ESAB Heliarc 283i AC/DC User manual

Service manual
0464 523 010 GB 20160329 Valid for: 283i=S2733450468, 353i=S2733450508
Heliarc283i, Heliarc353i

TABLE OF CONTENTS
0464 523 010 © ESAB AB 2016
READ THIS FIRST................................................................................................ 3
INTRODUCTION................................................................................................... 4
Component positions ..........................................................................................4
FAULT FINDING ................................................................................................... 9
General information .............................................................................................9
Visual inspection................................................................................................10
Not enough power..............................................................................................10
One of the motor fans is not working ..............................................................10
No LEDs lit on the front panel........................................................................... 11
The over temperature LED is blinking ............................................................. 11
Fault indication "CC" when torch trigger is pushed.......................................12
Not possible to adjust current with the encoder.............................................13
Power source in TIG mode does not strike .....................................................15
The solenoid valve does not work....................................................................16
Welding in DC but not in AC .............................................................................16
Fault finding without power supply..................................................................16
Fault finding with power supply .......................................................................17
Fault finding indications....................................................................................19
SERVICE INSTRUCTIONS................................................................................. 20
What is ESD?...................................................................................................... 20
Calibration procedure........................................................................................20
Test EN 60974-4 .................................................................................................. 24
AT COMPLETION ............................................................................................... 26
After repair, inspection and test .......................................................................26
Visual inspection................................................................................................26
Functional test.................................................................................................... 27
Rights reserved to alter specifications without notice.

READ THIS FIRST
0464 523 010 -3- © ESAB AB 2016
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 replacment parts.
Thie service manual is intended for use by technicians with electrical/electronic training or
help in connection with fualt-tracing and repair.
Use the wiring diagram as a form of index for the description of operation.
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.
This manual contains details of design changes that have been made up to and uncluding
October 2013.
The manual is valid for: Heliarc® AC/DC 283i, Heliarc® AC/DC 353i
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 Heliarc283i and Heliarc353i are designed and tested in accordance with international
and European standards IEC/EN60974-1 and IEC/EN60974-10. On completion of service
or repair work, it is the responsibility of the person(s) doing the work to ensure that the
product still complies with the requirements of the above standards.
CAUTION!
Read and understand the instruction manual before
installing or operating.
WARNING!
Personnel working with the equipment must be aware of the fact that high voltage
is present in the equipment. Parts with high voltage are not accessible during
normal operation. If the cover is opened for mainenance or other reason, parts
connected to mains such as connection terminals may be exposed.
WARNING!
High voltage is accumulated in capacitors after power has been switched off.
Always wait at least five minutes after the power is switched off, before starting
any work with the power source.
CAUTION!
Electrostatic discharge (ESD). Sensitive components such as integrated circuits
may be damaged by static electricity.
CAUTION!
Use an approved antistatic wrist strap to avoid damage to sensitive components.
Use the original packaging during transportation and storage of sensitive
components.

INTRODUCTION
0464 523 010 -4- © ESAB AB 2016
INTRODUCTION
Component positions
Item Denomination Note
1 Power switch S1
2 Auxiliary transformer T AUX1
3 Fuse board FUB2
4 Primary inverter PCB10
5 Secondary inverter PCB11
6 Secondary inductance L2
7 AC/DC Converter PCB2
8 Remote control filter board PCB4

INTRODUCTION
0464 523 010 -5- © ESAB AB 2016
Item Denomination Note
1 EMC filter
2 Primary inductance L1
3 Fuse board FUB1
4 Primary inverter PCB1
5 Secondary inverter PCB9
6 Logic board PCB7
7 AC drive board PCB8
8 HF board spark gap PCB5
9 HF transformer PCB3
10 Torch trigger filter board PCB6
11 Gas valve

INTRODUCTION
0464 523 010 -6- © ESAB AB 2016
Front panel
Item Denomination Item Denomination
1 Power source live LED 14 Slope up/down button ( slope up
0.1-10 sec, slope down 0.1-10 sec)
2 Welding enabled LED 15 Encoder knob for current setting and
other settings
3 Over temperature LED 16 HF LED
4 Volt display 17 HF button
5 Ampere display 18 Select mode button
6 AC mode button 19 Remote control button
7 AC mode LED 20 Remote button LED
8 AC frequency setting, 20-200 Hz 21 Mode TIG dual schedule LED
9 AC balance setting, 10-90% 22 Mode TIG spot LED
10 Pulse mode button (0.4-300 Hz DC,
0.4-2 Hz AC)
23 Mode TIG 4 stroke LED
11 Pulse mode LED 24 Mode TIG 2 stroke LED
12 Pre-gas (0.1-2.5 sec) Post-gas
(0.1-30 sec) button
25 Mode Stick LED
13 Base current button (10-90%)
Front connections

