2 Esab Warrior 400 I 500 I

Warrior™ 400i CC/CV
Warrior™ 500i CC/CV
Service manual
0740 800 221 GB 20150602 Valid for: Serial no. 339-xxx-xxxx, 405-xxx-xxxx
TABLE OF CONTENTS
READ THIS FIRST................................................................................................ 4
INTRODUCTION ................................................................................................... 5
Design structure of the power source ...............................................................5
Working principle ................................................................................................. 5
TECHNICAL DATA ............................................................................................... 7
WIRING DIAGRAM ............................................................................................... 9

Component description..................................................................................... 10
Warrior 400i/500i CC/CV .................................................................................... 12
Warrior component positions ...........................................................................14
DESCRIPTION OF OPERATION........................................................................ 17
Warrior internal voltage map............................................................................. 17
1AP1 MMC board................................................................................................ 18
1AP1:1 Power supply....................................................................................... 18
1AP1:2 Display and LEDs................................................................................ 19
1AP1:3 Encoder ............................................................................................... 19
1AP1:4 Selectors ............................................................................................. 20
1AP1 Component positions.............................................................................. 21
2AP1 Mains filter board ..................................................................................... 22
2AP1 Component positions.............................................................................. 23
15AP1 Power board ........................................................................................... 23
15AP1:1 Power supply..................................................................................... 24
15AP1:2 DC bus and precharge circuit............................................................ 26
15AP1:3 IGBT drives ....................................................................................... 27
15AP1:4 Primary current.................................................................................. 28
15AP1:5 DC bus voltage monitoring ................................................................ 29
15AP1:6 Temperature monitoring .................................................................... 30
15AP1:7 Torch.................................................................................................. 30
15AP1:8 Fan and cooler .................................................................................. 31
15AP1 Component positions............................................................................ 32
15AP2 Capacitor board...................................................................................... 33
20AP1 Control board ......................................................................................... 34
20AP1:1 Power supply..................................................................................... 34
20AP1:2 DC bus monitoring............................................................................. 37
20AP1:3 Primary current.................................................................................. 37
20AP1:4 Secondary current ............................................................................. 38
20AP1:5 Arc voltage ........................................................................................ 39
20AP1:6 Current regulator ............................................................................... 40
20AP1:7 PWM circuit ....................................................................................... 41
20AP1:8 Gate drives ........................................................................................ 42
20AP1:9 Digital inputs/outputs ......................................................................... 43
20AP1:10 Remote interface ............................................................................. 43
0740 800 221 © ESAB AB 2015

TABLE OF CONTENTS
20AP1:11 Wire feeder interface ....................................................................... 44

20AP1:12 MMC interface ................................................................................. 45
20AP1:13 Processor and miscellaneous circuits ............................................. 46
FAULT INDICATIONS ......................................................................................... 48

Fault descriptions .............................................................................................. 48
SERVICE INSTRUCTIONS................................................................................. 50
What is ESD?...................................................................................................... 50
Service aid .......................................................................................................... 50
Special tools ....................................................................................................... 51
Mounting components on the heat sink ..........................................................51
Tightening torque for screw joints on power components............................52
Power On/Off sequence..................................................................................... 54
Checking the IGBT transistor modules............................................................55
Measurement with the IGBT modules connected to the power
board ............................................................................................................ 56
Measurement with the IGBT modules disconnected from the power
board ............................................................................................................ 57
Checking the precharge power resistors R4, R5 ............................................57
Checking the primary rectifier bridge ..............................................................58
Checking the secondary rectifier diodes.........................................................59
Soft start ............................................................................................................. 60
AC power supply – preparations before soft starting ....................................... 60
DC power supply – preparations before soft starting ....................................... 61
Checking the IGBT gate pulses ....................................................................... 63
Checking the main transformer primary voltage .............................................. 64
Checking the welding outlet voltage................................................................. 64
Restoring the power source after soft starting ................................................. 64
Calibrating the arc voltage ................................................................................ 65
Calibrating the welding current ........................................................................66
IN-SERVICE INSPECTION AND TESTING........................................................ 67

General requirements ........................................................................................ 67
Periodic inspection and test ............................................................................. 67
Cleaning instruction .......................................................................................... 67
After repair, inspection and test .......................................................................68
Visual inspection................................................................................................ 69
Electrical test...................................................................................................... 70
Functional test.................................................................................................... 73
Test report........................................................................................................... 74
SPARE PARTS AND ACCESSORIES ............................................................... 75

Rights reserved to alter specifications without notice.
0740 800 221 © ESAB AB 2015

READ THIS FIRST
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
December 2012.
The manual is valid for: Warrior 500i CC/CV, 380 - 460 V 0465 350 880
Warrior 500i CC/CV, 460 V 0465 350 881
Warrior 400i CC/CV, 380 - 460 V 0465 350 882
Warrior 500i CC/CV, 575 V 0465 350 887
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 Warrior 400i CC/CV and Warrior 500i CC/CV (460VAC versions) are designed and
tested in accordance with international standard IEC 60974-1. 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 above standard.
The Warrior 500i CC/CV (575VAC version) is designed and tested in accordance with
international standard IEC 60974-1, Canadian standards CAN/CSA-E60974-1:11 and
US standards ANSI/IEC 60974-1:2008. 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 above standards.
CAUTION!
Read and understand the instruction manual before
installing or operating.
0740 800 221 -4- © ESAB AB 2015

