ESAB SST 1 Soft-Starting Tool 1 User manual

SST 1
Soft-starting tool 1
SST 3 replaces SST 1
Instruction manual
0740 800 165
090831
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Soft starting
CaddyArc 150, CaddyTig 150, OrigoTig 150, OrigoArc 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Soft starting
OrigoArc 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Soft starting
CaddyTig 200, OrigoTig 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Checking the gate pulses
CaddyArc 150, CaddyTig 150, CaddyTig 200, OrigoTig 150, OrigoTig 200 . . . . . . . . . . . . . . .
10
Checking the gate pulses
OrigoArc 150, OrigoArc 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Rights reserved to alter specifications without notice.
conte
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Introduction
Soft-starting tool SST 1
The soft-starting tool is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
The SST 1 is made for the CaddyArc, CaddyTig, OrigoTig and OrigoArc. It can be ordered
from ESAB, ordering no. 0459 534 880.
The tool includes: Soft starting rectifier, cable set, voltage test board, gate pulse load and
shunt voltage resistor for the OrigoArc.
This manual describes the soft-starting procedure for the CaddyArc, CaddyTig, OrigoTig
and OrigoArc. Complete service manuals for the machines have the following filename /
ordering no:
0740
0740
0740
0740
800
800
800
800
161
162
163
164
CaddyArc 150, CaddyTig 150, OrigoTig 150
OrigoArc 150
OrigoArc 200
CaddyTig 200, OrigoTig 200
Note!
The SST 3 replaces SST 1.
The SST 3 is made for ESAB's single phase inverters and for 3-phase inverters with 250 A
output current. The difference in function is that the SST 1 can only be used for single
phase inverters.
The instruction manual for the SST 3 has ordering no. / filename: 0740 800 204.
csst1d1
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S0740 800 165/E090831/P12
CaddyArc 150, CaddyTig 150, OrigoArc 150, OrigoTig 150
Soft starting
We recommend soft starting of the machine after replacing control circuit board 20AP1,
power supply board 2AP1 and circuit boards or components in the power module. Soft
starting supplies the power module with a low voltage in order to avoid injury to persons or
damage to components.
It is a good idea to use soft starting when fault tracing.
Special equipment
To soft-start the machine you need soft-starting tool SST 1, this is described on page 3.
Instructions
1.
Disconnect wires 1501, 1502, 1503 and 1504 from circuit boards 2AP1 and 15AP1.
Disconnections prior to soft starting
2.
3.
Connect the 230 V AC input of the SST 1 to terminals B1 and B2 on circuit board
2AP1.
Connect the 325 V DC output of the SST 1 to terminals F1 and F3 on circuit board
2AP1.
The SST 1 connected to 2AP1
4.
5.
6.
7.
8.
Disconnect connector 20XS4 from terminal PS of power supply board 2AP1. Connect
the voltage test cable of the SST 1 to terminal PS of power supply board 2AP1.
Connect the power source to the mains and turn on the mains switch.
Verify the output voltages from 2AP1, all LEDs must light.
(OrigoArc: only the +24V LED must light).
Switch off the machine. Disconnect the voltage test cable and reconnect connector
20XS4 to terminal PS of circuit board 2AP1.
Disconnect connector 15XS3 (supply to the fan) from terminal E of circuit board 2AP1.
Connect the 24 V DC input of the SST1 to terminal E of circuit board 2AP1.
csst1t27f4soft
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S0740 800 165/E090831/P12
CaddyArc 150, CaddyTig 150, OrigoArc 150, OrigoTig 150
9.
Connect the 24 V DC output of the SST 1 to terminals C1 and C2 of power board
15AP1.
Circuit connections and measuring points for soft starting
10.
11.
12.
13.
Switch on the machine and set it to MMA mode.
Check that the DC voltage across smoothing capacitor 15C1 is 22-24 V.
Check that the DC voltage at the welding terminals is 7-8 V.
If all the measurements are as described above, reconnect the wires to restore the
power source to normal operation mode and make a test weld.
csst1t27f4soft
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S0740 800 165/E090831/P12
OrigoArc 200
Soft starting
We recommend soft starting of the machine after replacing control circuit board 20AP1,
power supply board 2AP1 and circuit boards or components in the power module. Soft
starting supplies the power module with a low voltage in order to avoid injury to persons or
damage to components.
It is a good idea to use soft starting when fault tracing.
Special equipment
To soft-start the machine you need soft-starting tool SST 1, this is described on page 3.
Instructions
1.
Disconnect wires 1501, 1502, 1505, 1506, 1503 and 1504 from circuit boards 2AP2,
2AP1 and 15AP1.
Disconnections prior to soft starting
2.
3.
Connect the 230 V AC input of the SST 1 to terminals C1 and C3 on circuit board
2AP2.
Connect the 325 V DC output of the SST 1 to terminals F1 and F3 on circuit board
2AP1.
The SST 1 connected to 2AP2 and 2AP1
4.
5.
6.
7.
Disconnect connector 20XS4 from terminal PS of power supply board 2AP1. Connect
the voltage test cable of the SST 1 to terminal PS of power supply board 2AP1.
Connect the power source to the mains and turn on the mains switch.
Verify the output voltage from 2AP1, the +24 V LED must light.
(The voltage must be +24 V $0.6 V.)
Switch off the machine. Disconnect the voltage test cable and reconnect connector
20XS4 to terminal PS of power supply board 2AP1.
csst1h25bf4soft
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S0740 800 165/E090831/P12
OrigoArc 200
8.
