Appendix 23: System Schematic 200A, 380-415V - ESAB 100i Service Manual

iSERIES 100 /200 /300 /400
APPENDIX 23: System Schematic 200A, 380-415V PG 1
1
A
(1)
(2)
(3)
B
(1)
L1
1
(2)
L2
1
(3)
L3
1
C
Earth
1
CHASSIS GND
380-415
VAC
INPUT
(Customer
supplied
power cord
must pass
through
ferrite core
assembly.)
D
18 AWG wire
CB1
both in and out of
CB1
ON / OFF
16 A (FRONT PANEL)
F1 F2
8A, 500V, SB 8A, 500V, SB
(86A)
(27A)
E (85A)
(86B)
(27B)
(85B)
J63 = Mini-Fit Jr goes to
J12 on T1 primary
400 VAC -- Single 18 AWG
in pins 1 & 12
480 VAC -- Single 18 AWG
in pins 1 & 12
230 VAC -- 18 AWG
wires in pins
F
1, 6, 7, 12
Art # A-13077
1
A-42
2
EMI
(20)
1 FIL- 2
2 TER 1
PCB
IN1 OUT1
(21)
1 2
2 1
IN2
OUT2
(22)
1 2
GND2B
2 1
IN3 OUT3
CHASSIS GND
W1A
EMI
(20)
1 FIL- 2
TER
2 1
W1B
PCB
IN1 OUT1
(21)
1 2
2 1
IN2 W1C
OUT2
(22)
1 2
GND2B
2 1
IN3 OUT3
CHASSIS GND
AC
SUPPRESSION
PCB
(10)
J50
J51
LT1
019X504000
1 1
2 2
3 3
(1)
4 4 LT1 & LT2
(11)
5
INPUT POWER
6 PANEL AC INDICATOR
(12)
NEON INDICATORS
(2) 7
J52
8 Rear Panel & Internal
LT2
9 1
10 2
11 3
12 4
GND
(3) 13 (13)
14
INTERNAL AC INDICATOR
AC LINE
CHASSIS GND
SYSTEM BIAS SUPPLY PCB
J62
019X501900
24 VDC
+24VDC 1
24 VDC
2
MISSING PHASE a
+ V
3
MISSING PHASE b
AC INPUT 4
AC V HIGH a
1 5
AC V HIGH b
2
6
3 AC V LOW a
4 7
24 VDC_RET
5
8
6 24 VDC_RET
7 9
AC V LOW b
8
10
9 GND
VAC_IDA a
10 11
/ VAC_IDA b
11
12
12 VAC_IDB a
13 13
/ VAC_IDB b
14
14
K1A K1B
15
16
17
18
/VAC_IDAb
J60
/VAC_IDBb
J63
J61
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
TO AUX TRANSFORMER
(48)
J61-3 for 400 VAC
VOLTAGE SELECTION
J61-4 for 480 VAC
(44A)
(43A)
System Bias LEDs & Test Points
LEDS
D3, RED, MISSING PHASE
TO J12
D4, RED, AC V HIGH
T1 PRIMARY D14, RED, AC V LOW
D26, GREEN, +12V PRI
(Sht 2, A1)
D30, GREEN, 24VDC
D44, GREEN, T1 ON
2
APPENDIX
3 4
INVERTER 1/2 MODULE (IM) #2 (top)
J105A
L6
1
(7) AC INPUT
2
J104A
(8) 1
2
J103A
(9)
1
2
Toriod Core
019x502000
INVERTER MODULE (IM) #`1 (bottom)
J105B AC INPUT
(7) MAIN PCB LEDS
L5
1
D3, RED, CAP
2
IMBALANCE
J104B
D4, GREEN, READY
(8) 1
2 CAP BIAS PCB LEDS
J103B
D6, GREEN, -12V
(9)
1
D11, GREEN, +12VP
2
D13, GREEN, +12V
Toriod Core
019x502700
J105A
AC INPUT
L4
1
(7)
2
J104A
(8)
1
2
(9) J103A
1
2
Toriod Core
019x502000
Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
CB1 Circuit Breaker /ON/OFF SW, 15A 480V
(Sht 1, E1)
CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
F1, 2 Fuse, 8A, 500V, S.B. (Sht 1,E1)
FAN1,2 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FL1 Flow meter, pulse output (Sht 2, B2)
FS1 Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
HCT1 Current Sensor, Hall E ect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-5 Toriod Core Common Mode Ind (Sht1 B8, B&C3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
To J27 on CCM I/O PCB
(Sht 1, B2 & C2)
(Sht 2, E3) M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
(29)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
(30)
contact (Sht2, A1)
(31)
MC2 Relay, 120 VAC, Fan Control, coil
(32)
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
(33)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(34)
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
(35)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
(36)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
(37)
SA1-3 Snubber, Contactor & Relay coils
(38)
(Sht 2, A8 & A9)
(39)
T1 Aux Transformer (Sht 2, B2)
(40)
TB4 Terminal Block (Sht 1, C9)
(41)
(42) TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
230V 400V 480V ERR
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
0 1 0 1
0 0 1 1
"1" = 24V
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
3 4
5
IM #2 Section A (lower)
IM #1 Section B (upper)
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
IM #1 Section A (lower)
WORK (+)
Manual 0560956456