ESAB ES 150i User manual

Service manual
0463 714 001 GB 20201008
Valid for: Serial No. HA017-, HA018-, HA019-, HA020-, HA026-,
HA027-xxxx-xxxx
ES150i, ES180i,
ES180iPro,ES200iPro,
ET180i, ET 200iP, ET 200iP Pro

TABLE OF CONTENTS
0463 714 001 © ESAB AB 2020
READ THIS FIRST.................................................................................... 4
BEFORE STARTING SERVICE ............................................................... 6
Service aid .............................................................................................. 6
ESAB tools.............................................................................................. 6
Recommended measuring devices ...................................................... 6
INTRODUCTION....................................................................................... 7
Design structure of the power source.................................................. 7
Welding equipment ................................................................................ 8
Installation of MMA................................................................................. 12
ERROR CODES/ERROR DESCRIPTIONS IN THE SERVICE LOG ....... 15
Error code descriptions and service technician actions.................... 15
WIRING DIAGRAM................................................................................... 16
ES 150i, ES 180i...................................................................................... 18
ES 180i Pro, ES 200i Pro........................................................................ 19
ET 180i..................................................................................................... 21
ET 200iP .................................................................................................. 22
ET 200iP Pro ........................................................................................... 23
Components description ....................................................................... 24
ES 150i, ES 180i .................................................................................. 24
ES 180i Pro, ES 200i Pro ..................................................................... 28
ET 180i, ET 200iP, ET 200iP PRO ....................................................... 33
TECHNICAL DATA ................................................................................... 34
ES 150i, ES 180i...................................................................................... 34
ES 180i Pro, ES 200i Pro........................................................................ 35
ET 180i..................................................................................................... 37
ET 200iP .................................................................................................. 39
ET 200iP Pro ........................................................................................... 40
PANEL OPERATION INSTRUCTIONS .................................................... 42
Power source output high current regulation ..................................... 42
Hidden functions .................................................................................... 42
VRD ON and OFF.................................................................................... 43
TROUBLESHOOTING.............................................................................. 44
Fault tracing............................................................................................ 44
Visual Inspection.................................................................................... 44
Components testing............................................................................... 44
Restoring the power source after pre power up checks .................... 46
Power up checks .................................................................................... 46
Advanced measurements...................................................................... 52
IN-SERVICE INSPECTION AND TESTING.............................................. 55
General requirements ............................................................................ 55

TABLE OF CONTENTS
0463 714 001 © ESAB AB 2020
Periodic inspection and test.................................................................. 55
Cleaning instruction............................................................................... 55
After repair, inspection and test ........................................................... 56
Visual inspection.................................................................................... 57
Electrical test .......................................................................................... 58
Functional test........................................................................................ 59
Test report............................................................................................... 60
SPARE PARTS AND ACCESSORIES ..................................................... 62
Rights reserved to alter specifications without notice.

READ THIS FIRST
0463 714 001 -4- © ESAB AB 2020
READ THIS FIRST
Maintenance and repair work must be performed by an experienced person, and electrical
work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit boards
are divided into numbered blocks, which are described individually in more detail in the
description of operation. Component names in the wiring diagram are listed in the
component description.
Use the spare parts list as a guide to where the components are located in the equipment.
The spare parts list is published as a separate document, see the "SPARE PARTS AND
ACCESSORIES" chapter in this manual.
This manual contains details of design changes that have been made up to and including
January 2020.
Product Valid from serial
number
The manual is valid for:
ES 150i, Europe HA017-xxxx-xxxx
ES 180i, Europe HA018-xxxx-xxxx
ES 180i Pro, Europe HA019-xxxx-xxxx
ES 200i Pro, Europe HA020-xxxx-xxxx
ES 200i Pro, Middle East HA020-xxxx-xxxx
ES 200i Pro, India HA020-xxxx-xxxx
ES 200i Pro, SEA HA020-xxxx-xxxx
ET 180iP, Europe HA026-xxxx-xxxx
ET 200iP, India HA027-xxxx-xxxx
ET 200iP Pro, Europe HA027-xxxx-xxxx
ET 200iP Pro, Middle East HA027-xxxx-xxxx
ET 200iP Pro, India HA027-xxxx-xxxx
ET 200iP Pro, South East Asia HA027-xxxx-xxxx
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for safety and
function, of the specific set-up, lies with the integrator.
The "ES 150i", "ES 180i", "ES 180i Pro", "ES 200i Pro", "ET 180iP", "ET 200iP" and
"ET200iPPro" are designed and tested in accordance with the standards stated in the
instruction manual. On completion of service or repair work, it is the responsibility of the
person(s) performing the work to ensure that the product still complies with the requirements
of the involved standards.
CAUTION!
Read and understand the instruction manual before
installing or operating.

