable 2701 and the copper bar to the
inductor. (The copper bar only exists in the ES 300i power source, not in the other
product variants.)
Remove the current sensor.
7.
Attach the new current sensor and reinstall in the reverse order. Tighten all screw
joints, using the correct tightening torques according to the illustration.
8. Reattach the front panel and reconnect the copper bars to the welding outlets
according to instructions in section "Replacing the front panel (ES 300i)", page
91.
9. Calibrate the power source according to chapter "CALIBRATION OF VOLTAGE
AND CURRENT", page 78.
10. Reattach the side panels and the top panel, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11.10
1.
2.
3.
4.
5.
Replacing the front panel (ES 300i)
Remove the power source side panels and top panel, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Remove the screws connecting the copper bars to the welding outlets.
Detach the setting panel from the front panel and disconnect the setting panel
cable (for details, see "Replacing the setting panel", page 82).
Remove the two screws located at the bottom of the front panel. Use a thin
screwdriver or similar to loosen the snap fittings and remove the front panel.
Connect the setting panel again and attach it to the new front panel, carefully
following the instructions in section "Replacing the setting panel", page 82.
NOTE!
The new adhesive foam included in the spare part delivery, should be
used when attaching the setting panel to the new front panel.
6.
7.
8.
Attach the front panel to the power source and tighten the two screws at the bottom
of the panel to a torque of 3 Nm (26.6 in. lb).
Reconnect the copper bars to the welding outlets. Tighten the screws to a torque of
6 Nm (53.1 in. lb).
Reattach the side panels and the top panel, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11.11
1.
2.
3.
4.
5.
6.
7.
Replacing the front panel (ET 300i and ET 300iP)
Remove the power source side panels and top panel, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Remove the screw connecting the copper bar to the right welding outlet and the
screw connecting the HF coil cable to the left welding outlet.
Detach the setting panel from the front panel and disconnect the setting panel
cable (for details, see "Replacing the setting panel", page 82).
Loosen the hose clip and the gas hose from the gas output connector on the front
panel. Loosen the nut and remove the gas output connector.
Loosen the four screws holding the TIG torch trigger connector.
Remove the two screws located at the bottom of the front panel. Use a thin
screwdriver or similar to loosen the snap fittings and remove the front panel.
Connect the setting panel again and attach it to the new front panel, carefully
following the instructions in section "Replacing the setting panel", page 82.
NOTE!
The new adhesive foam included in the spare part delivery, should be
used when attaching the setting panel to the new front panel.
8.
9.
Attach the front panel to the power source and tighten the two screws at the bottom
of the panel, using the correct tightening torque according to the illustration.
Reconnect the copper bar to the right welding outlet and the HF coil cable to the
left welding outlet. Tighten the screws using the correct tightening torque.
NOTE!
To prevent stray current, make sure the insulating sleeve is located
correctly! The insulating sleeve should be threaded onto the plastic
surrounding the welding terminal and secured using a cable tie. At the
other end of the insulating sleeve, at least 10 mm of the cable isolation
should be inside the insulating sleeve.
10. Reattach the side panels and the top panel, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11.12
1.
2.
Replacing the EMC filter board
Remove the power source side panels and top panel, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Disconnect cables 7021, 7022 and 7023 from connector CN21, located on the
power board 15AP1.
NOTE!
In power sources ET 300i and ET 300iP, an insulating sleeve is threaded
onto cables 7021, 7022 and 7023.
3.
4.
5.
6.
Disconnect cables 221, 222 and 223 from the connector on the EMC filter board.
Disconnect the earth connection cable 7060 from flat pin X2 and the shield cable
7063 from flat pin X8.
Remove the three screws holding the filter board and remove the board.
Locate the insulation sheet on the back of the new EMC filter board, reconnect all
cables and fasten the new board, using the correct tightening torques for all screw
joints according to the illustration.
WARNING!
Make sure the insulation sheet is located underneath the new EMC filter
board when fastened. If no insulation sheet is located underneath the
filter board, risk of short-circuit and electric shock exist!
NOTE!
The tightening torque for the three screws holding the filter board is only
0.6 Nm (5.3 in. lb).
7.
Reattach the side panels and the top panel to the power source, according to
instructions in chapter "DISASSEMBLY AND REASSEMBLY", page 74.
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11.13
1.
2.
3.
4.
5.
Replacing the control board
Remove the left side panel from the power source, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
Disconnect the cables from the following connectors on the control board (clockwise
from the left): CN85, CN84, CN52, CN51, CN83, CN82, CN26, CN29 and CN28.