INTRODUCTION
INTRODUCTION
Design structure of the power source

The Warrior power source is 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:
1 MMC module
The MMC board including two three-digit displays, and two LEDs. Attached to the MMC
board are two selector switches, one potentiometer and one encoder.
2 Mains module
Mains filter board, mains switch, auxiliary transformer
15 Power module
Power board including primary rectifier and IGBT transistor modules. Capacitor board, main
transformer, secondary inductor, secondary diode modules.
20 Control module
The control board, with a microprocessor, that monitors and controls the welding process.
Working principle
The mains input voltage range is three-phase 380±10% VAC to 460±10% VAC at rated load
(for 460VAC version).
The mains input voltage range is three-phase 380±10% VAC to 575±10% VAC at rated load
(for 575VAC version).
The auxiliary transformer 2T1 has multiple primary connections and has to be correctly
connected depending on the mains voltage.
The primary rectifier creates the DC bus voltage by rectifying the input AC voltage.
The primary inverter of the Warrior power source is a 4-transistor IGBT fullbridge, operating
at a switching frequency of 22 kHz. All power semiconductors are built into modules.
The primary inverter output is connected to a main transformer with a 7:1 turns ratio (for
460VAC version) or a 9:1 turns ratio (for 575VAC version).
The main transformer output is connected to a secondary rectifier which contains four diode
modules.
The Warrior power source is rated 400A/36VDC or 500A/40VDC at 60% duty cycle.
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INTRODUCTION
Block diagram of the Warrior 400i/500i CC/CV power sources
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TECHNICAL DATA
TECHNICAL DATA
Warrior 400i CC/CV Warrior 500i CC/CV Warrior 500i CC/CV
460 VAC version 460 VAC version 575 VAC version
Mains voltage 380–460 VAC ±10% 380–460 VAC ±10% 380–575 VAC ±10%
3~ 50/60 Hz 3~ 50/60 Hz 3~ 50/60 Hz
Primary current
Imax MIG/MAG 27 A 37 A 38 A
Imax TIG 23 A 30 A 31 A
Imax MMA 29 A 38 A 38 A
No-load power in 30 W 30 W 40 W
energy-saving mode,
6.5 min. after welding
Setting range
MIG/MAG 16A/15V - 400A/34V 16A/15V - 500A/39V 16A/15V - 500A/39V
TIG 5A/10V - 400A/26V 5A/10V - 500A/30V 5A/10V - 500A/30V
MMA 16A/20V - 400A/36V 16A/20V - 500A/40V 16A/20V - 500A/40V
Permissible load at MIG/MAG
60 % duty cycle 400 A / 34 V 500 A / 39 V 500 A / 39 V
Permissible load at TIG
Permissible load at MMA
Power factor at maximum current
MIG/MAG 0.84 0.88 0.87
TIG 0.75 0.85 0.83
MMA 0.82 0.88 0.87
Efficiency at maximum current
MIG/MAG 91 % 90 % 90 %
TIG 88 % 87 % 88 %
MMA 91 % 91 % 90 %
Electrode types Basic Basic Basic
Rutile Rutile Rutile
Cellulosic Cellulosic Cellulosic
Open-circuit voltage
without VRD function 71 VDC 71 VDC 84 VDC
Operating temperature -10 to +40°C -10 to +40°C -10 to +40°C
Transportation -20 to +55°C -20 to +55°C -20 to +55°C
temperature
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TECHNICAL DATA
Warrior 400i CC/CV Warrior 500i CC/CV Warrior 500i CC/CV

460 VAC version 460 VAC version 575 VAC version
Constant sound <70 db (A) <70 db (A) <70 db (A)
pressure when idling
Dimensions l × w × h 712 × 325 × 470 mm 712 × 325 × 470 mm 712 × 325 × 470 mm
Weight 52.5 kg 52.5 kg 52.5 kg
Insulation class H H H
Enclosure class IP 23 IP 23 IP 23
Application class
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 for 40°C / 104°F.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
0740 800 221 -8- © ESAB AB 2015

WIRING DIAGRAM
WIRING DIAGRAM
The power source consists of a number of function modules, which are described in the
component descriptions on the following pages. Wire numbers and component names in the
wiring diagrams show to which module each component belongs.
Wires/cables within modules are marked 100 - 6999.
Wires/cables between modules are marked 7000 - 7999.
Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors
XS1 - XS99 (S = socket), XP1 - XP99 (P = plug), 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
0740 800 221 -9- © ESAB AB 2015

WIRING DIAGRAM
Component description
Component Description
1 MMC module. Wire numbers 100-199.
1AP1 Display board
1G1 Encoder
1R1 Potentiometer 10kΩ (inductance/arc force selection)
1S1 Switch selector, three positions (electrode type)
1S3 Switch selector, five positions (process type)
2 Mains module. Wire numbers 200-299.
2AP1 Mains filter board
2QF1 Mains switch
2T1 Auxiliary transformer, with multiple input windings
Input voltage windings:
• 380V
• 400V
• 415V
• 440V
• 460V
• 575V (only for 575V version)
Output voltages:
• 20V (primary)
• 40V (secondary)
• 42V (secondary)
15 Power module. Wire numbers 1500-1699.
15AP1 Power board
15AP2 Capacitor board
15BR1 Primary rectifier bridge, 3 phase
15C1 Capacitor 0.1µF
15CS1 Secondary current sensor, 1:2000
15EV1 Fan, 24VDC
15FU1 Automatic fuse 10A
15L1 Secondary inductor
15L2-15L9 Ferrite ring cores
15PM1, 15PM2 IGBT power transistor modules. Each module consists of two
transistors and two freewheel diodes.
15PM3, 15PM4, 15PM5, Secondary rectifier diode modules. Each module consists of two
15PM6 diodes.
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WIRING DIAGRAM
Component Description
15ST2 Temperature switch, on the primary heatsink
15ST3 Temperature switch, on the secondary heatsink
15T1 Main transformer
• 7:1 turns ratio (for 460VAC version)
• 9:1 turns ratio (for 575VAC version)
20 Control module. Wire numbers 2000-2099
20AP1 Control board
XS.. Socket (sleeve)
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling
electrostaticsensitive devices.
• Use proper static-proof bags and boxes.
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WIRING DIAGRAM
Warrior 400i/500i CC/CV
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WIRING DIAGRAM
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WIRING DIAGRAM
Warrior component positions
Left view
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WIRING DIAGRAM
Right view
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WIRING DIAGRAM
Right view, power modules
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DESCRIPTION OF OPERATION
This section describes the function of circuit boards and other components in the equipment.
It is divided into sections, numbered to correspond to the circuit board numbers and divisions
into function blocks.
Warrior internal voltage map
Principle diagram of the Warrior 400i/500i CC/CV internal power supplies
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1AP1 MMC board

The user interface contains a circuit board with two three-digit LED displays and two LEDs.
Two selector switches, one potentiometer and one encoder are connected to the MMC
board.
1AP1:1 Power supply
The MMC board is supplied at 24VDC and 15VDC from the control board 20AP1. An
illuminated LED D4 indicates that +5V is OK.
+24V (±0.1V ) is converted to +5V by the switching circuit IC5, D5, L1.
+15V (±0.5V) supplies the selector switches 1S1 and 1S3, the potentiometer 1R1 and the
encoder 1G1.
+5V (4.6±0.2V ) supplies the displays, the LEDs and the logic circuitry. The actual voltage is
not really 5V but 4.6V.
0740 800 221 - 18 - © ESAB AB 2015

1AP1:2 Display and LEDs
The displays and LEDs are controlled by the LED drivers IC1-IC3. The data to the LED
drivers is received from the control board 20AP1 over a three-line serial bus through the IC4
buffer circuits. The normal data speed is about 1kHz.
An illuminated LED D8 indicates a thermal error, which means that one or both of the
temperature switches 15ST2-15ST3 have tripped. An illuminated LED D9 indicates that
VRD is active.
The three-digit display DY1-DY3 shows the arc voltage The three-digit display DY4-DY6
shows the welding current.
NOTE!
The decimal points of displays DY3 and DY6 are not connected.
At power on, all the display segments (except for DY3 and DY6 dots) and the LEDs are
illuminated for about one second, to indicate correct function.
1AP1:3 Encoder
The panel encoder 1G1 generates two square wave pulse trains when turned. Square
wave A is 90° phase shifted relative to square wave B. This phase shift is necessary for the
processor to determine in which direction the encoder is being turned.
0740 800 221 - 19 - © ESAB AB 2015