9.
Disconnect connector 15XS3 (supply to the fan) from terminal E of circuit board 2AP1.
Connect the 24 V DC input of the SST 1 to terminal E of circuit board 2AP1.
Connect the 24 V DC output of the SST 1 to terminals N1:1 and N2:1 of power board
15AP1.
Circuit connections and measuring points for soft starting
10.
11.
12.
13.
Switch on the machine.
Check that the DC voltage across smoothing capacitor 15C1 is 22-24 V.
Check that the DC voltage at the welding terminals is 7-8 V.
If all the measurements are as described above, reconnect the wires to restore the
power source to normal operation mode and make a test weld.
csst1h25bf4soft
-7-
S0740 800 165/E090831/P12
CaddyTig 200, OrigoTig 200
Soft starting
We recommend soft starting of the machine after replacing control circuit board 20AP1,
power supply board 2AP1 and circuit boards or components in the power module. Soft
starting supplies the power module with a low voltage in order to avoid injury to persons or
damage to components.
It is a good idea to use soft starting when fault tracing.
Special equipment
To soft-start the machine you need soft-starting tool SST 1, this is described on page 3.
Instructions
1.
Disconnect wires 1501, 1502, 1503 and 1504 from circuit boards 2AP1 and 15AP1.
Disconnections prior to soft starting
2.
3.
Connect the 230 V AC input of the SST 1 to terminals B1 and B2 on circuit board
2AP1.
Connect the 325 V DC output of the SST 1 to terminals F1 and F3 on circuit board
2AP1.
The SST 1 connected to 2AP1
4.
5.
6.
7.
8.
Disconnect connector 20XS4 from terminal PS of power supply board 2AP1. Connect
the voltage test cable of the SST 1 to terminal PS of power supply board 2AP1.
Connect the power source to the mains and turn on the mains switch.
Verify the output voltages from 2AP1, all LEDs on the SST 1 must light.
Switch off the machine. Disconnect the voltage test cable and reconnect connector
20XS4 to terminal PS of circuit board 2AP1.
Disconnect connector 15XS3 (supply to the fan) from terminal E of circuit board 2AP1.
Connect the 24 V DC input of the SST 1 to terminal E of circuit board 2AP1.
csst1t27bf4soft
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S0740 800 165/E090831/P12
CaddyTig 200, OrigoTig 200
9.
Connect the 24 V DC output of the SST 1 to terminals N1:1 and N2:1 of power board
15AP1.
Circuit connections and measuring points for soft starting
10.
11.
12.
13.
Switch on the machine and set it to MMA mode.
Check that the DC voltage across smoothing capacitor 15C1 is 22-24 V.
Check that the DC voltage at the welding terminals is about 7-8 V.
If all the measurements are as described above, reconnect the wires to restore the
power source to normal operation mode and make a test weld.
csst1t27bf4soft
-9-
S0740 800 165/E090831/P12
CaddyArc 150, CaddyTig 150, CaddyTig 200, OrigoTig 150, OrigoTig 200
Checking the gate pulses
When checking the gate pulses, the machine can either be in soft-start mode or in normal
operation mode.
Special equipment
To measure the gate pulses, you need a gate pulse load. This is included in soft-starting
tool SST 1, which is described on page 3.
Instructions
1.
2.
3.
Disconnect the machine from the mains.
Disconnect connector 20XS5 from terminal G on control board 20AP1.
Connect the gate pulse test cable of the SST 1 to terminal G on control board 20AP1.
Measuring connection for the gate pulses
4.
5.
6.
7.
8.
9.
Switch on the machine.
Connect an oscilloscope to the SST 1, with the probe to terminal G2 and the screen to
terminal G1 of SST1.
Set the machine to MMA welding mode.
Measure the pulse frequency. It must be 65 kHz +/- 1kHz.
Measure the duration of the negative pulse. It must be 41 - 43 % of the cycle time,
measured at a voltage level of -10 V.
The waveform of the pulses must be as shown below.
Gate pulses from circuit board 20AP1
csst1t27f5gate
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S0740 800 165/E090831/P12
OrigoArc 150, OrigoArc 200
Checking the gate pulses
When checking the gate pulses, the machine can either be in soft-start mode or in normal
operation mode.
Special equipment
To measure the gate pulses, you need a gate pulse load and a shunt voltage resistor. This
is included in soft-starting tool SST 1, which is described on page 3.
Instructions
1.
Disconnect the machine from
the mains.
2. Disconnect connector 15XS8
from terminal S on control
board 20AP1.
3. Connect the cable marked
“20AP1 S1, S2” to terminal S.
Shunt voltage resistor connected to terminal S
4. Disconnect connector 20XS5
from terminal G on control
board 20AP1.
5. Connect the gate pulse test
cable of the SST 1 to terminal
G on control board 20AP1.
6. Switch on the machine.
7. Connect an oscilloscope to the
SST 1, with the probe to
terminal G2 and the screen to
Measuring connection for the gate pulses
terminal G1.
8. Set the current reference to 70 A or more. This will set the pulses to maximum pulse
width. At minimum current reference, there are no pulses.
9. Measure the pulse frequency. It must be 65 kHz +/- 1kHz.
10. Measure the duration of the negative pulse. It must be 41 - 43 % of the cycle time,
measured at a voltage level of -10 V.
11. The waveform of the pulses must be as shown below.
Gate pulses from circuit board 20AP1
csst1h25f5gate
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S0740 800 165/E090831/P12
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081016