In power sources ET 300i and ET 300iP, also disconnect the cables from these
connectors: CN23, CN25, CN21 and CN27.
Disconnect the shield wire for the panel connection cable.
Detach the control board from the snap fittings, using a pair of flat pliers, and remove
the board.
There are minor differences between the control board in power sources ES 300i and
ET 300i/ET 300iP. However this instruction applies to all power source variants.
Locate the insulation sheet on the back of the new control board, attach the new
board to the snap fittings and reconnect all cables to the afforementioned connectors.
Reconnect the panel cable shield wire and tighten the screw to a torque of 3 ±0.5 Nm
(26.6 3 ±4.4 in. lb).
NOTE!
To avoid interference, make sure the cables for the gate drive circuits
(cables 1521, 1522, 1523 and 1524) are placed perpendicular to the cables
for the PFC inductor.
6.
If needed, configure the power source. When ordering a new control board as a spare
part, the default configuration is as follows:
○ VRD: Off
○ Cellulosic welding process regulator: KCO
○ Panel type: Full functionality panel (default configuration in product variants with
ordering numbers 0445 100 880 and 0445 100 883)
If another configuration than the default configuration is needed, configure the power
source according to section "Software configuration", page 42.
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7.
Calibrate the power source according to chapter "CALIBRATION OF VOLTAGE AND
CURRENT", page 78.
NOTE!
Since the calibration data are stored in a memory on the control board, the
arc voltage must be recalibrated after having replaced the control board.
8.
Reattach the left side panel to the power source, according to instructions in chapter
"DISASSEMBLY AND REASSEMBLY", page 74.
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11.14
1.
2.
3.
4.
5.
6.
Replacing the PFC inductor
Remove the control board according to section "Replacing the control board",
page 94.
Remove the EMC filter board and the underlying insulation sheet, according to
section "Replacing the EMC filter board", page 93.
Remove the EMC shield plate beneath the filter board.
Disconnect the PFC inductor cables (cables 1541, 1542, 1543 and 1544) from
connection points CN13, CN14, CN15 and CN16 on the power board.
Remove the four screws holding the PFC inductor board assembly and remove the
assembly.
Insert the new PFC inductor board assembly into the cavity of the power source
chassis and tighten the four screws to a tightening torque of 0.6 Nm (5.3 in. lb).
NOTE!
The tightening torque for the screws holding the PFC inductor board
assembly is only 0.6 Nm (5.3 in. lb).
7.
8.
Route the PFC inductor cables from the PFC inductor at the top of the power
source down and around the capacitors on the power board.
Connect the PFC inductor cables to the connection points on the power board and
tighten the screws to a tightening torque of 2 Nm (17.7 in. lb).
NOTE!
Notice the correct positions of cables 1541, 1542, 1543 and 1544
(according to the illustration) when reconnecting them to connection
points CN13, CN14, CN15 and CN16!
9. Put back the EMC shield plate on top of the new PFC inductor board assembly.
10. Reattach the EMC filter board, including the underlying insulation sheet, according
to section "Replacing the EMC filter board", page 93.
11. Reattach the control board according to section "Replacing the control board",
page 94.
12. Reattach the power source top panel and side panels, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
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11.15
1.
2.
3.
4.
5.
6.
Replacing the power board
Remove the power source side panels and top panel, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Remove the control board according to section "Replacing the control board", page
94.
Disconnect cables 7021, 7022 and 7023 from connector CN21 on the power board.
Disconnect the cables for the gate drive circuits (cables 1521, 1522, 1523 and 1524)
from connector CN84 on the power board.
Remove the two screws holding the DC bus capacitor.
Disconnect the cables to the primary side of the transformer, 1611D and 1612U, from
connection points CN17 and CN18 on the power board.
NOTE!
Be careful so that the spacer between the cable 1611D cable eye and
connection point CN17 is not lost!
7.
Disconnect the PFC inductor cables from connection points CN13, CN14, CN15 and
CN16 on the power board.
8. Remove the insulation hose for the shield connection spacing screw and remove the
two jointed spacing screws.
9. Remove the four screws connecting the power module to the primary heat sink.
10. Remove the surge protection board by disconnecting the cable lugs from connectors
CN11 and CN12 on the power board. (In power sources with serial no. up to and
including 725-xxx-xxxx, remove the varistor harness by disconnecting the cable lugs
from the aforementioned connectors.)
