ESAB Renegade EC 1000 Service Manual Download Page 2

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TABLE OF CONTENTS

0463 428 001

READ THIS FIRST

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BEFORE STARTING SERVICE

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Service aid

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INTRODUCTION

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Design structure of the cooling unit

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Component positions

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ERROR CODES

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Error code descriptions

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WIRING DIAGRAM

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Component description

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TECHNICAL DATA

...................................................................................

SOFTWARE UPDATE AND CONFIGURATION

.......................................

TROUBLESHOOTING

..............................................................................

Service log

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Troubleshooting the electrical hardware

...............................................

Measuring the incoming 24 V supply voltage.........................................

Cooling fan .............................................................................................

Water pump ............................................................................................

Switch for ELP........................................................................................

Coolant thermal sensor ..........................................................................

Status indications on the cooler board 5AP1

........................................

LED 3 – Overtemperature condition.......................................................

LED 1 and LED 2 – Software run level...................................................

DISASSEMBLY AND REASSEMBLY

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REPLACEMENT INSTRUCTIONS

...........................................................

Replacing the CAN interface cable

.........................................................

Replacing the water pump

.......................................................................

Replacing the cooling fan

........................................................................

Replacing the heat exchanger

................................................................

Replacing the cooler board

.....................................................................

Replacing the coolant

..............................................................................

SPARE PARTS AND ACCESSORIES

.....................................................

Rights reserved to alter specifications without notice.

Summary of Contents for Renegade EC 1000

Page 1: ...Service manual 0463 428 001 GB 20170519 Valid for serial no 720 xxx xxxx EC 1000 ...

Page 2: ...al hardware 12 Measuring the incoming 24 V supply voltage 12 Cooling fan 13 Water pump 13 Switch for ELP 14 Coolant thermal sensor 15 Status indications on the cooler board 5AP1 16 LED 3 Overtemperature condition 16 LED 1 and LED 2 Software run level 17 DISASSEMBLY AND REASSEMBLY 18 REPLACEMENT INSTRUCTIONS 20 Replacing the CAN interface cable 20 Replacing the water pump 21 Replacing the cooling f...

Page 3: ...PARE PARTS chapter in this manual This manual contains details of design changes that have been made up to and including May 2017 The manual is valid for EC 1000 with serial number 720 xxx 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 EC 1000 is designed and tested in accordance with the stand...

Page 4: ...he 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 x 610 mm 24 24 in A 1 5 metre 3 28 ft long ground cable with a crocodile clip An adjustable wrist strap and cable with an inbuilt protective resistor Antistatic service kit ...

Page 5: ...t through the heat exchanger and onwards in the system The cooling fan is used to cool down the coolant during its way through the heat exchanger A thermal sensor is attached to the heat exchanger The sensor monitors the temperature of the coolant and facilitates control of the cooling unit functionality The ELP is a detection system which checks whether a water cooled TIG torch is connected to th...

Page 6: ...INTRODUCTION 0463 428 001 6 ESAB AB 2017 Component positions 1 Water pump 4 5AP1 cooler board 2 Coolant thermal sensor 5 Water tank 3 Heat exchanger with cooling fan 6 ELP ESAB Logic Pump ...

Page 7: ...xceeded see TECHNICAL DATA page 10 The error code will automatically disappear and the LED indicating temperature fault will be turned off when the coolant temperature has decreased below 55 C 131 F If the coolant temperature is below 55 C 131 F and error code Err 2 is still displayed troubleshoot the thermal sensor see Coolant thermal sensor page 15 Err 8 Cooler hose disconnected The hose for coo...

Page 8: ...capacitors are named such as C1 C99 connectors XS1 XS99 S socket XT1 XT99 T terminal Circuit boards within each module have names such as 20AP1 20AP99 20 module association 1 69 AP circuit board 1 individual identification number 0 99 Transistors within particular modules have identification numbers such as 15Q1 15Q99 15 module association 1 69 Q transistor 1 individual identification number 0 99 ...

Page 9: ...WIRING DIAGRAM 0463 428 001 9 ESAB AB 2017 ...

Page 10: ...rtation temperature 20 C to 55 C 4 F to 131 F Dimensions l w h 540 200 170 mm 21 26 7 874 6 693 in Weight empty 8 kg 17 6 lb Enclosure class IP23 The cooling unit is rated 300 A at 40 duty cycle at 25 C 77 F ambient temperature Duty cycle The duty cycle refers to the time as a percentage of a ten minute period that you can weld or cut at a certain load without overloading The duty cycle is valid f...

Page 11: ...ION 0463 428 001 11 ESAB AB 2017 SOFTWARE UPDATE AND CONFIGURATION For information about software update and configuration of the welding equipment see the SOFTWARE UPDATE AND CONFIGURATION chapter in the power source service manual ...

Page 12: ...it connect the internal CAN cable between the power source and the cooling unit and turn the power source mains supply switch on 3 Measure the incoming 24 V supply voltage from the power source to the cooler board between pins 3 and 2 of connector CN1 on the cooler board 5AP1 The voltage should be 25 2 V If the measurement specification is not met disconnect the CAN cable and measure the output vo...