1AP1:4 Selectors
Potentiometer 1R1 steplessly sets either the inductance or the arc force, depending on the
chosen welding process.
Selector switch 1S1 chooses the electrode type in three steps through the voltage divider
R39-R42.
Selector switch 1S3 chooses the type of welding process in five steps through the voltage
divider R29-R34.
The values set by 1R1,1S1,1S3 are inputs to the control board 20AP1.
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1AP1 Component positions
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2AP1 Mains filter board
WARNING!
There is always mains voltage connected to the mains filter board. Before
replacing the mains filter board, disconnect the power source from the mains
and make sure the mains filter capacitors are discharged. The mains filter
capacitor discharge time is 1 second.
Also make sure that the DC bus capacitors on the power board are discharged.
The DC bus capacitor discharge time is at least 2 minutes!
The mains filter suppresses incoming electromagnetic interference which can disturb the
welding process and damage circuit boards and other components in the power source.
The mains filter also suppresses electromagnetic interference from the welding process
which otherwise might disturb or damage sensitive equipment connected to the same mains
supply as the power source.
The varistors R1–R3 protect the power source against sudden voltage peaks.
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15AP1 Power board
WARNING!
Dangerous voltage – the power board is at mains and DC bus voltage.
Depending on the mains voltage, the DC bus voltage can be 650 VDC.
DC- (GND_HV) is connected to the mains.
WARNING!
Never make any measurements on this board when the power source is
connected to the mains supply.
Wait until the DC bus capacitors are discharged. The DC bus capacitor
discharge time is at least 2 minutes!
0740 800 221 - 23 - © ESAB AB 2015

15AP1:1 Power supply

Auxiliary transformer
The Power board 15AP1 is voltage supplied from three galvanically separated windings of
the auxiliary transformer 2T1.
The transformer circuit is protected by the fuse S3.
The primary side of the transformer 2T1 is connected to the mains voltage, phases L1 and
L3, through the fuse S3 and the flat pin connector CN36.
A cable must be connected between the flat pin connector CN36 and one of the flat pin
connectors CN23–CN28. Which one of CN23–CN28 should be connected depends on the
mains voltage:
• CN23 if 380VAC
• CN24 if 400VAC
• CN25 if 415VAC
• CN26 if 440VAC
• CN27 if 460VAC
• CN28 if 575VAC (only on 575V version of Warrior power source)
CAUTION!
Make sure the cable is connected to the correct flat pin connector CN23–CN28.
If the cable is incorrectly connected, it might cause serious damage to the power
source.
0740 800 221 - 24 - © ESAB AB 2015

20VAC
The 20VAC winding of the auxiliary transformer 2T1 is rectified to 24VDC and converted to
15VDC by voltage regulator VR20.
The 20VAC circuit is protected by the fuse S1.
+24V_HV supplies the precharge circuit relay on the primary side.
+15V_HV (±1V) supplies the primary side circuits of the DC bus monitoring circuit.
40VAC
The 40VAC winding of the auxiliary transformer 2T1 is rectified and then switched to
24VDC. The 40VAC winding also supplies an optional external cooling unit through
connector CN3.
The 40VAC circuit is protected by the fuse S2.
+24V_SEC (24.5±1V) supplies the chain of temperature switches 15ST2-15ST3 in the
temperature monitoring circuit, and provides control voltage for an external cooler.
+24V_SEC also creates +24V_PWR through two diodes.
+24V_PWR (23±1.2V) supplies the secondary side circuits of the DC bus monitoring and
precharge circuits, and it also supplies the control board 20AP1 through pins
CN23:1, :10, :19.
0740 800 221 - 25 - © ESAB AB 2015

42VAC
The 42VAC winding of the auxiliary transformer 2T1 supplies the torch circuit and an
external wire feeder.
The 10A automatic fuse 15FU1 protects from short circuit in the wire feeder circuit.
15AP1:2 DC bus and precharge circuit
The DC bus is created by rectifying the three-phase mains voltage. At main switch 2QF1
switch-on the capacitors C52–C59 and the capacitors on the Capacitor board 15AP2 are
precharged through the precharge power resistors R4, R5, to reduce the initial charging
current.
Some seconds after the main switch 2QF1 has been turned on, the DC bus is checked. If
the DC bus is above the undervoltage limit (see Section “15AP1:5 DC bus voltage
monitoring”, page 29), the precharge power resistors are short-circuited by relay RE1.
When the power source is switched off, the DC bus capacitors C52–C59 and the capacitors
on the Capacitor board 15AP2 are discharged through resistors R51–R53 and the resistors
on the capacitor board. The capacitor discharge time is approximately 2 minutes.
The precharge circuit is supplied at +24V_HV and +15V_HV. These supply voltages are
galvanically separated from the precharge control signal at pin CN11:6. Pin CN11:6 is at 0V
during the precharging phase. When pin CN11:6 is at +3.3V the relay RE1 is energized.
0740 800 221 - 26 - © ESAB AB 2015

15AP1:3 IGBT drives
The square wave pulse trains from Control board 20AP1 control the pulse transformers
TR10, TR11 and the gate drive circuits. The pulse frequency (inverter frequency) is
22 (±0.5) kHz. The peak voltage of the square wave pulses is approximately +23 V at the
connectors CN11:15-18.
The gate drive circuits output gate pulses through connectors CN17-20 to the transistors in
the power modules 15PM1-2. The peak voltage of the gate pulses is approximately 14.5 V
at the gate-source connectors CN17-20 of the IGBT modules 15PM1-2.
The gate pulses at connectors CN17-18 are in phase. The gate pulses at connectors
CN19-20 are in phase. The gate pulses at CN17-18 are in anti-phase relative to CN19-20.
The gate pulse frequency is 22 (±0.5) kHz. The maximum duty cycle is 45%.
0740 800 221 - 27 - © ESAB AB 2015

15AP1:4 Primary current
The current transformer TR6 on Power board 15AP1 monitors the current through the
primary winding of the main transformer 15T1. The current transformer TR6 has a 1:100
turns ratio. This means that 50 A primary current generates a 0.5 A signal current into pins
CN11:8-9.
0740 800 221 - 28 - © ESAB AB 2015

15AP1:5 DC bus voltage monitoring
This circuit monitors over- and undervoltage on the DC bus.

