Appendix 4: System Schematic 100A, 380-415V Pg 1 - ESAB 100i Instruction Manual

100i / 200i / 300i / 400i

APPENDIX 4: System Schematic 100A, 380-415V PG 1

1
A
L1
1
B
L2
1
L3
1
Earth
1
CHASSIS GND
C
18 AWG wire
both in and out of
CB1
(1-20)
D
(2-21)
CB1
(3-22)
ON / OFF
16 A
F2
F1
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-11972_AD
1
A-12
2
W1A
( ) 1 2 ( ) 3 (23)
W1B
(2) (24) (24)
(3) (25) (25)
W1C
(23)
(24)
(25)
AC
SUPPRESSION
PCB
(10)
J50
J51
LT1
019X504000
1 1
2 2
(1) 3 3
4 4
(11)
5
6 PANEL AC INDICATOR
(12)
(2) 7
J52
8
LT2
9 1
10 2
11 3
12 4
GND
(3) 13 (13)
14
INTERNAL AC INDICATOR
AC LINE
LT1 & LT2
INPUT POWER
CHASSIS GND
NEON INDICATORS
Rear Panel & Internal
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 /VAC_IDAb
/VAC_IDBb
18
J60
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V
J63
J61
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
TO AUX TRANSFORMER
J61-3 for 400 VAC
(48)
J61-4 for 480 VAC
(44A) System Bias LEDs & Test Points
(43A)
LEDS TEST POINTS
D3, RED, MISSING PHASE TP1 SECONDARY GND
D4, RED, AC V HIGH TP2 24VDC
TO J12
D14, RED, AC V LOW TP3 DC INPUT POSITIVE
T1 PRIMARY
D26, GREEN, +12V PRI TP4 VCC1
(Sht 2, A1)
D30, GREEN, 24VDC TP5 VCC2
D44, GREEN, T1 ON TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
2
APPENDIX
3 4
INVERTER MODULE (IM) #1
J105B
IM #1 Section B (upper)
AC INPUT
1
2
J104B
MAIN PCB LEDS CAP BIAS PCB LEDS
1
D3, RED, CAP D6, GREEN, -12V
2
IMBALANCE D11, GREEN, +12VP
J103B
D4, GREEN, READY D13, GREEN, +12V
1
2
019X502700
AC INPUT
J105A
1
2
J104A
1
2
J103A
1
2
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 Effect 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
(Sht 1, B2 & C2)
To J27 on CCM I/O PCB
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, E3) (Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
(29)
MC2 Relay, 120 VAC, Fan Control, coil
(30)
(31) (Coil at Sht 2, A7)(Contacts at Sht 2, D1)
(32)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(33)
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
(34)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
(35)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
(36)
SA1-3 Snubber, Contactor & Relay coils
(37)
(Sht 2, A8 & A9)
(38)
T1 Aux Transformer (Sht 2, B2)
(39)
TB4 Terminal Block (Sht 1, C9)
(40)
TS1 Temperature Sensor, NTC, Coolant Return
(41)
(Sht 2, A5)
(42)
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
3 4
5
J100 -- 30 CKT RIBBON
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
IM #1 Section A (lower)
J100 -- 30 CKT RIBBON
Manual PN: 0560956430