11. Remove the four screws in the outer corners of the power board and the two screws
holding the current transformer TR41.
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12. Remove the power board.
13. Clean the primary heat sink thoroughly.
NOTE!
When the power board is removed, it is recommended to test the
electrolytic DC bus capacitor 15C1, according to section "Testing the
electrolytic DC bus capacitor 15C1", page 58.
14. Apply thermal paste on the back of the new power module.
Start by cleaning the power module, and then apply a thin and even layer of thermal
paste, 0.15 ±0.5 mm thick, to the contact surfaces of the components. The purpose of
the paste is to fill out any hollows in the surfaces of the components. Those parts of
the component and the heat sink that are in true metallic contact may have such
contact.
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15.
NOTE!
Before attaching the new power board, make sure the positive pole (+) of
the DC bus capacitor is orientated upwards! Also make sure the capacitor
foam is located between the capacitor and the power board.
Locate the insulation sheet on the back of the new power board and attach the board.
Fasten all screws and connect all cables in the reverse order. Make sure the correct
tightening torques, according to the illustration, are used for all screw joints.
NOTE!
The four screws connecting the power module to the primary heat sink,
should be tightened crosswise in two steps, first to a tightening torque of
0.5 Nm (4.4 in. lb) and then to a final torque of 4.5 Nm (39.8 in. lb).
The tightening torque for the four screws in the outer corners of the power
board and the two screws holding the current transformer TR41 (in total 6
screws) is only 0.6 Nm (5.3 in. lb).
Do not forget to put back the insulation hose for the shield connection
spacing screw!
When the PFC inductor cables are reconnected, make sure they are routed
and connected according to the instructions in section "Replacing the PFC
inductor", page 96!
Make sure the cables to the primary side of the transformer are not mixed
up! The cables are marked 1611D and 1612U, where D denotes "Down",
i.e. connection point CN17, and U denotes "Up", i.e. connection point
CN18. Also do not forget to put back the spacer between the cable 1611D
cable eye and connection point CN17!
Also make sure the surge protection board (or the varistor harness in
power sources with serial no. up to and including 725-xxx-xxxx) is properly
reconnected to connectors CN11 and CN12.
16. Reattach the control board according to section "Replacing the control board", page
94.
17. Reattach the power source side panels and top panel, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
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11.16
1.
2.
3.
Replacing the DC bus capacitor
Remove the power board according to section "Replacing the power board", page
97.
Remove the DC bus capacitor.
Insert the new DC bus capacitor and, if needed, rotate the capacitor so that the
positive pole (+) is orientated upwards!
NOTE!
The white stripe marking on the capacitor differs for different
manufacturers of capacitors! On the capacitors from some
manufacturers, the white stripe denotes the positive pole (+). On
capacitors from other manufacturers, the white stripe denotes the
negative pole (-). The positive pole (+) should always be orientated
upwards!
4.
Locate the capacitor foam against the capacitor.
5.
Reattach the power board according to section "Replacing the power board",
page 97.
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11 REPLACEMENT INSTRUCTIONS
11.17
1.
2.
3.
Replacing the booster board
Remove the right side panel from the power source, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Disconnect cables 2701, 1631, 2702 and 1642 from connection points X01 - X04 on
the booster board (bottom side of circuit board).
Remove the screws from points V01, V02 and X10 on the booster board (bottom side
of circuit board).
NOTE!
Then carefully detach the booster board, ensuring that the two spacers,
located in points V01 and V02, between the circuit board and the copper
bars, are not lost!
4.
5.
6.
Disconnect the earth connection cables 7065 and 7068 from the connection point on
the primary heat sink.
Disconnect the 16 pin flat ribbon cable from connector X05 on the booster board
(component side of circuit board).
Disconnect cables 2711, 2712, 1651 and 1652 from connectors X06 and X07 on the
booster board (component side of circuit board) and then remove the board.
7.
8.
Clean the secondary heat sink thoroughly.
Apply electrically conductive thermal paste on the heat sink bar of the new booster
board.
Start by cleaning the heat sink, and then apply a thin and even layer of electrically
conductive thermal paste, 0.15 ±0.5 mm thick, to the contact surfaces of the
components. The purpose of the electrically conductive paste is to fill out any hollows
in the surfaces of the components and the heat sink, improving thermal and electrical
conductivity. Those parts of the component and the heat sink that are in true metallic
contact may have such contact.
9. Connect cables 2711, 2712, 1651 and 1652 to connectors X06 and X07 on the new
booster board (component side of circuit board).