The overvoltage limit is 1100 V. If the overvoltage limit has been exceeded, the bus voltage
has to decrease to 990 V to be within limits again, because of the hysteresis created by the
IC1 circuit.
The undervoltage limit is 235 V. If the bus voltage has been below the undervoltage limit, it
has to increase to 275 V to be within limits again, because of the hysteresis created by the
IC4 circuit.
If the DC bus is within limits, pin CN11:7 is at 0 V.
If the DC bus voltage falls outside its limits, pin C11:7 is at +3.3 V and:
• the front panel display shows “Err”.
• the gate pulses on Control board 20AP1 are shut down.
To reset an over-/undervoltage error, the power source has to be restarted, that is the main
switch has to be switched off and then switched on again.
The voltage monitoring circuits are supplied at +15V_HV. This supply voltage is galvanically
separated from the voltage monitoring output at pin CN11:7.
0740 800 221 - 29 - © ESAB AB 2015

15AP1:6 Temperature monitoring
The thermal switches 15ST2-15ST3 are normally closed and the voltage at pin CN11:4
is 0 V. If any one of the thermal switches 15ST2-15ST3 opens, the processor lights the
Temp LED on the front panel and performs a controlled weld stop. Welding start is inhibited
until the switches are closed again.
Thermal switch 15ST2 is located on the primary heatsink. If the temperature increases
above 80°C, the switch opens and the voltage at pin CN11:4 rises to +2.7 V. When the
temperature decreases below 60°C the switch closes again.
Thermal switch 15ST3 is located on the secondary heatsink. If the temperature increases
above 80°C the switch opens and the voltage at pin CN11:4 rises to +2.7 V. When the
temperature decreases below 60°C the switch closes again.
15AP1:7 Torch
The welding torch switch is supplied from the 42 VAC winding of the auxiliary
transformer 2T1. Closing the switch activates optocoupler IC2 which pulls the voltage at pin
CN11:5 to 0 V. If the switch is open the voltage at pin CN11:5 is +3.3 V.
The torch circuit supplied at 42 VAC is galvanically separated from the torch output at
pin CN11:5.
The 10 A automatic fuse 15FU1 protects from short circuit in the wire feeder circuit.
0740 800 221 - 30 - © ESAB AB 2015

15AP1:8 Fan and cooler
The fan 15EV1 at the back of the power source is controlled from the Control board 20AP1.
0 V at pin CN11:3 switches on transistor Q3 which activates the fan by connecting pin
CN12:3 to 0 V.
+3.3 V at pin CN11:3 switches off transistor Q3 which stops the fan by breaking the 0 V
connection. Pin CN12:3 is now at the same voltage potential as pin CN12:1, that is
approximately +24 V.
The fan starts when welding starts and continues for six minutes after welding has stopped.
If a temperature error is indicated the fan will run until the thermal switches are OK again.
If an external cooler is connected, its control voltage is supplied through connector CN3:1-2
which is in parallel with the fan 15EV1. The cooler and the fan will then start and stop
simultaneously.
The 40 VAC winding of the auxiliary transformer 2T1 supplies the cooler with power voltage
through connector CN3:3-4. The 40 VAC circuit is protected by the fuse S2.
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0740 800 221 - 32 - © ESAB AB 2015

15AP2 Capacitor board
WARNING!
Dangerous voltage - the power board is at DC bus voltage. Depending on the
mains voltage, the DC bus voltage can be 900 VDC. DC- is connected to the
mains.
WARNING!
Never make any measurements on this board when the power source is
connected to the mains supply.
Wait until the DC bus capacitors are discharged. The DC bus capacitor
The Capacitor board 15AP2 contains four capacitors. The function of this board is to further
stabilize the DC bus voltage by increasing the capacitance of the DC bus.
0740 800 221 - 33 - © ESAB AB 2015

20AP1 Control board

The Control board monitors and controls the various functions of the power source. The
Control board obtains information on welding data and welding processes and
communicates with other units. The main component is a microprocessor.
CAUTION!
This circuit board might look identical to the control board used in other power
sources, but there are differences both in hardware and software. If the wrong
board is used, it might cause serious damage to the power source. Make sure
that the replacement board has the correct article number, see the spare parts
list.
20AP1:1 Power supply

+24V
The Control board 20AP1 is power supplied at approximately 24 VDC from the Power board
15AP1 through pins CN23:1, :10, :19. +24V_PWR decreasing below 21 V indicates that the
power supply is going down and causes the processor to store recently altered parameters.
It also causes the PWM circuit to shut down the gate pulses. +24V_EXT is current limited by
the transistors Q24, Q25.
+24V_PWR (23±1.2 V) supplies the gate drive circuits and the MMC board 1AP1.
+24V (22.5±1.2 V) is switched down to ±15 V.
+24V_EXT (22.8±1.2 V) provides a control voltage for an external wire feeder.
0740 800 221 - 34 - © ESAB AB 2015

+15V
+24V is switched down to +15V by the switching circuit IC17. +15V_UI is created by +15V
and is current limited by PTC resistor R262.
+15V (±0.5V) supplies the current sensor 15CS1, the MMC board 1AP1 and various internal
circuits on the control board 20AP1. It also provides control voltage for an external wire
feeder.
+15V_UI (14.5±0.5V) is a bus voltage for the serial interfaces to wire feeder and MMC.
ADC_REF (3.3±0.1V) is a reference voltage for the processors A/D converter.
-15V
+24V is switched to -15V by the switching circuit IC18.

-15V (±0.5V) supplies various internal circuits on the control board and the current
sensor 15CS1.
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+15VB
+24V_EXT is converted to +15VB by the DC/DC converter IC23. +15VB and +10VB are
galvanically separated from +24V_EXT.
+15VB (±0.3V) is converted to +10VB by voltage regulator VR2.
+10VB (±0.5V) provides control voltage for a remote control.
+3.3V
+15V is converted to +3.3V by the voltage regulator VR1. The resistors R213–R214
divide +3.3V to a +1.65V voltage called REF.
+3.3V (±0.2V) is mainly used as processor voltage supply and as pull up voltage for various
circuits.
REF (1.65±0.1V ) is a reference voltage used in the current regulator and PWM circuits.
0740 800 221 - 36 - © ESAB AB 2015

20AP1:2 DC bus monitoring
The DC bus voltage is monitored on the Power board 15AP1. The overvoltage limit is
1100 V. The undervoltage limit is 235 V. If the DC bus is within limits, pin CN23:7 is 0 V. If
the DC bus voltage falls outside its limits, pin CN23:7 is at +3.3 V and:
• the processor displays “Err” on the front panel.
• the gate pulses on connectors CN23:15–18 are shut down.
Setting the switch SW2:2 to ON position disengages the monitoring circuit.
WARNING!
The DC bus monitoring circuit protects the primary side of the power source from
over- and undervoltage. Disengaging this circuit can severely damage the power
source!
Other gate pulse stop signals are generated by:

