ESAB 100i Service Manual
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ESAB 100i Service Manual

Plasma system
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100i, 200i, 300i, and 400i
Plasma System

Service Manual

Article Number: 0560956456
Revision Date: June 14, 2016
Revision Number: AA
Language: ENG

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Summary of Contents for ESAB 100i

  • Page 1: Service Manual

    100i, 200i, 300i, and 400i Plasma System Service Manual Article Number: 0560956456 Revision Date: June 14, 2016 Revision Number: AA Language: ENG...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-ESAB-123, or visit us on the web at www.ESAB.com.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply with Automated Gas Control 100i / 200i / 300i / 400i Published by: ESAB Welding and Cutting Products.

  • Page 4: User Responsibility

    Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,”...
  • Page 5 ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR. VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR. ATTENTION Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement. Si vous n’avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous vous suggérons de lire notre brochure «...
  • Page 6 This Page Intentionally Blank...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY ..................1-1 1.01 Safety Precautions - ENGLISH ................ 1-1 1.02 Précautions de sécurité - FRENCH CANADIAN ..........1-6 SECTION 2: TORCH MAINTENANCE ..............2-1 2.01 Coolant Leak Trouble-Shooting ..............2-1 APPENDIX 1: CNC - CONTROL MODULE PCB CONNECTIONS ........A-1 APPENDIX 2: CNC ..................
  • Page 8 TABLE OF CONTENTS APPENDIX 24: SYSTEM SCHEMATIC 200A, 380-415V PG 2 ........A-44 APPENDIX 25: SYSTEM SCHEMATIC 300A, 380-415V PG 1 ........A-46 APPENDIX 26: SYSTEM SCHEMATIC 300A, 380-415V PG 2 ........A-48 APPENDIX 27: SYSTEM SCHEMATIC 400A, 380-415V PG 1 ........A-50 APPENDIX 28: SYSTEM SCHEMATIC 400A, 380-415V PG 2 ........A-52 APPENDIX 29: ADVANCED TROUBLESHOOTING .............A-54 APPENDIX 30: HE 400 CONNECTION ..............A-88 APPENDIX 31: PUBLICATION HISTORY ..............A-92...

  • Page 9: Section 1: Safety

    iSERIES 100 /200 /300 /400 SECTION 1: SAFETY 1.01 Safety Precautions - ENGLISH WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc.
  • Page 10 iSERIES 100 /200 /300 /400 ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. 1.
  • Page 11 iSERIES 100 /200 /300 /400 CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder.
  • Page 12 iSERIES 100 /200 /300 /400 Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved. Means immediate hazards which, if not avoided, will result in immediate, serious per- DANGER sonal injury or loss of life. CAUTION Means potential hazards which could result in personal injury or loss of life.
  • Page 13 iSERIES 100 /200 /300 /400 This Page Intentionally Blank Manual 0560956456 SAFETY INSTRUCTIONS...

  • Page 14: 1.02 Précautions De Sécurité - French Canadian

    iSERIES 100 /200 /300 /400 1.02 Précautions de sécurité - FRENCH CANADIAN AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité sup- plémentaires.
  • Page 15 iSERIES 100 /200 /300 /400 5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie. 6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projec- tion de métal incandescent ne risque de provoquer un incendie ultérieurement.
  • Page 16 iSERIES 100 /200 /300 /400 LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particu- lièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l’asphyxie. Par conséquent : 1.
  • Page 17 iSERIES 100 /200 /300 /400 4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur, notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères corrosives et des intempéries. 5.
  • Page 18 iSERIES 100 /200 /300 /400 MISE EN GARDE L’équipement pourrait basculer s’il est placé sur une surface dont la pente dépasse 15°. Vous pourriez vous blesser ou endommager l’équipement de façon importante. 15° Art# A-12726 MISE EN GARDE Soulevez à l’aide de la méthode et des points d’attache illustrés afin d’éviter de vous blesser ou d’endommager l’équipement.

  • Page 19: Torch Maintenance

    iSERIES 100 /200 /300 /400 SECTION 2: TORCH MAINTENANCE 2.01 Coolant Leak Trouble-Shooting Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged or installed im- properly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant leakage from the torch head.
  • Page 20 iSERIES 100 /200 /300 /400 Torch Electrodes Art # A-09653 Recommended Wear Depth for Electrode Amperage Plasma Gas Replacement Inch 0.04 0.04 0.04 0.04 0.08 0.04 0.04 0.08 0.04 0.08 0.04 0.08 0.08 0.06 0.08 0.08 0.06 0.08 0.08 0.06 0.06 0.08 0.08...