READ THIS FIRST
0463 714 001 -5- © ESAB AB 2020
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.

BEFORE STARTING SERVICE
0463 714 001 -6- © ESAB AB 2020
BEFORE STARTING SERVICE
NOTE!
Follow the instructions in chapter "IN-SERVICE INSPECTION AND TESTING",
page55 when performing service work on the equipment!
Service aid
ESAB can offer a number of service tools that will simplify the service.
Antistatic service kit
Ordering no. 0740 511 001
The kit makes it easier to protect sensitive
components from electrostatic discharge.
Contents:
• A conductive mat (size 610×610mm /
24×24in.)
• A 1.5m (3.28ft) long ground cable with
a crocodile clip
• An adjustable wrist strap and cable with
a built-in protective resistor
ESAB tools
Tool Ordering number
ESAB test box TB1 0460 868 880
Checkmaster 9000
Checkmaster 9000 DC
Or resistive load with equal performance
Recommended measuring devices
• For safety test: Fluke 1503, Fluke 1507, Fluke 1577 and Fluke 1587.
• For measurements: Fluke 175, Fluke 177 and Fluke 179.

INTRODUCTION
0463 714 001 -7- © ESAB AB 2020
INTRODUCTION
The "ES 150i", "ES 180i", "ES 180i Pro" and "ES 200i Pro" are an inverter-based power
sources intended for MMA (Manual Metal Arc) and TIG (Tungsten Inert Gas) welding.
The "ET 180i", "ET 200iP" and "ET 200iP Pro" are an inverter-based power sources
intended for MMA (Manual Metal Arc), TIG (Tungsten Inert Gas) welding and HF TIG (High
Frequency Tungsten Inert Gas) welding.
Design structure of the power source
The "ES 150i", "ES 180i", "ES 180i Pro", "ES 200i Pro", "ET 180i", "ET 200iP" and
"ET200iPPro" power sources are transistor-controlled, operating on the inverter principle. It
consists of a number of function modules. Each module has a module number, which is
always included as the first part of the name/identification of components in the module. The
modules have the following main functions:
The modules have the following main functions:
Setting panel module
The main function is for the user to define welding process settings.
Input module
The main function is to convert power mains input voltage to stable voltage free from
conducted disturbances as required by the EMC directive.
TIG module (valid for ET 180iP, ET 200iP Pro)
The main function of the TIG module is to produce high voltage, high frequency pulses, thus
enabling non-contact ignition of the electric welding arc.
Primary module
The main function is a full bridge inverter operating at a switching frequency of 97kHz. IGBT
transistors are used as switching elements.
Transformer module
The main function is to transform high voltage / low current to high current / low voltage.
Output inductor module
The main function is to supply the welding current. The module contains an inductor and a
current sensor.
Control module
This is the master of the system. The module handles the system status. It is a hub for
events/errors occurring in the system, and it collects meta-data on other boards in the
system.
Secondary module
The main function is to supply the welding current. This module contains an additional board
for increasing the output voltage at low currents, to enable higher welding performance for
cellulosic electrodes.

INTRODUCTION
0463 714 001 -8- © ESAB AB 2020
Welding equipment
ES 150i, ES180i
1. Current display 6. VRD indicator
2. Positive probe 7. Thermal protection indicator
3. Negative probe 8. Current adjusting knob
4. Power cable 9. Welding selection mode button
5. Power switch 10. Plastic front panel

INTRODUCTION
0463 714 001 -9- © ESAB AB 2020
ES 180i Pro, ES 200i Pro
1. Current display 7. Thermal protection indicator
2. Positive output 8. Current adjusting knob
3. Negative output 9. Welding mode selection button
4. Power cable 10. Plastic front panel
5. Power switch 11. Aviation socket harness
6. VRD indicator
ES 150i, ES 180i, ES 180i Pro, ES 200i Pro
1. Handle 3. Rogue label
2. Left side panel

INTRODUCTION
0463 714 001 - 10 - © ESAB AB 2020
1. Warning label 3. ESAB label
2. Left side panel
1. Rating plate 2. Bottom panel