INTRODUCTION
0464 523 010 -7- © ESAB AB 2016
Type Connection PIN Description
TIG
YES A Gas
TIG TORCH B Negative
YES D-F Pin
EARTH CLAMP E Positive
Type Connection PIN Description
MMA
NO A Gas
EARTH CLAMP B Negative
POSSIBLE REMOTE F Pin
ELECTRODE E Positive
2 pin connector (D)
PIN Description
Torch trigger
A Torch switch
B Torch switch
14 pin connector (F)
PIN Description
Torch trigger A Torch switch
B Torch switch
Remote control
E Remote control circuit common,
POTLOW
F POTWIPER
G +5 V DC output remote control,
POTHIGH
D +5 V DC output remote control
GND H Chassis common
Cooling unit connection
PIN Description
Power supply
1 Power supply common
2 Power supply 115/230 V AC
3 Power supply 400 V AC
GND 4 Chassis common

INTRODUCTION
0464 523 010 -8- © ESAB AB 2016
Diagram

FAULT FINDING
0464 523 010 -9- © ESAB AB 2016
FAULT FINDING
General information
This chapter lists the most common symptoms and fault indications. Some fault indications
are displayed on the front panel by the LEDs. In case the fault indication descriptions do not
cover a fault condition it is possible to follow the fault finding instructions in section "Fault
finding without power supply" and "Fault finding with power supply".
Safety precautions
WARNING!
Work on high voltage installations must be carried out by authorized personnel
only.
WARNING!
Personnel working with the equipment must be aware of the fact that high voltage
is present in the equipment. Parts with high voltage are not accessible during
normal operation. If the cover is opened for maintence or other reason, parts
connected mains such as connection terminal may be exposed.
WARNING!
High voltage is accumulated in capacitors after power has been switched off.
Always wait at least five minutes after the power is swithced off, before starting
any work with the power source.
CAUTION!
Electrostatic discharge (ESD). Sensitive components such as integrated circuits
may be damaged by static electricty.
CAUTION!
Use an appropriate antistatic wrist strap to avoid damage to sensitive
components. Use the original packaging during transportation and storage of
sensitive components.
Required conditions
Make sure that the necessary safety precautions are done to avoid accidents and injury.
Use an approved ESD equipment to avoid damage to sensitive components.
The accuracy of measuring instruments shall be class 2.5 as a minimum, except for the
measurement of insulation resistance, where the accuracy of the instruments is not specified
but shall be taken in account for the measurment.
The clamp meter shall have an internal resistance of at least 1 Mohm.
Support equipment
• Bit holder
• Torx driver bits (20, 25)
• Hex sockets bits (6,7)
• Adjustable spanner
• A set of shaft spanners (6, 7, 10, 13, 24)
• Nut driver and a set of bits

FAULT FINDING
0464 523 010 - 10 - © ESAB AB 2016
• A socket wrench set
• A pair of pliers
• Crosshead screwdriver (PH2 × 100, PH0 × 75)
• A slotted screwdriver
• Multimeter
• Clamp meter
Visual inspection
Before fault finding the power source, do a visual inspection. Check the power source for
exploded, burnt components or deteriorated wiring. Replace damaged part, component or
deteriorated wiring. If no visible damage is discovered go through the possible symptoms
and solutions listed in this chapter.
Not enough power
Symptom
The power source is working and the display shows the correct current value, but there is not
enough power to weld the material. Measurements with a clamp meter on the return cable
show that the power source deliver half the current value.
1. Turn off the power source and wait for five minutes.
2. Remove the cover of the power source.
3. Disconnect J1 on PCB1.
4. Turn on the power source.
5. Select "Stick mode" on the control panel. Is the voltage approximately 68 V DC on the
welding outlets?
Yes: Replace PCB1.
No: Go to step 6.
6. Turn off the power source and wait for five minutes.
7. Connect the flat cable connector J1 on PCB1 and disconnect the flat cable connector J1
on PCB10.
8. Turn on the power source.
9. Select "Stick mode" on the control panel. Is the voltage approximately 68 V DC on the
welding outlets?
Yes: Replace PCB10.
No: Fault find the power source as described in section "Fault finding without power
supply" and "Fault finding with power supply".
NOTE!
If both the boards PCB1 and PCB10 are down the error message "CC" is shown
on the display.
One of the motor fans is not working
Symptom
The power source is working but one of the motor fans is not working and the duty cycle is
shorter than normal.