  • Page 21: Appendix 1: Cnc - Control Module Pcb Connections

    iSERIES 100 /200 /300 /400 APPENDIX 1: CNC - Control Module PCB Connections (LV) OK To Move 2 High +10V Analog Current Control Wiper / Input Low (-) Divided Arc Volts Output Start/Stop Input Stop (NC) (LV) OK To Move 2 CNC Plasma Enable OK To Move Pilot On Output...

  • Page 22: Appendix 2: Cnc

    iSERIES 100 /200 /300 /400 APPENDIX 2: CNC CNC functions CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply. While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1, TB2 & TB3 are common to each other.
  • Page 23 iSERIES 100 /200 /300 /400 Internal CNC connections. TB1, TB2 & TB3 on CCM module. Connections are provided on the CCM module TB1, TB2 & TB3 terminal blocks including most of the rear panel functions plus some additional features. All these signals are isolated from the plasma power supply but signals marked (comm.) and (-) are common to each other.

  • Page 24: Cnc Input / Output Descriptions

    iSERIES 100 /200 /300 /400 CNC Input / Output Descriptions E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper between TB1-1&2 must be removing when connecting user supplied E-Stop circuit. Start/Stop input—Switch (momentary or sustained) rating 35ma. @ 20 VDC Start / Stop circuit configurations.
  • Page 25 iSERIES 100 /200 /300 /400 OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated for maximum of 24 VAC/DC @ 1A. Simplified CNC Circuit. +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remote Analog Current Control (CC) input an external 10 V supply was required for Pot High..

  • Page 26: Simplified Cnc Circuit

    iSERIES 100 /200 /300 /400 Simplified CNC Circuit Ult racut X T Simplified CNC OK TO MOV E SELECT 18 V D C or Con tacts SW6A D C VO LT S +18VDC OK2 (cont act) C ONTA CT S +10V (CC Pot Hi ) CC Pot W iper CC Pot L ow...
  • Page 27 iSERIES 100 /200 /300 /400 J54 - Rem ote HM I & CN C CO M M (100) 1 - 24 V AC (101) 2 - 24 V AC Re t (102) 3- Jumper to 24 V AC Harness to Relay PCB (109) 5-H M I Pl asma Enabl e SW (108)

  • Page 28: Cnc Connections

    iSERIES 100 /200 /300 /400 CNC Connections Cutting Machine CNC Cable Power Supply START/STOP ..Source, 16 VDC, 10 ma..Divided Arc V (-) ..Divided Arc V (+) ..Pre Flow ON (+) ..Pre Flow ON (-) ..

  • Page 29: Appendix 3: Gsc Control Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 3: GSC Control PCB Layout D-17 D_E1 D_E15 Art # A-09188_AC Manual 0560956456 APPENDIX...

  • Page 30: Appendix 4: Dpc Control Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 4: DPC Control PCB Layout TP11 TP10 Art # A-09189_AB A-10 APPENDIX Manual 0560956456...

  • Page 31: Appendix 5: Gsc / Dpc Power Supply Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 5: GSC / DPC Power Supply PCB Layout Art # A-09597_AB Manual 0560956456 APPENDIX A-11...

  • Page 32: Appendix 6: Ccm Cpu Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 6: CCM CPU PCB Layout = Test Point Art # A-11675_AC A-12 APPENDIX Manual 0560956456...
  • Page 33 iSERIES 100 /200 /300 /400 CCM CPU PCB Test Points TP1 GND TP2 ISO +5.0V TP3 +24V TP4 +3.3V TP5 ISO GND TP6 +5.0V TP7 TOTAL DEMAND 3.3V=400A TP9 /WR TP10 TP11 CPU TEMP SENSE TP12 +3.3VA TP13 -15VDAC TP14 TP15 +15VDAC TP16...