• a low +24V_PWR (below 21 V)
• an activated Reset signal, which also resets and restarts the processor
• the processors PWM shut down signal
20AP1:3 Primary current
A signal current proportional to the current in the primary winding of the main transformer
15T1 is generated on the Power board 15AP1. The primary current circuit on the Control
board then rectifies and converts this signal current to a signal voltage which is input to the
PWM circuit.
50 A primary current generates 0.5 A signal current that is converted into 0.425 V signal
voltage.
0740 800 221 - 37 - © ESAB AB 2015

20AP1:4 Secondary current
The current sensor connected to CN18 is scaled 1:2000. This means that 200 A welding
current generates a 100 mA signal current which generates a 420 mVDC voltage at
pin CN18:3. The current sensor is supplied at ±15 V.
The input from the current sensor (actual value) is compared with a current reference (set
value) in the current regulator. The input from the current sensor also:
• blocks the PWM circuit pulse by pulse if the current is too high.
• is monitored by the processor.
For calibration of the secondary current, see Section “Calibrating the welding current”,
page 66.
0740 800 221 - 38 - © ESAB AB 2015

20AP1:5 Arc voltage
The arc voltage is measured regardless of polarity at the welding outlets XS1, XS2 or at the
filler wire.
The arc voltage contributes to the current regulator and is monitored by the processor.
If the arc voltage at no load exceeds a limit value, the gate pulses from the PWM circuit are
shut down. If VRD is activated, by transistor Q2, the limit is set to 30 V. If VRD is
deactivated, the limit is set to 64 V. The limit is disengaged, by transistor Q1, during welding
(all methods).
The VRD function can be activated/deactivated by a switch, as described in Section
“20AP1:13 Processor and miscellaneous circuits”, page 46.
For calibration of the arc voltage, see Section “Calibrating the arc voltage”, page 65.
0740 800 221 - 39 - © ESAB AB 2015

20AP1:6 Current regulator
The current regulator compares the set welding current value (from the processor) to the
actual welding current value (from the secondary current sensor), and outputs a reference
voltage to the PWM circuit. A small part of the arc voltage contributes to the current
regulator at MMA welding starts.
0740 800 221 - 40 - © ESAB AB 2015

20AP1:7 PWM circuit
The PWM circuit outputs two 180° phase shifted square wave pulse trains. The pulse
frequency is 22 (±0.5)kHz. The duty cycle depends on the reference voltage from the
current regulator but is max 45%. The pulse trains from the PWM circuit outputs control the
gate drive circuits.
The square wave pulses are shut down if:
• the arc voltage is too high.
• the DC bus voltage is outside its permitted limits.
• the +24V_PWR is below 21V.
• the processor activates a PWM shut down signal (triggered by for instance the
Temperature monitoring circuit).
• the Reset signal is activated, which also resets and restarts the processor.
An illuminated LED D33 indicates that the PWM circuit is generating gate pulses.
0740 800 221 - 41 - © ESAB AB 2015

20AP1:8 Gate drives
The square wave pulse trains from the PWM outputs are transferred by the gate drives to
the pulse transformers on the Power board 15AP1. The peak voltage of the gate pulses at
pins CN23:15–18 is approximately +23 V.
0740 800 221 - 42 - © ESAB AB 2015

20AP1:9 Digital inputs/outputs
Two outputs from the Control board 20AP1 controls the Precharge and Fan circuits on the
Power board 15AP1.
Two inputs from the Power board 15AP1 indicates the status of the Torch switch and the
Temp monitoring circuit.
The precharge circuit is bypassed when CN23:6 is at +3.3 V.
The precharge circuit is active when CN23:6 is at 0 V.
The fan is activated when CN23:3 is at 0 V.
The fan is deactivated when CN23:3 is at +3.3 V.
Torch switch closed: CN23:5 is at 0 V.
Torch switch open: CN23:5 is at +3.3 V.
Temperature monitoring circuit OK: CN23:4 is at 0 V.
Temperature monitoring circuit fault: CN23:4 is at +2.8 V.
20AP1:10 Remote interface
An analogue Remote control can be connected to connector XS4 at the front of the Warrior
power source.
The Remote control contains a potentiometer that is supplied from +10VB through
pin CN17:3. The set value from the Remote control is transferred to the processor through
pin CN17:2. The voltage at pin CN17:2 is between +10 V and 0 V.
0740 800 221 - 43 - © ESAB AB 2015

20AP1:11 Wire feeder interface
An external Wire feeder can be connected to connector XS3 at the front of the Warrior
power source.
A potentiometer at the wire feeder is supplied at +15 V through pin CN20:14.
The input value from the potentiometer is transferred to the processor through pin CN20:16.
The voltage at pin CN20:16 is between +15 V and 0 V.
The communication between the control board and the wire feeder is handled by a serial
interface through pins CN20:8, :9, :18. The bus signals are at approximately +15 V.
0740 800 221 - 44 - © ESAB AB 2015

20AP1:12 MMC interface
The Warrior power source user interface (MMC) is connected to the Control board 20AP1
through a ribbon cable at connector CN22.
The set values from two selector switches and one potentiometer are transferred to the
processor through pins CN22:4–6. The voltage at pins CN22:4–6 are between +15 V
and 0 V.
Two 90° phase shifted pulse trains from an encoder are transferred to the processor through
pins CN22:8–9. The peak pulse voltage at pins CN22:8–9 is approximately +15 V.
The communication between the control board and the user interface (MMC) is handled by a
serial interface through pins CN22:10–12. The bus signals are approximately +15 V.
0740 800 221 - 45 - © ESAB AB 2015

20AP1:13 Processor and miscellaneous circuits
The processor IC15 controls the arc voltage and the welding current, as well as the
communication with other units.
The processor IC15 monitors supply voltages and all inputs/outputs on the Control board
20AP1.
The processor IC15 contains the program memory. If there is a memory error:
• the front panel display shows “Err”.
• the gate pulses on Control board 20AP1 are shut down.
To reset a memory error the power source has to be restarted, that is the main switch has to
be switched off and then switched on again.
The processor is voltage supplied at +3.3V (+3.3V and ADC_REF).
The connector CN10:2-3 is a serial interface only intended for software development work
by the R&D department. The connector CN10:5-6 is not in use. The connector CN4 is a
JTAG interface intended for downloading software.
The SW2:1 switch controls the VRD function.
• SW2:1 in ON position activates VRD.
• SW2:1 in OFF position deactivates VRD.
0740 800 221 - 46 - © ESAB AB 2015