FAULT FINDING
0464 523 010 - 11 - © ESAB AB 2016
1. Is the not working motor fan supplied with the correct mains power supply?
Yes: Replace the defective motor fan.
No: Go to step 2.
2. Is there a correct mains power supply on the power switch S1?
Yes: Check the motor fan wiring connection.
No: Go to step 3.
3. Is there a correct mains power supply on the mains power cable?
Yes: Replace the power switch S1.
No: Check the mains power supply.
No LEDs lit on the front panel
Symptom
No LEDs are lit on the front panel when the power source is turned on.
1. Check that the voltages are present on the auxiliary transformer (T AUX 1). Are they
0-24 VAC, 0-9 VAC and 0-18 VAC?
Yes: Replace the logic board PCB7.
NOTE!
It is not necessary to replace the AC drive board PCB8 attached to the logic
board PCB7.
No: Go to step 2.
2. Is there a correct mains power supply to the auxiliary transformer (T AUX 1)?
Yes: Replace the auxiliary transformer (T AUX 1).
No: Go to step 3.
3. Is the fuse (F1) on the rear of the power source damaged or blown?
Yes: Replace the fuse (F1). Value = 100 mA T.
No: Go to step 4.
4. Is there a correct mains power supply at the power switch (S1)?
Yes: Replace the power switch (S1).
No: Check the mains power supply.
The over temperature LED is blinking
Symptom
The over temperature LED is blinking continuosly.
Before any actions are made, check the following:
• Make sure that the power source is not working above the maximum capacity.
• Make sure that the welding conditions and parameters are correct, compare with the data
on the rating plate.

FAULT FINDING
0464 523 010 - 12 - © ESAB AB 2016
1. Check the thermal switches on PCB1, 2, 9, 10 and 11 by measuring their continuity. The
thermal switches are normally closed.
Are the thermal switches ok?
Yes: Try to replace PCB7. If not ok, go to step 2.
No: Replace the defective thermal switch.
2. Select "Stick mode" on the control panel and disconnect the flat cable connector J1 on
PCB1. Is the voltage approximately 68 VDC on the welding outlets?
Yes: Replace PCB1.
No: Go to step 3.
3. Connect the flat cable connector J1 on PCB1. Disconnect the flat cable connector J1 on
PCB10. Is the voltage appproximately 68 VDC on the welding outlets?
Yes: Replace PCB10.
No: Fault find the power source as described in section "Fault finding without power
supply" and "Fault finding with power supply".
Fault indication "CC" when torch trigger is pushed
Symptom
The power source is turned on and all the LEDs are ok. When the operator push the torch
trigger the indication for short circuit "CC" is shown on the display.
1. Turn off the power source and wait for 5 minutes. Disconnect the 2 positive and 2
negative power cables from PCB2.
CAUTION!
Note the positions of the power cables, to prevent mixing them up when
connecting them to PCB2 again.
WARNING!
Isolate the power cables to prevent short circuit between them.
2. Turn on the power source.
Select "Stick mode" on the control panel.
Is the error message "CC" still present on the display?
Yes: Go to step 3.
No: Replace PCB2.
NOTE!
Always replace PCB8 before you replace PCB2.

FAULT FINDING
0464 523 010 - 13 - © ESAB AB 2016
3. Turn off the power source.
Disconnect the mains power supply and wait for five minutes.
a) Measure the diodes on PCB9 and PCB11. Use a multimeter in diode test mode.
Value should be 300 to 400 mV.
Not possible to adjust current with the encoder
Symptom
The power source is turned on and all the LEDs are ok. There is open circuit voltage (OCV)
but it is not possible to adjust the current with the encoder knob.