  • Page 34: Appendix 7: Ccm I/O Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 7: CCM I/O PCB Layout = Test Point A-14 APPENDIX Manual 0560956456...
  • Page 35 iSERIES 100 /200 /300 /400 CCM I/O PCB J Connectors Test Points J21 BASIC CNC TP1 GND J22 EXTENDED CNC TP2 /COOLANT FANS ON J23 RELAY - INTERFACE BOARD TP3 /TORCH PUMP ON J24 ARC / TIP VOLTS TP4 LOW COOLANT FLOW (SW) J25 TEST TP5 COOLANT FLOW SIGNAL (PULSE) J26 GAS BOX...

  • Page 36: Appendix 8: Pilot Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 8: Pilot PCB Layout = Test Point Art # A-11677_AB A-16 APPENDIX Manual 0560956456...
  • Page 37 iSERIES 100 /200 /300 /400 Pilot PCB Test Points TP1 GND TP2 PILOT GATE TP3 +5V TP4 TIP LED Reference Green PILOT ENABLE Green +5V Manual 0560956456 APPENDIX A-17...

  • Page 38: Appendix 9: Relay And Interface Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 9: Relay and Interface PCB Layout = Test Point Art # A-11678_AB A-18 APPENDIX Manual 0560956456...
  • Page 39 iSERIES 100 /200 /300 /400 Relay and Interface PCB Test Points TP1 GND TP2 -15V TP3 +5VDC TP4 +12V TP5 +24V TP6 +15V TP7 +5VDC LED Reference Green 1 TORCH GAS ON Green PILOT ENABLE Green PILOT CURRENT DETECTED D12 Green WORK CURRENT DETECTED D22 Green CONTACTORS ON D23 Green RF ON D24 Green FANS ON...

  • Page 40: Appendix 10: Display Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 10: Display PCB Layout = Test Point Art # A-11679 A-20 APPENDIX Manual 0560956456...
  • Page 41 iSERIES 100 /200 /300 /400 Display PCB Test Points TP1 GND TP2 +5VDC TP3 +24VDC Manual 0560956456 APPENDIX A-21...

  • Page 42: Appendix 11: System Bias Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 11: System Bias PCB Layout = Test Point Art # A-11680_AB A-22 APPENDIX Manual 0560956456...
  • Page 43 iSERIES 100 /200 /300 /400 System Bias PCB Test Points TP1 GND TP2 24VDC TP3 DC INPUT POSITIVE TP4 Vcc1 TP5 Vcc2 TP6 GATE TP7 PRIMARY GND TP8 +12V PRIMARY TP9 P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference MISSING PHASE AC V HIGH D14 Red AC V LOW...

  • Page 44: Appendix 12: Main Inverter Bottom Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 12: Main Inverter Bottom PCB Layout = Test Point A-24 APPENDIX Manual 0560956456...
  • Page 45 iSERIES 100 /200 /300 /400 Main Inverter Bottom PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A...

  • Page 46: Appendix 13: Main Inverter Top Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 13: Main Inverter Top PCB Layout = Test Point A-26 APPENDIX Manual 0560956456...
  • Page 47 iSERIES 100 /200 /300 /400 Main Inverter Top PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A...

  • Page 48: Appendix 14: Control And Fault Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 14: Control and Fault PCB Layout = Test Point Art # A-11683_AC A-28 APPENDIX Manual 0560956456...
  • Page 49 iSERIES 100 /200 /300 /400 Control and Fault PCB Test Points TP1 GND TP22 +12VDC TP23 +5VDC TP24 GATE 1+ TP25 A_OUT1 TP26 B_OUT1 TP27 GATE 1- TP28 I_SNS1 TP29 GATE 2+ TP30 I_DMD1 0.5V-6.7V TP31 GATE 2- TP32 -12VDC TP33 START 2 TP34...

  • Page 50: Appendix 15: Cap Bias Bottom Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 15: Cap Bias Bottom PCB Layout Art # A-11685_AC A-30 APPENDIX Manual 0560956456...

  • Page 51: Appendix 16: Cap Bias Top Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 16: Cap Bias Top PCB Layout Art # A-11686_AC Manual 0560956456 APPENDIX A-31...

  • Page 52: Appendix 17: Suppressor Pcb Layout

    iSERIES 100 /200 /300 /400 APPENDIX 17: Suppressor PCB Layout Art # A-11684_AC A-32 APPENDIX Manual 0560956456...