0740 800 221 - 47 - © ESAB AB 2015

FAULT INDICATIONS
FAULT INDICATIONS
Fault indications are used in order to indicate and identify a fault in the equipment.
Fault descriptions
This manual describes the fault indications for the power source. Faults in other units are
described in the manual for each unit.
Three errors are indicated on the front panel.
Errors in the power source can be displayed on the front panel as:
• a message “Err” on the front panel display (Errors 1 and 3).
• an illuminated Temperature LED (Error 2).
NOTE!
Errors 1 and 3 are indicated in exactly the same way. It is not possible to
distinguish between them on the display.
0740 800 221 - 48 - © ESAB AB 2015

FAULT INDICATIONS
Description
Err on display 1 DC bus over/under voltage
Welding is stopped. The fault is reset after power off/on.
Cause: The DC bus voltage is, or has been, too high or too low. The
overvoltage limit is 1100V. The undervoltage limit is 235V.
Action: Restart the power source. If the fault persists, check:
• the mains voltage.
• the DC bus capacitors C52-C59.
• the Capacitor board 15AP2.
• the connection between the Power board 15AP1 and the Capacitor
board 15AP2.
• the primary rectifier 15BR1.
• the 20VAC supply voltage.
• the welding cables (too long welding cables result in too high
inductance which can cause over voltage).
• the fuse S1 on the Power board 15AP1. If the fuse blows frequently
replace the Power board 15AP1.
• the precharge power resistors R4, R5 on Power board 15AP1.
Replace the Power board if the resistors are defect.
Temp LED lit 2 Temperature error
Welding is stopped. The fault is automatically reset when temperature is
within limits.
Cause: Thermal switch 15ST2 is open because the temperature on the
primary heatsink has exceeded 80°C, and/or thermal switch 15ST3 is
open because the temperature on the secondary heatsink has exceeded
80°C.
Action: Wait until the heat sinks of the power source have cooled off.
Check the fan 15EV1 and the air filter. Check if the heat sinks are dirty
and if they are, clean them. If the fault persists, check:
• the thermal switches 15ST2, 15ST3.
• the connections between the thermal switches and the Power board
15AP1.
Err on display 3 Memory error
Welding is stopped. The fault is reset after power off/on.
Cause: Incorrect checksum in the Flash memory.
Action: Restart the power source. If the fault persists, replace the Control
board 20AP1.
0740 800 221 - 49 - © ESAB AB 2015

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.
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 x 610 mm)
• A 1.5 meter long ground cable with a
crocodile clip
• An adjustable wrist strap and cable with
an inbuilt protective resistor
Antistatic service kit
0740 800 221 - 50 - © ESAB AB 2015

Special tools
Test box TB 1
Ordering no. 0460 868 880
To be used for in-service inspection and testing.
Mounting components on the heat sink

Thermal paste
Apply thermal conducting paste to the following components before fitting them.
Start by cleaning the heat sink, and then apply a thin and even layer of thermal paste,
60–100 μm thick, to the contact surfaces of the components. The purpose of the paste is to
fill out any hollows in the surfaces of the components and the heat sink. Those parts of the
component and the heat sink that are in true metallic contact may have such contact.
Mount the components as described below.
Fitting instructions
IGBT transistor modules 15PM1, 15PM2
Clean the heat sink and apply thermal conducting paste as described above. Fit the
transistor module and tighten the screws alternately to a torque of 2.5 Nm, and then further
tighten them to 4.5 Nm.
NOTE!
The screws must be tightened diagonally.
Tighten the screws that connect the IGBT transistor module to the circuit board to a torque
of 2.5 Nm, and then further tighten them to 4.5 Nm.
WARNING!
Incorrectly fitted IGBT transistor modules can cause failure. Do not tighten the
screws to more than 4.5 Nm.
Diode modules 15PM3, 15PM4, 15PM5, 15PM6

Clean the heat sink and apply thermal conducting paste as described above. Fit the diode
module and tighten the screws to a torque of 0.5 Nm, and then further tighten them to
1.5 Nm.
Tighten the connections to the busbars and cables to a torque of 0.5 Nm, and then further
tighten them to 1.5 Nm.
Rectifier bridge 15BR1
Clean the heat sink and apply thermal conducting paste as described above. Fit the bridge
and tighten the screws to a torque of 2.5 Nm, and then further tighten them to 4.5 Nm.
Tighten the screws that connect the bridge to the circuit board and cables to a torque of
2.5 Nm, and then further tighten them to 4.5 Nm.
0740 800 221 - 51 - © ESAB AB 2015

Tightening torque for screw joints on power components

The illustrations below show important tightening torques for screw joints in the power
source, transmitting heat and/or high currents. Not using the correct tightening torque might
cause serious damage to the power source.
NOTE!
When two torques are specified, e.g. “2.5 Nm + 4.5 Nm”, you should tighten the
screws in two steps: First torque 2.5 Nm, Final torque 4.5 Nm
The screws attaching the IGBT transistor modules to the heat sink should be
tightened crosswise.
Use thread locker (Loctite 243 or equivalent) when fastening the auxiliary
transformer 2T1.
0740 800 221 - 52 - © ESAB AB 2015

0740 800 221 - 53 - © ESAB AB 2015

Power On/Off sequence

Power On
The Main switch 2QF1 is a two-position switch. The left position is the OFF position. The
right position is the ON position.
1. Turn switch 2QF1 to the right.
a) Auxiliary transformer 2T1 is connected to the mains, which can be 380 - 575 VAC.
b) The DC bus capacitors precharge phase starts. The capacitors are charged through
the mains rectifier 15BR1 and the precharge power resistors R4, R5 on the power
board 15AP1.
c) Power board 15AP1 is supplied at 20VAC, 40VAC, 42VAC from the auxiliary
transformer 2T1.
d) Control board 20AP1 is supplied at 24VDC from the power board 15AP1.
e) Control board 20AP1 is initiated after approximately 1 second.
f) The DC bus capacitor precharge phase ends after approximately 5 seconds. The
relay RE1 on the power board 15AP1 is energized, and the capacitors are charged
through the mains rectifier 15BR1 and the relay contact RE1.
g) A LED test is performed where all the LEDs and display segments (except for the two
decimal points on the right end displays) on the front panel are illuminated for
approximately 1 second.
h) The front panel displays the set current/voltage values.
Power Off
The Main switch 2QF1 is a two-position switch. The left position is the OFF position. The
right position is the ON position.
1. Turn switch 2QF1 to the left.
a) The auxiliary transformer 2T1 is disconnected from the mains.
b) Supply voltages to circuit boards 15AP1, 20AP1, 1AP1 starts to go down.
c) The processor stores vital parameters.
d) The DC bus capacitors are discharged through resistors R51 - R53 on the power
board 15AP1. The capacitors are discharged after approximately 2 minutes.
e) The relay RE1 on the power board 15AP1 is deenergized.
0740 800 221 - 54 - © ESAB AB 2015