10. Connect the 16 pin flat ribbon cable to connector X05 on the new booster board
(component side of circuit board).
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11. Apply some electrically conductive thermal paste onto one of the ends of the two
spacers.
Start by cleaning, and then apply a thin and even layer of electrically conductive
thermal paste, 0.15 ±0.5 mm thick, to the contact surfaces of the components. The
purpose of the electrically conductive paste is to fill out any hollows in the surfaces of
the components and the heat sink, improving thermal and electrical conductivity.
Those parts of the component and the heat sink that are in true metallic contact may
have such contact.
Then place the spacers in the correct positions on the copper bars, using the electrical
conductive thermal paste to fix the spacers in the correct positions while fastening the
new booster board. Carefully put the booster board in position, making sure the two
spacers remain in the correct positions and fasten the two screws in points V01 and
V02. Also fasten the screw in point X10.
NOTE!
Always make sure the two spacers are in the correct positions when
attaching the booster board!
12. Connect the earth connection cables 7065 and 7068 from the new booster board to
the connection point on the primary heat sink.
NOTE!
In power sources with ordering numbers 0445 100 880, 0445 100 883,
0445 100 900, 0445 100 903, 0445 100 920 and 0445 100 923: Install the
ferrite ring core 70L1 onto the earth connection cables 7065 and 7068
before connecting the cables to the earth connection point!
NOTE!
When reconnecting the earth connection cables, do not connect anymore
cable to the same screw as the incoming earth connection cable.
Also, all earth connection wire joints should contain a toothed washer,
located closest to the heat sink.
13. Reconnect cables 2701, 1631, 2702 and 1642 to connection points X01 - X04 on the
new booster board.
14. Tighten all screw joints using the correct tightening torques according to the
illustration.
15. Calibrate the power source according to chapter "CALIBRATION OF VOLTAGE AND
CURRENT", page 78.
16. Reattach the right side panel, according to instructions in chapter "DISASSEMBLY
AND REASSEMBLY", page 74.
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11.18
1.
2.
3.
4.
5.
6.
7.
Replacing the thermal switch on the secondary heat sink
Remove the booster board according to section "Replacing the booster board",
page 101.
Remove the screw holding the thermal switch to the secondary heat sink and
remove the thermal switch.
Clean the secondary heat sink thoroughly.
Apply electrically conductive thermal paste on the new thermal switch.
Start by cleaning, and then apply a thin and even layer of electrical conductive
thermal paste, 0.15 ±0.5 mm thick, to the contact surfaces of the components. The
purpose of the electrical conductive paste is to fill out any hollows in the surfaces of
the components and the heat sink, improving thermal and electrical conductivity.
Those parts of the component and the heat sink that are in true metallic contact
may have such contact.
Attach the new thermal switch to the secondary heat sink and fasten the screw to a
tightening torque of 1.4 Nm (12.4 in. lb).
Reattach the booster board according to section "Replacing the booster board",
page 101.
Reattach the right side panel, according to instructions in chapter "DISASSEMBLY
AND REASSEMBLY", page 74.
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11 REPLACEMENT INSTRUCTIONS
11.19
Replacing the secondary rectifier diode modules
NOTE!
Always replace all rectifier diode modules at the same time!
1.
2.
3.
4.
5.
6.
7.
Remove the booster board according to section "Replacing the booster board",
page 101.
Remove the screws connecting transformer cables 1632L and 1641R to the copper
bars.
Remove the ten screws connecting the copper bars to the diode modules.
Remove the six screws connecting the diode modules to the secondary heat sink
and remove the diode modules.
Clean the heat sink and the copper bars thoroughly.
Apply electrically conductive thermal paste on the new diode modules.
Start by cleaning, and then apply a thin and even layer of electrically conductive
thermal paste, 0.15 ±0.5 mm thick, to the contact surfaces of the components. The
purpose of the electrically conductive paste is to fill out any hollows in the surfaces
of the components and the heat sink, improving thermal and electrical conductivity.
Those parts of the component and the heat sink that are in true metallic contact
may have such contact.
Attach the new diode modules and reattach all parts in the reverse order, using the
correct tightening torques according to the illustration.
NOTE!
When reconnecting the transformer cables, make sure the cable marked
1632L is connected to the Left connection point and that the cable
marked 1641R is connected to the Right connection point.
8.
9.
Reattach the booster board according to section "Replacing the booster board",
page 101.