  • Page 53: Appendix 18: Cooling Diagram

    iSERIES 100 /200 /300 /400 APPENDIX 18: COOLING DIAGRAM Manual 0560956456 APPENDIX A-33...

  • Page 54: Appendix 19: Remote Arc Starter Schematic

    iSERIES 100 /200 /300 /400 APPENDIX 19: Remote Arc Starter Schematic Jumper in cable to ID Arc Starter IGNITION UNIT SIG 4.5 is connected. PLASMA 1000 XT POWER SUPPLY J59-RAS Chassis gnd 115 Vac 115 Vac RET (99) 120 VAC 120 VAC RET (98) (49)
  • Page 55 iSERIES 100 /200 /300 /400 This Page Intentionally Blank Manual 0560956456 APPENDIX A-35...

  • Page 56: Appendix 20: Schematic, Dfc Auto Gas Box System

    iSERIES 100 /200 /300 /400 APPENDIX 20: Schematic, DFC Auto Gas Box System DMC3000 - MANIFOLD CONTROLLER ASSEMBLY 19X2367 755x000 ULTRACUT POWER SUPPLY CONTROL CABLE (JMP) PLASMA ENABLE + Power Supply PCB (19X2384) LEDS 120VAC DMC PLASMA ENABLE - See list by DPC 3000 Power Supply 120VAC DMC RET (2a) 19X2384...
  • Page 57 iSERIES 100 /200 /300 /400 DPC3000 - PRESSURE CONTROL ASSEMBLY 19X2383 PANEL INDICATORS Power Supply PCB (19X2384) LEDS POWER LED (GRN) POWER LED (GRN) STATUS LED (RED) STATUS LED (RED) D5 = +VDC Fused (24VDC ) MANIFOLD (partial) P3 - HWID P3 - HWID D6 = +12VDC DPC3000 CONTROL PCB...

  • Page 58: Appendix 21: System Schematic 100A, 380-415V

    iSERIES 100 /200 /300 /400 APPENDIX 21: System Schematic 100A, 380-415V PG 1 380-415 INVERTER MODULE (IM) #`1 (bottom) INPUT J105B AC INPUT IM #1 Section B (upper) MAIN PCB LEDS (Customer (20) D3, RED, CAP FIL- supplied CONTROL PCB LEDS IMBALANCE power cord J104B...
  • Page 59 iSERIES 100 /200 /300 /400 TORCH TORCH To TB4-7 (49) PILOT BOARD TEST POINTS TP1 GND (49) LED'S TP2 PILOT GATE D2 PILOT ENABLE TP3 +5V D11 +5V PILOT ELECTRODE To TB4-6 PILOT PCB J58A (52) R3 & R4 J41 (J87) CHASSIS GND J58C SHIELD...

  • Page 60: Appendix 22: System Schematic 100A, 380-415V

    iSERIES 100 /200 /300 /400 APPENDIX 22: System Schematic 100A, 380-415V PG 2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 480 VAC -- Single 18 AWG in pins 1 & 8 (90) 230 VAC -- 18 AWG wires in pins 1,5,2,6 (89)
  • Page 61 iSERIES 100 /200 /300 /400 TO PILOT PCB J70 - HE (70) 230 VAC to HE 400 (70) (Sht 1, B8) Fan Control 230 VAC _ SW (D2) 230 VAC Ret 230 VAC _ SW _ RET (96) (D2) ARC_SUPPRESSOR Pump Motor Control J59 - RAS CHASSIS GND...

  • Page 62: Appendix 23: System Schematic 200A, 380-415V

    iSERIES 100 /200 /300 /400 APPENDIX 23: System Schematic 200A, 380-415V PG 1 INVERTER 1/2 MODULE (IM) #2 (top) (20) FIL- OUT1 J105A (21) IM #2 Section A (lower) AC INPUT OUT2 J104A (22) GND2B OUT3 J103A Toriod Core 019x502000 CHASSIS GND INVERTER MODULE (IM) #`1 (bottom) J105B...
  • Page 63 iSERIES 100 /200 /300 /400 TORCH To TB4-7 TORCH (49) (49) PILOT BOARD LED'S TEST POINTS TP1 GND (49) TP2 PILOT GATE D2 PILOT ENABLE TP3 +5V D11 +5V PILOT ELECTRODE To TB4-6 PILOT PCB J58A (52) R3 & R4 TO CCM CPU PCB J41 (J87)

