ESAB 100i Service Manual 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; On the Control board D24, PWM will only be on when
the inverter is enabled and its brightness varies with the duty cycle of the PWM.
Signals:
General description of some Inverter Signals passed to the CCM that can generate fault codes in Group 2.
"Ready" also called AC IN FLT (D4, READY LED, green, on Main Inverter board)
On the inverter main board we measure the input voltage. The 3 phases are rectified and lightly filtered to
achieve an average voltage. Due to the light filtering a missing phase will also lower the average voltage so it
will be detected. Voltage in the correct range turns on the READY LED D4 (on the far left of the main boards,
in the upper part of the "B" section or lower part of the "A" section). Voltage outside the correct range or miss-
ing phase will turn D4 off.
An AC Input Fault by itself (no other faults occurring at the same time) will set codes in the 241-246 group
depending on which inverter sees the problem.
INV FLT (D1, INV FLT LED, red, on the Inverter Control and Fault board)
Several things can cause Inv Flt (Inverter Fault). Inverter fault is indicated by an LED, D1 on the Inverter Con-
trol and Fault board. Inverter Fault, when it occurs, is latched on. The latch is reset next time the inverter is
enabled unless it is still active in which case it is immediately latched again. Inverter Fault will set the codes
247-252 unless it's in conjunction with another fault in which case that fault code may be set.
Things that can set the inverter fault:
• The local (to the inverter) + 12V & -12V bias supplies out of tolerance. There are LEDs on the Cap/Bias
board that light indicating these bias supplies are present but don't verify they are in tolerance. It's not
likely this would happen. More likely that fault related to the +/-12V the supply would be missing and
it's LED not on.
• Capacitor imbalance. In a cap imbalance condition D3, red Led on the main board (lower left corner of
bottom or "A" section and upper left corner of the upper or "B" section), will latch on.
• Primary over current. This is an over current condition in main switching transformer's primary. This will
latch on but is cleared when the inverter is enabled unless it is still active in which case it is immediately
latched again.
• Inverter over temperature sets the Fault signal and LED but has its own fault signal to the CCM. See OT
Flt below.
OT FLT (D14, OT FLT, Inverter Control and Fault board)
• Inverter over temperature lights LED D14 on the Inverter Control and Fault board and will latch the fault
signal and it's LED but also has its own separate fault so that will be reported as a code in the range of
253-258 or 259-264.
PWR Present
• When power is first applied to the inverter (contactor closed) CCM checks for presence of the +12V bias
on the Inverter Control and Fault board. If not present will set codes in the range of 265-270.
A-64 APPENDIX Manual 0560956456