Reattach the right side panel, according to instructions in chapter "DISASSEMBLY
AND REASSEMBLY", page 74.
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11 REPLACEMENT INSTRUCTIONS
11.20
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Replacing the output inductor module and/or the transformer
module
Remove the power board (see section "Replacing the power board", page 97) and
also the DC bus capacitor (see section "Replacing the DC bus capacitor", page
100).
Remove the EMC filter board (see section "Replacing the EMC filter board", page
93).
Remove the front panel (see section "Replacing the front panel (ES 300i)", page
91).
Detach the rear panel (see instructions in chapter "DISASSEMBLY AND
REASSEMBLY", page 74). Loosen the strain relief screw for the mains cable (see
section "Replacing the mains cable", page 84) and pull out the rear panel
approximately 5 cm.
Disconnect the primary heat sink from the intermediate wall by removing the four
screws (MRT M5×8).
Disconnect the secondary heat sink and the inductor from the intermediate wall by
removing the five plastic screws (Nylon M6S M6×10).
Push the two primary transformer cables 1611D and 1612U and their grommets
through the intermediate wall.
Disconnect the 16 pin flat ribbon control cable from connector X05 on the booster
board (for information see section "Replacing the booster board", page 101).
Disconnect the fan cable (for information see section "Replacing the fan", page 87)
and cut the cable tie holding the cable connectors 20XS3 and 20XP1.
Disconnect the cable to the current sensor (cable numbers 1531, 1532 and 1533, for
information see section "Replacing the current sensor", page 90).
Detach the intermediate wall from the bottom panel by removing the two plastic
screws (Remform 5×16).
Remove the intermediate wall.
Remove the current sensor (see section "Replacing the current sensor", page 90).
Remove the inductor clamp by removing the four plastic screws (Remform 5×16).
Disconnect the output inductor by removing the two screws (MRT Combi M5×12)
connecting cables 2701 and 2702 to the inductor.
Remove the output inductor by lifting it straight up.
If you are only going to replace the output inductor module, attach the new output
inductor, reconnect all cables and reattach all parts in the reverse order. Make sure
the correct tightening torques, according to the illustration, are used for all screw
joints.
If you are going to replace the transformer module, proceed as follows below.
Remove the two screws (MRT M5×12) holding the inductor bracket.
Remove the transformer IP protection.
Remove the screw (MRT Combi M5×12) connecting the cable marked BAR L to the
left copper bar.
Remove the screw (MRT Combi M5×12) connecting the cable marked BAR R to the
right copper bar.
Disconnect cables 1631 and 1642 from the booster board (for information see section
"Replacing the booster board", page 101).
Remove the two plastic screws (Remform 5×16) holding the transformer (one of them
also connecting the protective earth connection cable).
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11 REPLACEMENT INSTRUCTIONS
24. Remove the old transformer module and position the new transformer module in the
same place.
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11 REPLACEMENT INSTRUCTIONS
25. Reattach all parts and reconnect all connectors in the reverse order. Make sure the
correct tightening torques, according to the graphic, are used for all screw joints.
NOTE!
When fastening the transformer module (23 in the graphic), do not forget to
include the earth connection cable when tightening the screw closest to the
power source front.
When reassembling the intermediate wall, make sure the insulation sheet
beneath the PFC inductor board assembly is in the correct position.
When reconnecting the fan cable, fasten the connectors 20XS3 and 20XP1
using a cable tie.
When connecting the secondary heat sink and the inductor to the
intermediate wall, the new plastic screws (Nylon M6S M6×10) included in
the spare part delivery should be used (6 in the graphic). Never replace
plastic screws with steel screws or screws with electrical conductive
material!
When reconnecting the primary heat sink to the intermediate wall, make
sure the module foam is reattached.
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11 REPLACEMENT INSTRUCTIONS
11.21
1.
2.
3.
4.
5.
Replacing the TIG board (applicable only to ET 300i and ET 300iP)
Remove the power source side panels and top panel, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Disconnect the cable to the control board (cable 7070) from connector CN01 on the
TIG board.
Disconnect the HF coil cables from connectors CN03 and CN04 on the TIG board.
Remove the four screws holding the TIG board and remove the board.
Fasten the new TIG board, using the correct tightening torque according to the
illustration.
NOTE!
The tightening torque for the four screws holding the TIG board is only
0.6 Nm (5.3 in. lb).
6.
Reconnect the cables to the afforementioned connectors.
NOTE!
The HF coil cable with the colour marking should be connected to
connector CN04!