  • Page 64: Appendix 24: System Schematic 200A, 380-415V

    iSERIES 100 /200 /300 /400 APPENDIX 24: System Schematic 200A, 380-415V PG 2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8 230 VAC -- 18 AWG wires in pins 1,5,2,6 (89) COOLANT LEVEL...
  • Page 65 iSERIES 100 /200 /300 /400 TO PILOT PCB J70 - HE Sht 1, B8) (70) 230 VAC to HE 400 (70) Fan Control 230 VAC _ SW (D2) 230 VAC Ret 230 VAC _ SW _ RET (D2) ARC_SUPPRESSOR Pump Motor Control J59 - RAS CHASSIS GND (96)

  • Page 66: Appendix 25: System Schematic 300A, 380-415V Pg 1

    iSERIES 100 /200 /300 /400 APPENDIX 25: System Schematic 300A, 380-415V PG 1 INVERTER MODULE (IM) #3 (top) FIL- J105B IM #3 Section B OUT1 AC INPUT J104B OUT2 GND2B J103B OUT3 Toriod Core 019X502700 CHASSIS GND J105A IM #3 Section A AC INPUT FIL- J104A...
  • Page 67 iSERIES 100 /200 /300 /400 TO CCM CPU PCB J36 (Sht 2, C3) TORCH J100 -- 30 CKT RIBBON To TB4-7 (49F) TORCH (49) (49) ELECTRODE (-) (51F) PILOT BOARD LED'S TEST POINTS TP1 GND WORK (+) (49) TP2 PILOT GATE D2 PILOT ENABLE TP3 +5V D11 +5V...

  • Page 68: Appendix 25: System Schematic 300A, 380-415V

    iSERIES 100 /200 /300 /400 APPENDIX 26: System Schematic 300A, 380-415V PG 2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8 230 VAC -- 18 AWG wires in pins 1,5,2,6 (89) COOLANT LEVEL...
  • Page 69 iSERIES 100 /200 /300 /400 TO PILOT PCB J70 - HE Sht 1, B8) (70) 230 VAC to HE 400 (70) Fan Control 230 VAC _ SW (D2) 230 VAC Ret 230 VAC _ SW _ RET (D2) ARC_SUPPRESSOR Pump Motor Control J59 - RAS CHASSIS GND (96)

  • Page 70: Appendix 27: System Schematic 400A, 380-415V

    iSERIES 100 /200 /300 /400 APPENDIX 27: System Schematic 400A, 380-415V PG 1 INVERTER MODULE (IM) #3 (top) FIL- J105B IM #3 Section B OUT1 AC INPUT J104B OUT2 GND2B J103B OUT3 Toriod Core 019X502700 CHASSIS GND J105A IM #3 Section A AC INPUT FIL- J104A...
  • Page 71 iSERIES 100 /200 /300 /400 TO CCM CPU PCB J36 (Sht 2, C3) TORCH J100 -- 30 CKT RIBBON To TB4-7 TORCH (49F) (49) ELECTRODE (-) PILOT BOARD LED'S TEST POINTS (51F) TP1 GND WORK (+) (49) TP2 PILOT GATE D2 PILOT ENABLE TP3 +5V D11 +5V...

  • Page 72: Appendix 28: System Schematic 400A, 380-415V

    iSERIES 100 /200 /300 /400 APPENDIX 28: System Schematic 400A, 380-415V PG 2 INVERTER MODULE (IM) #3 (top) FIL- J105B IM #3 Section B OUT1 AC INPUT J104B OUT2 GND2B J103B OUT3 Toriod Core 019X502700 CHASSIS GND J105A IM #3 Section A AC INPUT FIL- J104A...
  • Page 73 iSERIES 100 /200 /300 /400 TO CCM CPU PCB J36 (Sht 2, C3) TORCH J100 -- 30 CKT RIBBON To TB4-7 TORCH (49F) (49) ELECTRODE (-) PILOT BOARD LED'S TEST POINTS (51F) TP1 GND WORK (+) (49) TP2 PILOT GATE D2 PILOT ENABLE TP3 +5V D11 +5V...