Checking the IGBT transistor modules
WARNING!
Disconnect the power source from the mains supply and make sure the
capacitors in the mains filter board 2AP1 and the DC bus capacitors are
discharged.
The group of power transistors contains two IGBT modules, 15PM1 and 15PM2, fitted on
the heat sink behind the power board 15AP1 (see illustration below and the third illustration
in Section “Warrior component positions”, page 14).
Power board 15AP1 with the IGBT transistor modules 15PM1, 15PM2
0740 800 221 - 55 - © ESAB AB 2015

The IGBT modules consist of two IGBT transistors each (see illustration below). All of the
transistors operate in H-bridge and work in alternate switching mode. Only one transistor in
each module supplies the primary winding of the transformer, therefore working alternately.
While the first transistor in the module is leading, the second is in barrier state. Transistors
do not work in a continuous mode, but in pulse mode with a maximum duty cycle close
to 45%.
If an IGBT transistor has failed, both modules must be replaced. Also see Section
“Mounting components on the heat sink”, page 51.
CAUTION!
These components are very sensitive to static electricity (ESD). Use protective
equipment to protect against ESD. Place the transistors on a conducting and
grounded surface. Never touch the gate connections!
Measurement with the IGBT modules connected to the power board

It is possible to check the IGBT transistors when they are mounted in the power source.
1. Use a diode tester and measure with the positive and negative probes connected as
shown in the illustration below. Check both modules 15PM1 and 15PM2. The measuring
result should be according to the illustration.
Voltage measurement for IGBT transistors with IGBT modules connected to power
board. CAUTION! Beware of ESD!
0740 800 221 - 56 - © ESAB AB 2015

Measurement with the IGBT modules disconnected from the power board
1. Disconnect all connections and remove all screws from the power board 15AP1.
Remove circuit board 15AP1.
2. Short-circuit the gate and emitter connections (terminals 4 − 5 and 6 − 7 respectively)
before making the measurements. Make sure that you and the short circuiting link are
not statically charged relative to the IGBT transistor. Touch your hand and the short
circuiting link to terminals 1, 2 and 3 on the transistor before fitting the link. Without the
short circuiting link, the measurements will be incorrect.
3. Use a diode tester and measure with the positive and negative probes connected as
shown in the illustration below. Check both modules 15PM1 and 15PM2. The measuring
result should be according to the illustration.
Voltage measurement for IGBT transistors with IGBT modules disconnected from power
board. CAUTION! Beware of ESD!
Checking the precharge power resistors R4, R5

Measure the resistance between the (-) connection of 15BR1 and flat pin connector CN31.
The resistance should be 12 Ω (see illustration below).
Part of the Power board with measuring points for check of the precharge power resistors
R4, R5
0740 800 221 - 57 - © ESAB AB 2015

Checking the primary rectifier bridge

The primary rectifier bridge 15BR1 is screwed on to Power board 15AP1.
Part of the Power board with the primary rectifier measuring points
Use a diode tester to check the primary rectifier bridge.
1. Disconnect the power source from the mains supply.
2. Make sure the DC bus capacitors are discharged.
WARNING!
3. Disconnect the fuse S3 on the Power board.

4. Measure between the connections of the primary rectifier.
a) Measure (-) - L1. Required value, approximately 0.4V.
b) Measure (-) - L2. Required value, approximately 0.4V.
c) Measure (-) - L3. Required value, approximately 0.4V.
d) Measure (-) - (+). Required value, approximately 0.7V.
e) Measure L1 - (+). Required value, approximately 0.4V.
f) Measure L2 - (+). Required value, approximately 0.4V.
g) Measure L3 - (+). Required value, approximately 0.4V.
h) All other combinations should be “open circuit”.
5. Reconnect the fuse S3 on the Power board.
NOTE!
It might take a few seconds to reach some of the required values due to
capacitors in the connected circuits.
0740 800 221 - 58 - © ESAB AB 2015

Checking the secondary rectifier diodes
The secondary rectifier diode modules

Use a diode tester to check the secondary rectifier diodes. There are four diode modules
and each module contains two diodes. All the diodes are connected in parallel. A copper bar
connects all anodes (A1,A2). The diodes have to be disconnected from either the copper
bar or the cathode (K1,K2) cables to be checked individually.
WARNING!
3. Measure between the connections of the secondary rectifier modules.

a) Measure A1 - K1. Required value, approximately 0.4V.
b) Measure K1 - A1. Required value, open circuit.
c) Measure A2 - K2. Required value, approximately 0.4V.
d) Measure K2 - A2. Required value, open circuit.
NOTE!
It might take a few seconds to reach the required values due to capacitors in the
connected circuits.
0740 800 221 - 59 - © ESAB AB 2015

Soft start
The soft start supplies the power source with a low voltage in order to avoid injury to
persons and damage to power source components.
NOTE!
Soft starting should always be used after replacing Control board 20AP1, Power
board 15AP1 or power module components. Soft starting should always be used
when fault tracing the power module components.
An oscilloscope and a multimeter are needed for the measurements. The oscilloscope must
be galvanically separated from ground.
Two power supply alternatives for soft start are described below, one using AC and one
using DC.
AC power supply – preparations before soft starting

For location of connectors and switches mentioned below, see illustrations of printed circuit
boards on the next page (control board) and the page after (power board).
One external power supply is needed: 42VAC ≥30VA
2. Make sure the DC bus capacitors are discharged. Discharge time 2 minutes!
3. Disable the DC bus monitoring circuit by setting switch SW2:2 on Control board 20AP1
to ON position.
4. Disconnect connector CN22 from Power board 15AP1 and insulate the connector from
all other parts. This connector comes from the auxiliary transformer 2T1 and even when
the power source is supplied with 42VAC as in this soft start, the connector contains
voltages up to 575 VAC!
5. Disconnect the fan 15EV1 from connector CN12 on the power board and connect CN12
pin 1 (+24 VDC) via a 1.25A slow fuse to connector CN30 on the power board
(DC bus +). The purpose of the fuse is to protect CN12 in case of a short circuit on the
DC bus.
Do not connect CN30 (DC bus +) to power board connector CN3 pin 2 (supplying
+24 VDC to the cooling unit)! The conductor for CN3 pin 2 on the board is too thin!
6. Connect CN24 (0V) on Control board 20AP1 to connector CN31 (DC bus -) on the power
board.
Do not use any other “0 V connector”! The conductors for other 0 V connectors are too
thin!
7. Connect 42 VAC in series with a 1.25 A slow fuse and 2.2 Ω (5 W) wire wound resistor to
A – B in XS3 (19 pole). This will supply all circuits via the auxiliary transformer 2T1.
(The 2.2 Ω resistor reduces the inrush current and enables the use of a small fuse,
which gives a good protection of the external power supply in case of a fault in the
Warrior power source.)
Soft start connections – AC power supply
0740 800 221 - 60 - © ESAB AB 2015