7.
Reattach the side panels and the top panel to the power source, according to
instructions in chapter "DISASSEMBLY AND REASSEMBLY", page 74.
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11 REPLACEMENT INSTRUCTIONS
11.22
1.
2.
3.
4.
5.
6.
Replacing the analogue remote A/D board
Remove the left side panel from the power source, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
Disconnect the remote cable harness (cable 2030) from connectors CN2 and CN7
on the analogue remote A/D board (20AP2).
Disconnect the cable harness from the control board (cable 2040) from connector
CN1 on the analogue remote A/D board.
Disconnect the analogue remote A/D board from connector CN11 on the control
board and remove the analogue remote board.
Locate the insulation sheet on the back of the new analogue remote A/D board and
connect the board to connector CN11 on the control board. Reconnect the cables
to the afforementioned connectors.
Reattach the left side panel to the power source, according to instructions in
chapter "DISASSEMBLY AND REASSEMBLY", page 74.
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12 IN-SERVICE INSPECTION AND TESTING
12
IN-SERVICE INSPECTION AND TESTING
In-service inspection and testing in accordance with IEC 60974-4
12.1
General requirements
Qualification of test personnel
Tests of welding power sources can be hazardous and shall be carried out by an expert in
the field of electrical repair, preferably also familiar with welding, cutting and allied
processes.
Test conditions
Tests shall be carried out at an ambient air temperature between 10 °C and 40 °C (50 °F
and 104 °F) on a dry and cleaned welding power source.
Measuring instruments
The accuracy of measuring instruments shall be class 2.5 as a minimum, except for the
measurement of insulation resistance, where the accuracy of the instruments is not
specified but shall be taken into account for the measurement.
The voltmeter shall have an internal resistance of at least 1 MΩ and indicate mean value.
12.2
Periodic inspection and test
Periodic inspection and test shall be carried out in accordance with manufacturers
instructions and local regulations. The periodic inspection and test consists of:
•
•
Visual inspection (see section "Visual inspection", page 115)
Electrical test (see section "Electrical test", page 116)
The inspection and test shall be documented in a test report (see section "Test report",
page 118)
A signed and dated label shall be attached to the equipment after an approved test.
12.3
Cleaning instruction
To maintain the performance and increase the lifetime of the power source it is mandatory to
clean it regularly. How often depends on:
•
•
•
the welding process
the arc time
the working environment
CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared
workspace.
CAUTION!
During cleaning, always wear recommended personal safety equipment, such as
ear plugs, safety glasses, masks, gloves and safety shoes.
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12 IN-SERVICE INSPECTION AND TESTING
1.
Disconnect the power source from the mains supply.
WARNING!
Wait at least 30 seconds for the DC bus capacitor to discharge before
continuing.
2.
Remove the four screws holding the right side panel (R) and remove the panel.
3.
Disconnect the mains cable wires from the connection block and the earth connection
point (for details, see section "Replacing the mains cable", page 84).
Remove the fan including the surrounding foam (for details, see section "Replacing
the fan", page 87).
Clean the right side of the power source, using dry compressed air with reduced
pressure.
4.
5.
NOTE!
Since the power source contains one "dirty side" (the right side) and one
"clean side" (the left side), it is important that you do not remove the left
side panel before cleaning the right side of the power source.
6.
Remove the four screws holding the left side panel (L) and remove the panel.
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12 IN-SERVICE INSPECTION AND TESTING
7.
8.
Clean the left side of the power source, using dry compressed air with reduced
pressure.
Also the upper part of the power source needs cleaning but with a longer interval.
If cleaning of the upper part of the power source is needed, remove the four screws
holding the top panel. Use a thin screwdriver or similar to loosen the snap fittings and
remove the top panel.
9.
Clean the upper part of the power source, using dry compressed air with reduced
pressure.
10. Make sure that there is no dust left on any part of the power source.
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12 IN-SERVICE INSPECTION AND TESTING
11. After having finished cleaning the power source, reinsert the fan, reconnect the mains
cable and reattach the power source panels in the reverse order.
NOTE!
When reattaching the top panel, the "F" marking underneath the top panel
should point towards the front of the power source.
NOTE!
When reattaching the right side panel, make sure the IP shield on the
inside of the panel is in the correct position. The IP shield should be angled
approximately 90° into the power source, so that it is positioned between
the welding outlet connector and the transformer outlets.