  • Page 74: Appendix 29: Advanced Troubleshooting

    iSERIES 100 /200 /300 /400 APPENDIX 29: ADVANCED TROUBLESHOOTING System Overview The iSeries 100, 200, 300 & 400 power supplies include one, two or three inverter modules (IM). Each IM may have either 1 or 2 inverter sections designated A or B sections.
  • Page 75 iSERIES 100 /200 /300 /400 to it coming from the CCM which has 6 connectors, J31 – J36 corresponding to the inverter sections 1A through 3B. The ribbon cables are labeled on the inverter ends as INV with the number and section (INV 1A, INV 1B, etc.). A 100A unit will only have ribbon cables in J31 &...
  • Page 76 iSERIES 100 /200 /300 /400 2nd INVERTER SECTION (INV 1 B) PILOT SW (IGBT) 1st INVERTER SECTION (INV 1 A) WORK Art # 12301 The AC Suppression PCB has capacitors and other transient suppression components to protect the system from transients on the AC lines.
  • Page 77 iSERIES 100 /200 /300 /400 Troubleshooting (General) In many cases where the cause may be listed as a cable or wire disconnected but also includes loose or broken. All Ribbon cables have an extra receptacle near one end for measuring signals on the cable. A number of the measurements will require probing of some small connectors or measuring signal on ribbon cables.
  • Page 78 iSERIES 100 /200 /300 /400 Power Supply Status Codes Group 1, Process Codes Plasma Enable Is Disabled Code 101 is activated by either an open circuit between TB1-1 & 2 on CCM I/O PCB or Plasma Enable switched off on the GCM 2010 or on the TSC 3000. TB1-1 & 2 comes from the factory with a jumper installed. An installer may remove the jumper and connect a separate Plasma Enable switch or use the Plasma Enable wires included in the 37 pin CNC cable used with the iSeries.
  • Page 79 iSERIES 100 /200 /300 /400 Arc starter without Spark Gap (ISeries) 1. Check for power to the RAS’s Ignition Module during the 15 seconds following preflow (ignition phase). Arc starter power comes through the rear panel circuit breaker CB4, make sure it isn’t tripped. a.
  • Page 80 iSERIES 100 /200 /300 /400 b. If the Pilot current signal on the pilot ribbon cable was zero, measure between pins 23 (-) and 25 (+) on the 40 pin ribbon cable between the Relay board and the CCM. This would also normally be zero if there is no pilot current.
  • Page 81 iSERIES 100 /200 /300 /400 3. If D11 on the Pilot board is not on check if the 10 pin ribbon cable is connected between the Pilot board (J42) and the Relay board (J3). Measure for 24 VDC on the Pilot ribbon cable test connector pin 2 (+) and pin 10 (-).
  • Page 82 iSERIES 100 /200 /300 /400 Transfer Lost Arc transferred to metal for at least 50 ms. then went out. Causes for 104 code: • Cut demand set much lower than recommended for torch parts, i.e. 100A consumables in torch but cut current set for 30 or 50A (or zero).
  • Page 83 iSERIES 100 /200 /300 /400 Tip to Electrode Voltage Fault The Pilot voltage, measured between tip and electrode varies with different current and gas type, flow rate and consumable design. Once the arc is transferred the pilot switch opens leaving the tip basically floating. The voltage then is deter- mined by how much of a cold gas barrier surrounds the arc.
  • Page 84 iSERIES 100 /200 /300 /400 Group 2 – Plasma Power Supply codes General: LEDS Several LEDs are used as indicators on the different inverter module boards. RED LEDs indicate faults. Green LEDs should be on for the most part. Green LEDs are: On the main board, D4-READY; On the Cap Bias Board, D6, -12V, D11 +12VP (primary referenced), D13, +12V;...
  • Page 85 iSERIES 100 /200 /300 /400 Missing AC Phase The System Bias Supply board contains circuits to detect if one of the 3 AC input phases is missing. Along with that it can also detect if the AC voltage is too low or too high. Three phase voltage is supplied from the input terminals through the ON/OFF Switch / circuit breaker CB1 to the System Bias board.
  • Page 86 iSERIES 100 /200 /300 /400 of IM#1 are enabled and CCM measures the power supply output voltage between negative (Torch) to positive (Work) at the output terminals. If this is less than a set value during preflow or if at any time during piloting or cutting it drops to below that value for a short time, the inverters are shut off and code 205 is set.
  • Page 87 iSERIES 100 /200 /300 /400 tive. Another possibility is in the 40 pin ribbon cable either pin 27 or 28 is shorted to an adjacent pin. Otherwise the CCM is defective. 2. 207 code after START applied (during preflow): • Short between power supply negative output and Work circuit. •...
  • Page 88 iSERIES 100 /200 /300 /400 IM#1 and the Pilot board are enabled near the end of preflow. To have unwanted current there must be a path (short) for current to flow between the inverter negative output (negative cable/torch electrode) and the Pilot return/tip before the arc starter is enabled for pilot ignition.
  • Page 89 iSERIES 100 /200 /300 /400 1. For current too low due to a short disconnect work lead from back of unit. Check for continuity to chassis, there should be none. Inspect for incorrectly connected user equipment. 2. If no shorts were found or if fault was current signal too high see section on code 207 for detailed description of the power and signal paths for the work lead current sensor.
  • Page 90 iSERIES 100 /200 /300 /400 Causes & troubleshooting: • As this is just a continuity test it is very unlikely to be a bad inverter. Most likely a poor connection or defective ribbon cable. o Check ribbon cable connections at both ends of INV1A to CCM J31 (1A) cable. Make sure it is plugged into J31, the top connector, on the CCM.