FAULT FINDING
0464 523 010 - 14 - © ESAB AB 2016
1. Check the PCB7. Measure the values on J1 and J5 test points on PCB7.
J1 test point values
Pin Type Value
1 - GND = circuit common reference
2 input PWAC = reference for driver DC AC board
(+15 V = DC mode - square wave 20-200 Hz AC mode)
3 - GND = circuit common reference
4 - GND = circuit common reference
J5 test point values
Pin Type Value
1 input VOUT = reference signal from Vout
(64 V DC = 75 V DC no load voltage)
2 - GND = circuit common reference
3 output +15 V POT = +15 V DC power for primary inverter pwrn control
4 - GND = circuit common reference
5 input +IARC = common reference from secondary shunt
6 - GND = circuit common reference
7 input - IARC = set reference from secondary shunt (100 A = 30 mV)
8 - GND = circuit common reference
9 output ISET = set reference signal for primary inverter pwrn control
(0.04 V DC = 4 A - 1.9 V DC = 280 A)
10 - GND = circuit common reference
11 output -15 V = -15 V DC reference for primary inverter pwrn control
12 input TMAX = signal from thermal sensors
(0 V = temp. ok - 2.2 V DC = overtemp)
13 output INH = reference signal for primary inverter
( 4 V DC = inverter off -0 V = inverter on)
14 - GND = circuit common reference
Is the problem solved?
Yes: Go to chapter "At completion".
No: Go to step 2.
2. Turn off the power source and wait for five minutes.

FAULT FINDING
0464 523 010 - 15 - © ESAB AB 2016
3. Remove the cover of the power source.
4. Disconnect the flat cable connector J1 on PCB1.Turn on the power source.
5. Turon on the power source and select "Stick mode" on the control panel. Is the voltage
approximately 68 V DC on the welding outlets and is it possible to adjust the current with
the encoder knob.
Yes: Replace PCB1.
No: Go to step 3.
6. Turn off the power source and wait for five minutes.
7. Connect the flat cable connector J1 to PCB1 and disconnect the flat cable connector J1
on PCB10.
8. Turn on the power source and select "Stick mode" on the control panel. Is the voltage
approximately 68 V DC on the welding outlets and is it possible to adjust the current with
the encoder knob?
Yes: Replace PCB10.
No: Fault find the power source as described in section "Fault finding without power
supply" and "Fault finding with power supply".
Power source in TIG mode does not strike
Symptom
The power source is turned on and all the LEDs are ok. The power source does not strike in
TIG mode.
1. Check PCB5. Is there a spark in the gap when the torch trigger is pushed?
Yes: Go to step 2.
No:Got to step 3.
2. Measure the continuity in the torch cable? Is the cable defective?
Yes: Replace the cable.
No: Go to step 3.
3. Check that the voltages are present on the auxiliary transformer (T AUX 1), they should
be 0-24 VAC, 0-9 VAC and 0-18 VAC. Are they present?
Yes: Go to step 4.
No: Go to step 5.
4. Check the input voltage on pin 1 and 2 at PCB5. Is 24 VAC present?
Yes: Replace PCB5.
No: Go to step 5.
5. Check the wiring and connectors between T AUX1 and PCB5. Are they damaged or
defective?
Yes: Replace damaged and defective wiring and connectors.
No: Go to step 6.
6. Is there correct mains power supply on the auxiliary transformer (T AUX 1)?
Yes: Change the auxiliary transformer (T AUX 1).
No: Go to step 7.
7. Is the fuse F1 at the rear of the power source damaged or blown?
Yes: Replace the fuse F1. Value = 100 mA T.
No: Replace PCB7.