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12 IN-SERVICE INSPECTION AND TESTING
12. Tighten the screws using the correct tightening torque according to the illustration
below.
NOTE!
Do not forget to reattach and tighten the screws holding the top panel
(4 screws).
12.4
After repair, inspection and test
After repair, inspection and test shall be carried out according to manufacturers instructions
and local regulations. The after repair, inspection and test consists of:
•
•
•
Visual inspection (see section "Visual inspection", page 115)
Electrical test (see section "Electrical test", page 116)
Functional test (see section "Functional test", page 117)
The inspection and test shall be documented in a test report (see section "Test report",
page 118)
A signed and dated label shall be attached to the equipment after an approved test.
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12 IN-SERVICE INSPECTION AND TESTING
12.5
Visual inspection
WARNING!
Disconnect the welding power source from the mains supply and make sure the
DC bus capacitor is discharged before inspection. The DC bus capacitor
discharge time is at least 30 seconds!
During visual inspection, each safety related function judged as relevant by the test
personnel, shall be checked for correct operation.
During visual inspection, the following listed items shall be checked:
1.
2.
3.
4.
5.
6.
Torch/electrode holder, welding current return clamp
○ missing or defective insulation
○ defective connections
○ defective, damaged switches
○ other damage
Mains supply
○ defective, damaged cable
○ deformed, faulty plug
○ broken or thermally damaged plug pins
○ ineffective cable anchorage
○ cables and plugs unsuitable for the intended use and performance
Welding circuit
○ defective damaged cable
○ deformed, faulty or thermally damaged coupler/sockets
○ ineffective cable anchorage
○ cables and coupler unsuitable for the intended use and performance
Enclosure
○ missing or damaged parts
○ unauthorised modifications
○ cooling openings blocked or missing air filters
○ signs of overload and improper use
○ missing or defective protective covers (for example, gas cylinder holder)
○ missing or defective lifting means, holder etc.
○ conductive objects placed in the enclosure
Controls and indicators
○ defective switches, meters and lamps
○ incorrect fuses accessible from outside of the enclosure
General condition
○ cooling liquid circuit leakage or incorrect cooling liquid level
○ defective gas hoses and connections
○ poor legibility of markings and labelling
○ other damage or signs of improper use
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12 IN-SERVICE INSPECTION AND TESTING
12.6
1.
2.
3.
4.
5.
Electrical test
Disconnect the welding power source from the mains supply.
Check the continuity of the protective circuit:
Remove the right side panel.
Measure the resistance of the protective circuit from the primary heat sink to the
protective earth connection in the mains plug.
During the measurement the cable should be bent, flexed and twisted along the whole
length in order to detect interruptions in the protective conductor.
Required value for cables up to 5 m: Max 0.3 Ω
Check the insulation resistance using an insulation tester with the measurement
voltage set to 500 V DC:
a) Turn the welding power source mains switch to position ON.
b) Measure between the supply pins in the mains plug and the welding outlets.
Required value: 5 MΩ or more
c) Measure between the welding outlets and the protective earth connection in the
mains plug.
Required value: 2.5 MΩ or more
d) Measure between the supply pins in the mains plug and the protective earth
connection in the mains plug.
Required value: 2.5 MΩ or more
e) Turn the welding power source mains switch to position OFF.
Check the no-load voltage, using the ESAB test box TB 1. If the welding power
source has an activated VRD function, proceed to item 5 below instead.
a) Connect the positive and the negative welding outlets to the positive and the
negative terminals (VIN) of the TB 1.
b) Connect a voltmeter to VPEAK of the TB 1.
c) Connect the welding power source to the mains supply.
d) Turn the control knob of the TB 1 anti-clockwise to 0.2.
e) Turn the mains switch of the welding power source to position ON.
f) Set the welding current control on the welding power source to maximum.
g) Slowly turn the control knob of the TB 1 clockwise from 0.2 to 5.2 while
checking the voltmeter for the highest value.
The measured value must not exceed 113 VPEAK.
h) Turn the mains switch of the welding power source to position OFF.
i) Disconnect the welding power source from the mains supply.
Check the no-load voltage with the VRD function activated, using the ESAB test box
TB 1. This test should only be conducted when the VRD function is activated.
a) Connect the positive and the negative welding outlets to the positive and the
negative terminals (VIN) of the TB 1.
b) Connect a voltmeter to VPEAK of the TB 1.
c) Connect the welding power source to the mains supply.
d) Turn the control knob of the TB 1 anti-clockwise to 0.2.
e) Turn the mains switch of the welding power source to position ON.
f) Set the welding current control on the welding power source to maximum.
g) Measure the voltage using the voltmeter.