  • Page 91 iSERIES 100 /200 /300 /400 i. J61-2 for 208-230 VAC ii. J61-3 for 400 VAC iii. J61-4 for 480 VAC Check for proper connection and continuity. b. System Bias may be defective reporting the wrong voltage ID. On the output of the System Bias board at J62 measure relative to TP1 or ( J62-8, 24VDC_RET) to J62-12 for signal /VAC_IDAb and J62-14 for signal /VAC_IDBb.
  • Page 92 iSERIES 100 /200 /300 /400 b. If the fault remained unchanged in step a., on the inverter end put the ribbon cables back in their original positions. Now swap suspect ribbon cables on the CCM. If the fault now changes it’s the ribbon cable. If it remains the same it is the CCM.
  • Page 93 iSERIES 100 /200 /300 /400 • Bad connection at J61 jumper • System Bias board defective • CCM defective. Troubleshooting: 1. If the fault is L239 applying START will clear the fault unless it becomes active again. An occasional prob- lem may be due to incoming voltage swells (voltage increases lasting from ½...
  • Page 94 iSERIES 100 /200 /300 /400 3. It is unlikely that an open connection on the J61 jumper would result in a 240 fault, it is more likely to cause a Voltage Mismatch fault. However, if it’s intermittent at exactly the right time, perhaps not fully plugged in, it possibly could show up as 240.
  • Page 95 iSERIES 100 /200 /300 /400 • Too much current in the main transformer (switching transformer) primary, D32, PRI OC LED (red), on inverter control board. INV_FLT is a differential signal on pins 3(+) & 4(-) of the inverters 30 pin ribbon cable. If there is not a fault you should read 5-6V between the two pins.
  • Page 96 iSERIES 100 /200 /300 /400 1. If room temperature exceeds 40 deg C, cool the room, or operate the unit at reduced duty cycle or lower current. 2. Confirm that air is exhausting from opening in the right side panel. As the fan(s) are behind the radiator it’s hard to see them to confirm they are turning but perhaps you can use an inspection mirror.
  • Page 97 iSERIES 100 /200 /300 /400 b. If D22 is on but 120 VAC is not present at J8-1 and J8-9 (make sure meter is set for ACV) then the relay board is defective. c. D22 is not on, go to the 40 pin ribbon cable test connector and measure voltage on pin 17 (relative to TP1 on either the Relay board or the CCM I/O Board).
  • Page 98 iSERIES 100 /200 /300 /400 Troubleshooting: 1. Check that the fiber-optic cable is fully plugged in to both sockets. Clean the cable ends with a soft cloth and blow out the sockets with air. 2. Check gas control cables. If any of the gas control cables are not connected there will be no communication as there will be no power to the control.
  • Page 99 iSERIES 100 /200 /300 /400 switch. iSeries models also have a flow sensor in series the flow switch that can detect bubbles in the coolant. Upon leaving the radiator, coolant goes into the bottom inverter “cold plate” or liquid cooled heat sink. It flows through the inverters in series and returns to the tank.
  • Page 100 iSERIES 100 /200 /300 /400 If coolant flow is not low but code is being set, possible causes: • Flow switch disconnected or defective. • Relay PCB. • CCM. Troubleshooting: 1. First note whether the fault is an “E” meaning it’s currently low or an “L” meaning it was low but isn’t now. Flow that remains low could indicate a failed component or a blockage such as clogged filter or pinched hose.
  • Page 101 iSERIES 100 /200 /300 /400 1. Check for air blowing out of the unit. Remember, the fans only run when CNC START is applied and for 4 minutes after cutting, you may have to apply start again to restart the 4 minute time. Fans may be forced on by jumping TP2 on the CCM I/O board to TP1 (ground).
  • Page 102 iSERIES 100 /200 /300 /400 system that has been run before it normally takes only a few seconds to establish proper flow. In any case the pump will run for 4 minutes before setting the 404 fault. First determine if the pump motor is running and if so is there any coolant flowing. With the right lower side panel removed touch the pump and feel for vibration to indicate if the motor is running.
  • Page 103 iSERIES 100 /200 /300 /400 a. If the pump motor is not getting 230 VAC, measure for 24 VAC on the coil of MC3. If present and the relay contacts aren’t closed the relay is defective. Note, the coil is rectified so you won’t measure continuity of even a good coil.
  • Page 104 iSERIES 100 /200 /300 /400 In addition to the pressure test or in place of it if you don’t have a gauge, determine if the flow returning from the torch (the flow that passes through the FS1), is greater than the required minimum. With the unit switched off remove the return hose from the back of the power supply.
  • Page 105 iSERIES 100 /200 /300 /400 The 5 Group relates to CANBUS (Fiber optic) communication errors CANBUS Failure to Acknowledge fault. The CCM communicates with the gas controls over a fiber-optic cable using the CANBUS protocol. The CCM is looking for a signal from the gas control over the fiber-optic link. No signal has been detected. Communi- cation with the DPC which is relayed through the GSC sets a different code, 301, if there is a problem with it.
  • Page 106 iSERIES 100 /200 /300 /400 This is a warning, does not shut the system down but is an indication that it probably will shut down soon (502 code). Troubleshooting is same as for 501. Reserved for future use. Should not get this but if it happens may be due to EMI. Contact customer service. Group 6 codes relate to the CCM and program updates.
  • Page 107 iSERIES 100 /200 /300 /400 615-617 No Update File for CCM, DPC or GSC found Program files for the CCM, GSC & DPC may be updated through the plasma supply’s USB port. Program update files are in the format Cx_x_0.S (CCM); Mx_x_0.S (GSC) and Px_x_0.S (DPC). If the Bootloader finds there are 3 devices, CCM, GSC &...