INTRODUCTION
0463 714 001 - 11 - © ESAB AB 2020
Rating plates: ES 150i, ES 180i
Rating plates: ES 180i Pro, ES 200i Pro

INTRODUCTION
0463 714 001 - 12 - © ESAB AB 2020
Installation of MMA
Connection between Welder and Power Source
• ES 150i, ES 180i output voltage is 220-240VAC,50/60 Hz
• ES 180i Pro, ES 200i Pro output voltage is 90-260VAC,50/60 Hz
Installation of optional TIG torch
1. Remove the ground cable and the electrode holder from the weld output connections.
Install the ground cable to the positive(+) weld output connection.
2. Secure the ground clamp to the work piece.
3. Connect a regulator to a bottle of ARGON gas. Then connect the gas connection from
the TIG torch to the regulator.
4. Connect the TIG torch weld cable to the Negative(-) weld output connection
5. Set desired amperage on the amperage control knob on the front panel of the welder.
6. Turn on the input power switch on the welder.

INTRODUCTION
0463 714 001 - 13 - © ESAB AB 2020
Schematic diagram ES 150i, ES 180i
Schematic diagram ES 180i Pro, ES 200i Pro
Parts Functions
START PROTECTION
CONTROL
To avoid equipment breakdown, the power source
measures the mains voltage when the power switch is
turned ON. To protect the power source, check that the
mains voltage is correct according to the rating (230 VAC)
before switching on the PFC.
RECTIFY AND FILTER Transfer the power from AC into DC.

INTRODUCTION
0463 714 001 - 14 - © ESAB AB 2020
Parts Functions
INVERTER Increases the frequency (97 kHz) and transfer the power
from DC into AC.
DECREASE VOLTAGE Changes the high voltage into lower to get high energy.
SECOND TIME RECTIFY Transfer the power from AC into DC.
CONTROL CIRCUIT Estimates the PWM signal and controls the entire process.
DRIVING CIRCUIT Controls the switch for inverter circuit.
AUXILIARY POWER SUPPLY Supply power for CONTROL CIRCUIT and DRIVING
CIRCUIT.
FEEDBACK CIRCUIT Gets sampling from the output, sends feedback to
CONTROL CIRCUIT.
PFC Power factor correction.

ERROR CODES/ERROR DESCRIPTIONS IN THE SERVICE LOG
0463 714 001 - 15 - © ESAB AB 2020
ERROR CODES/ERROR DESCRIPTIONS IN THE SERVICE LOG
The error code is used to indicate that a fault has occurred in the equipment. Errors are
indicated by the text "Err" and the error code number flashing alternately in the power source
display.
Error code descriptions and service technician actions
Suggested service technician actions for error codes are described in the sub-sections
below. Measurement points and connectors on the circuit boards, referred to in the text are to
be found in section "TROUBLESHOOTING", page44
 E01  Thermal protection
1. Turn off the mains power supply to reset the unit.
2. If the error persists, take actions according to Troubleshooting procedures.

WIRING DIAGRAM
0463 714 001 - 16 - © ESAB AB 2020
WIRING DIAGRAM
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
The power source consists of a number of function modules. The circuit board and
component names and the wire numbers in the wiring diagram, show to which module each
board/component/wire belongs. The function modules, circuit boards and components are
listed in the component description below.
Input rectifier and Filter circuit
Primary rectifier Converts AC to DC.
Electrolytic capacitor Smooths the DC voltage.
Inverter circuit
IGBT Converts low frequency DC to
48kHz high frequency AC.
Main transformer Converts HF high voltage to HF
low voltage power.

WIRING DIAGRAM
0463 714 001 - 17 - © ESAB AB 2020
Secondary rectifier
Secondary diode (FRD) Converts HF AC to HF DC
power.
NOTE!
IGBT and FRD look very similar. Read the descriptions carefully before you do
repair to make sure you do not use the wrong part.

WIRING DIAGRAM
0463 714 001 - 18 - © ESAB AB 2020
ES 150i, ES 180i
Valid from serial number: HA017-xxxx-xxxx, HA018-xxxx-xxxx

WIRING DIAGRAM
0463 714 001 - 19 - © ESAB AB 2020
ES 180i Pro, ES 200i Pro
Valid from serial number: HA019-xxxx-xxxx, HA020-xxxx-xxxx

WIRING DIAGRAM
0463 714 001 - 20 - © ESAB AB 2020
Valid from serial number: HA019-xxxx-xxxx, HA020-xxxx-xxxx