The measured value must not exceed 35 V.
h) Check that the LED indicates an active VRD function (indicated by a fixed
green light).
i) Turn the mains switch of the welding power source to position OFF.
j) Disconnect the welding power source from the mains supply.
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12 IN-SERVICE INSPECTION AND TESTING
Circuit diagram of test box TB 1
12.7
1.
2.
3.
4.
5.
6.
7.
Functional test
Each safety related function judged as relevant by the test personnel shall be
checked for correct operation.
Conformity shall be checked by operating the device and by checking whether the
welding power source operates correctly.
Check the supply circuits on/off switching device:
a) Disconnect the welding power source from the mains supply.
b) Remove the side panels of the power source.
c) Turn the welding power source mains switch to position OFF.
d) Perform the following resistance measurements between the supply pins
of the mains plug and connector CN21 on the power board 15AP1:
– Between R in the mains plug and CN21.1. Required value: Open
circuit
– Between S in the mains plug and CN21.2. Required value: Open
circuit
– Between T in the mains plug and CN21.3. Required value: Open
circuit
e) Turn the welding power source mains switch to position ON.
f) Perform the following resistance measurements between the supply pins
of the mains plug and connector CN21 on the power board 15AP1:
– Between R in the mains plug and CN21.1. Required value: Less
than 0.5 Ω
– Between S in the mains plug and CN21.2. Required value: Less
than 0.5 Ω
– Between T in the mains plug and CN21.3. Required value: Less than
0.5 Ω
g) Reattach the side panels of the power source (see chapter
"DISASSEMBLY AND REASSEMBLY", page 74).
Check the signal and control lamps.
Check the function of the display indicators by turning on the unit and visually
checking the setting panel.
The LED and display test lights up all LEDs and display segments.
Finally the software version of the power source is displayed. Check that the
correct software version is installed.
Check the function of the welding power source by welding.
Disconnect the welding power source from the mains supply.
Write the test report (see section "Test report", page 118).
If the unit passes all tests, attach the appropriate label containing signature and
date of the test.
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12 IN-SERVICE INSPECTION AND TESTING
12.8
Test report
Company:
Equipment:
Location:
Serial number:
Arc welding power source
Manufacturer:
Type:
ESAB
Testing equipment:
VISUAL INSPECTION
Passed □
ELECTRICAL TEST
Limit
Protective conductor
resistance
≤ 0.3 Ω
Measured values
Insulation resistance:
•
Input circuit/Welding
circuit (500 VDC)
≥ 5 MΩ
•
Welding
circuit/Protective circuit
(500 VDC)
≥ 2.5 MΩ
•
Input circuit/Protective
circuit (500 VDC)
≥ 2.5 MΩ
No-load voltage:
•
without VRD
Vpeak ≤113 VDC
•
with VRD activated
Vpeak ≤35 VDC
Electrical test
Passed □
FUNCTIONAL TEST
Passed □
Remarks
Date
Tested by
Signature
Testing company
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13 SPARE PARTS AND ACCESSORIES
13
SPARE PARTS AND ACCESSORIES
For spare parts, see the spare parts list for the product. For accessories, see the instruction
manual for the product. These documents can be downloaded from the Internet:
www.esab.com
Document type
File name
Product
Spare parts list
0463 423 001 ES 300i, ET 300i, ET 300iP
Note
Instruction manual 0463 415 *
ES 300i
Ordering no. 0445 100 880
Instruction manual 0463 417 *
ES 300i
Ordering no. 0445 100 881
Instruction manual 0463 419 *
ES 300i
Ordering no. 0445 100 882
Instruction manual 0463 421 *
ES 300i
Ordering no. 0445 100 883
Instruction manual 0463 642 *
ES 300i
Ordering no. 0445 100 884
Instruction manual 0463 416 *
ET 300i, ET 300iP
Ordering no. 0445 100 900,
0445 100 920
Instruction manual 0463 418 *
ET 300iP
Ordering no. 0445 100 921
Instruction manual 0463 420 *
ET 300iP
Ordering no. 0445 100 922
Instruction manual 0463 422 *
ET 300i, ET 300iP
Ordering no. 0445 100 903,
0445 100 923
Instruction manual 0463 643 *
ET 300i, ET 300iP
Ordering no. 0445 1009 04,
0445 100 924
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© ESAB AB 2018
For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
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