  • Page 108: Appendix 30: He 400 Connection

    iSERIES 100 /200 /300 /400 APPENDIX 30: HE 400 CONNECTION FAN ASSEMBLY FAN1 (6A) 130F Art # A-13083 Revision Date ECO-B2687 8/20/2014 2800 Airport Rd. Denton, Texas 76207 USA Date Printed Date Revised 12/16/2014 11/25/2014 Drawn Date 8/20/2014 The information contained herein is proprietary to Thermal Dynamics. Size Sheet Not for release, reproduction or distribution without written consent.
  • Page 109 iSERIES 100 /200 /300 /400 Manual 0560956456 APPENDIX A-89...
  • Page 110 iSERIES 100 /200 /300 /400 A-90 APPENDIX Manual 0560956456...
  • Page 111 iSERIES 100 /200 /300 /400 This Page Intentionally Blank Manual 0560956456 APPENDIX A-91...

  • Page 112: Appendix 31: Publication History

    iSERIES 100 /200 /300 /400 APPENDIX 31: PUBLICATION HISTORY Cover Date Change(s) June 14, 2016 First issue A-92 APPENDIX Manual 0560956456...
  • Page 113 iSERIES 100 /200 /300 /400 Manual 0560956456 APPENDIX A-93...
  • Page 114 100 /200 /300 /400 Customer // Technical Support (843) 664-4405 (800) ESAB-123 (372-2123) ESAB Welding and Cutting Products PO BOX 100545 Ebenezer Road Florence, SC 29501-0545 http://www.esab.com ESAB Cutting Systems – Canada 6010 Tomken Road Mississauga, Ontario Canada L5T 1X9...

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