Page 13: ...he specification given above but the fan is still not running replace the fan see section Replacing the cooling fan page 22 Water pump 1 Connect a TIG torch to the welding power source and to the coolant connectors on the cooling unit 2 Trigger start of welding and wait at least 10 seconds 3 Measure the voltage between pins 1 and 2 of connector CN2 on the cooler board 5AP1 The voltage should be 25...

Page 14: ...r CN4 on the cooler board 5AP1 The voltage should be 25 2 V 2 Connect the coolant hose for the TIG torch to the coolant output connector from the cooling unit blue and measure the voltage between pins 1 and 2 of connector CN4 on the cooler board 5AP1 The voltage should be 0 V If the voltage is still 25 V despite the fact that a TIG torch is connected replace the ELP switch ...

Page 15: ...nector 5XS5 disconnected from CN5 The resistance should vary according to the table below depending on the measured temperature from the thermal sensor If the measurement specification is not met replace the thermal sensor Temperature C Resistance over thermal sensor Ω approx 3 0 16 312 5 12 691 10 9 948 15 7 856 20 6 246 25 5 000 30 4 028 35 3 265 40 2 662 45 2 183 50 1 799 55 1 491 60 1 242 65 1...

Page 16: ...meanings of the different indications are explained in the sub sections below The LEDs not described below are not in use LED 3 Overtemperature condition LED 3 is used to indicate overtemperature condition according to below LED 3 Red 3 Hz flash Overtemperature condition The cooling liquid temperature has exceeded 65 C 149 F The LED will go out when the cooling liquid temperature has decreased bel...

Page 17: ... no supply voltage to the cooler board Green Off Application start up Green fixed Green fixed Application running ok Idle run state as in TIG mode Green 1 Hz flash Green 1 Hz flash Application running ok Interactive run state i e the user may interact with the equipment As in MMA mode Green 3 Hz flash Green 3 Hz flash Application running ok Processing run state Red Green Application error recovera...

Page 18: ...B 2017 DISASSEMBLY AND REASSEMBLY Equipment Screwdrivers Torx T25 and T30 1 Remove the screws holding the cooling unit side panels four screws in the left side panel and four screws in the right side panel Remove the side panels 2 Remove the top panel ...

Page 19: ...left side panel route the internal CAN cable behind the cable bracket in the top panel Tighten the screws using the correct tightening torque according to the illustration below NOTE Make sure the top panel is fitted in the correct direction The yellow arrow on the top panel decal should point towards the front of the cooler i e towards the short side where the coolant connectors are located ...

Page 20: ... and reassembly page 18 Replacing the CAN interface cable 1 Disconnect the interface harness from connectors CN1 CN12 and CN9 on the cooler board 2 Loosen the cable grommet and remove the CAN interface cable 3 Insert the new CAN interface cable through the grommet and connect the harness to the afforementioned connectors 4 Tighten the cable grommet using the correct tightening torque according to ...

Page 21: ...he water pump 3 Remove the four screws holding the front bottom foot of the cooling unit Remove the foot 4 Insert a wrench through the holes in the cooling unit bottom panel and remove the two screws connecting the pump to the pump consol 5 Slide out the pump sideways to the right 6 Insert the new pump and reinstall in the reverse order Tighten the screws and the hose clips using the correct tight...

Page 22: ...r 1 Remove the fan according to section Replacing the cooling fan page 22 2 Loosen the hose clips and disconnect the two coolant hoses connected to the heat exchanger 3 Remove the screw connecting the thermal sensor to the heat exchanger inlet 4 Remove the nut attaching the heat exchanger to the bottom panel 5 Slide the heat exchanger towards the right side of the cooling unit until it is released...

Page 23: ... connection screw using the correct tightening torque according to the illustration Finally fold down the insulation sheet in front of the cooler board 5 Update the welding equipment software with the latest version see the SOFTWARE UPDATE AND CONFIGURATION chapter in the power source service manual Replacing the coolant 1 Flush the cooling system via the red coolant return connection NOTE Flushin...

Page 24: ...ee the spare parts list for the product For accessories see the instruction manual for the product These documents can be downloaded from the Internet www esab com Document type File name Product Note Spare parts list 0463 427 001 EC 1000 Instruction manual 0445 030 EC 1000 Ordering number 0445 045 880 ...

Page 25: ...SPARE PARTS AND ACCESSORIES 0463 428 001 25 ESAB AB 2017 ...

Page 26: ...e Henares MADRID Tel 34 91 878 3600 Fax 34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB International AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB Europe GmbH Baar Tel 41 1 741 25 25 Fax 41 1 740 30 55 UKRAINE ESAB Ukraine LLC Kiev Tel 38 044 501 23 24 Fax 38 044 575 21 88 North and South America ARGENTINA CONARCO Buenos Aires Tel...

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