FAULT FINDING
0464 523 010 - 16 - © ESAB AB 2016
The solenoid valve does not work
Symptom
The power source is working but the weld is not good and there is poor or no gas flow when
the torch trigger is pressed.
1. Check that the voltages are present on the auxiliary transformer (T AUX 1), they should
be 0-24 VAC, 0-9 VAC and 0-18 VAC. Are they present?
Yes: Go to step 2.
No: Go to step 3.
2. Is the input voltage on the solenoide valve 24 V AC?
Yes: Replace the solenoide valve.
No: Check the wiring and connectors between the solenoide valve and T AUX 1.
3. Is there correct mains power supply present at the auxiliary transformer (T AUX 1)?
Yes: Replace the auxiliary transformer (T AUX 1)
No: Go to step 4.
4. Is the fuse F1 at the rear of the power source damaged or blown?
Yes: Replace the fuse F1. Value = 100 mA T.
No: Replace PCB7.
Welding in DC but not in AC
Symptom
The power source is working, but only in DC mode not in AC.
1. Set the power source in DC mode. Make sure that everything is working normally. Set
the power source in AC mode. Does the power source work in AC mode?
Yes: The power source is working.
No: Replace PCB 2 and PCB 8.
2. Does the fault remain?
Yes: Go to step 3.
No: Go to section "At completion".
3. Measure between point 2 and 3 on connector J1, the value should be +15 VDC and 0
VDC at OCV. Are the values correct?
Yes: Fault find the power source as described in section "Fault finding without power
supply" and "Fault finding with power supply".
No: Replace PCB7.
Fault finding without power supply
To do fault finding without power supply, follow the instructions below.
1. Turn off the power source and wait for five minutes.
2. Remove the cover of the power source.
3. Loosen and remove PCB9 and then PCB1.

FAULT FINDING
0464 523 010 - 17 - © ESAB AB 2016
4. Check the PCB1, the primary power board. Measure on:
a) Inrush current resistor, 370 ohm
b) Primary rectifier, 700 mV DC
c) Freewheel diodes (inverter), 400 mV DC
5. Check the secondary rectifier PCB9. Measure the diode, 300 mV DC.
6. Loosen and remove PCB10 and then PCB11.
7. Check PCB10 in the same way as PCB1.
8. Check PCB11 in the same way as PCB9.
9. Check the AC converter PCB2. Measure the diodes, 400 mV DC.
Fault finding with power supply
To do fault finding with power supply, follow the instructions below.

FAULT FINDING
0464 523 010 - 18 - © ESAB AB 2016
1. Check the voltage over the smothing caps on PCB1 and PCB10.
2. Check that PCB5 is supplied with 24 V DC, it is indicated by the red diode on the board.
3. Turn off the power source and wait for five minutes.
4. Check the spark gap on PCB5 with a feeler gauge. The gap shall be 0.5 - 0.6 mm.

FAULT FINDING
0464 523 010 - 19 - © ESAB AB 2016
Fault finding indications
Description Indication on display
Over temperature
The duty cycle is exceeded.
The over temperature LED is lit and the Volt
display shows "tEm".
Action:
Refer to section "The over tempetature LED
is blinking".
Short circuit
A PCB is short circuited.
The display shows "CC".
Action:
Refer to section "Fault indication "CC" when
torch trigger is pushed".
Trigger alarm
The power source is turned on with the torch
trigger pushed.
The over temperature LED is lit, the Volt
display shows "tri" and the Ampere display
shows "ALA".
Action:
• Turn off the power source completely.
• Make sure that the torch trigger is not
pushed.
• Check if the torch trigger is damaged.
• Turn on the power source again.

SERVICE INSTRUCTIONS
0464 523 010 - 20 - © ESAB AB 2016
SERVICE INSTRUCTIONS
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling
electrostaticsensitive devices.
• Use proper static-proof bags and boxes.
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD stands
for Electrostatic Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components, but is not dangerous to people.
ESD damage occurs when an ungrounded person or object with a static charge comes into
contact with a component or assembly that is grounded. A rapid discharge can occur,
causing damage. This damage can take the form of immediate failure, but it is more likely
that system performance will be affected and the component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static electricity is prevented from building
up on you or on anything at your work station, then there cannot be any static discharges.
Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static
charge, so you should not bring unnecessary nonconductive items into the work area. It is
obviously difficult to avoid all such items, so various means are used to drain off any static
discharge from persons to prevent the risk of ESD damage. This is done by simple devices:
wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only antistatic
packaging materials. Overall, handling of ESD-sensitive devices should be minimized to
prevent damage.
Calibration procedure
Safety precautions
WARNING!
Work on high voltage installations must be carried out by authorized personnel
only.
WARNING!
Personnel working with the equipment must be aware of the fact that high voltage
is present in the equipment. Parts with high voltage are not accessible during
normal operation. If the cover is opened for maintence or other reason, parts
connected mains such as connection terminal may be exposed.