DC power supply – preparations before soft starting

For location of connectors and switches mentioned below, see illustrations of printed circuit
boards below (control board) and on next page (power board).
Two external power supplies are needed:
Va = 24 VDC
Vb = 40 - 60 VDC
Va and Vb must be galvanically separated. Vb must deliver 1.3 A for 100 ms at startup and
0.3 A steady state.
WARNING!
3. Disable the DC bus monitoring circuit by setting switch SW2:2 on Control board 20AP1
to ON position.
4. Disconnect the transformer cables from connectors CN1, CN2 on Power board 15AP1.
5. Connect Va to Power board 15AP1 but do not switch it on.
Va (+) to the flat pin connector CN30 and to CN1:1.
Va (-) to the flat pin connector CN31.
6. Connect Vb to Power board 15AP1 but do not switch it on.
Vb (+) or Vb (-) to connector CN2:1.
Vb (-) or Vb (+) to connector CN2:2.
Soft start connections – DC power supply
Connector and switch on Control board 20AP1, used when soft starting
0740 800 221 - 61 - © ESAB AB 2015

Connectors on Power board 15AP1 used when soft starting, and also connectors for check
of the IGBT gate pulses (see Section “Checking the IGBT gate pulses”, page 63)
0740 800 221 - 62 - © ESAB AB 2015

Checking the IGBT gate pulses

1. Set the power source to MMA mode.
2. Switch on the external power supply (AC or DC depending on power supply alternative
used, see Section “AC power supply – preparations before soft starting”, page 60 and
Section “DC power supply – preparations before soft starting”, page 61).
After 5 seconds:
○ Relay RE1 on Power board 15AP1 closes (a click is heard).
○ LED D33 on Control board 20AP1 is illuminated.
3. Connect the oscilloscope to the gates and emitters of the IGBTs on Power board 15AP1.
Check one IGBT at the time.
(For location of connectors mentioned below, see illustration of Power board printed
circuit board on previous page.)
For checking IGBT H in module 15PM1:
○ Positive clip to CN13:2
○ Ground clip to CN13:1
For checking IGBT L in module 15PM1:
For checking IGBT H in module 15PM2:
For checking IGBT L in module 15PM2:
4. Set the oscilloscope to 5V/div, 10μs/div and trigger on 0V slope up.
The oscilloscope should show gate pulses like the picture below.
IGBT gate pulses
0740 800 221 - 63 - © ESAB AB 2015

Checking the main transformer primary voltage

1. Connect the oscilloscope to the connectors CN8, CN9 on Power board 15AP1, which is
the primary side of the main transformer 15T1.
2. Set the oscilloscope to 10V/div, 10μs/div and trigger on 0V slope up.
The oscilloscope should show a pulse train like the picture below.
The primary side voltage of main transformer 15T1
Checking the welding outlet voltage

1. Measure the voltage on the welding outlets XS1, XS2 with a DC voltmeter:
○ 2.5 VDC (±10%) for 575VAC power sources
○ 3.25 VDC (±10%) for 460VAC power sources
Restoring the power source after soft starting

1. Switch off the external power supply (AC or DC depending on power supply alternative
used, see Section “AC power supply – preparations before soft starting”, page 60 and
Section “DC power supply – preparations before soft starting”, page 61).
2. Enable the DC bus monitoring circuit by setting switch SW2:2 on Control board 20AP1 to
OFF position.
3. Disconnect the external power supply and reconnect the regular connectors, depending
on power supply alternative used (see Section “AC power supply – preparations before
soft starting”, page 60 and Section “DC power supply – preparations before soft
starting”, page 61).
0740 800 221 - 64 - © ESAB AB 2015

Calibrating the arc voltage

1. Connect the power source to a resistive load.
2. Set the power source to MMA, Cellulosic mode.
3. Set a welding current 200 A.
4. Measure the load voltage using a calibrated multimeter.
5. Load the power source so that the load voltage is 26–30V.

6. Connect XS3:H to XS1(+).
7. Use the potentiometer R50 on Control board 20AP1 to adjust the voltage. The “Display
voltage” must be “Multimeter voltage” (±0.3V).
8. Connect XS3:H to XS2(-).
9. Use the potentiometer R52 on Control board 20AP1 to adjust the voltage. The “Display
voltage” must be “Multimeter voltage” (±0.3V).
0740 800 221 - 65 - © ESAB AB 2015

Calibrating the welding current

1. Connect the power source to a resistive load.
2. Connect a calibrated shunt in series with the load.
3. Set the power source to MMA, Cellulosic mode.
4. Set a welding current:
○ 400A for Warrior 400i CC/CV
○ 500A for Warrior 500i CC/CV
5. Measure the shunt voltage and the load voltage using calibrated multimeters.
6. Load the power source so that the load voltage is:

○ 34-38V for Warrior 400i CC/CV
○ 38-42V for Warrior 500i CC/CV
7. Use the potentiometer R34 on Control board 20AP1 to adjust the current to:
○ 400A (400-404A) for Warrior 400i CC/CV
○ 500A (500-504A) for Warrior 500i CC/CV
8. Check the current at low values:

○ 200A (±3A) at 26-30V for Warrior 400i CC/CV
○ 200A (±3A) at 26-30V for Warrior 500i CC/CV
If the current is outside the tolerance, replace the current sensor 15CS1.
9. Check the minimum current:
○ 12A (10-12A) at 20-25V for Warrior 400i CC/CV
○ 12A (10-12A) at 20-25V for Warrior 500i CC/CV
If the current is outside the tolerance, replace the current sensor 15CS1.
0740 800 221 - 66 - © ESAB AB 2015

IN-SERVICE INSPECTION AND TESTING

In-service inspection and testing in accordance with IEC 60974-4
General requirements
Qualification of test personnel
Tests of welding power sources can be hazardous and shall be carried out by an expert in
the field of electrical repair, preferably also familiar with welding, cutting and allied processes.
Test conditions
Tests shall be carried out at an ambient air temperature between 10°C and 40°C on a dry
and cleaned welding power source.
Measuring instruments
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 into account for the measurement.
The voltmeter shall have an internal resistance of at least 1MΩ and indicate mean value.
Periodic inspection and test

Periodic inspection and test shall be carried out in accordance with manufacturers
instructions and local regulations. The periodic inspection and test consists of:
• Visual inspection (see Section “Visual inspection”, page 69)
• Electrical test (see Section “Electrical test”, page 70)
The inspection and test shall be documented in a test report, (see Section “Test report”,
page 74).
A signed and dated label shall be attached to the equipment after an approved test.
Cleaning instruction
To maintain the performance and increase the lifetime of the power source it is mandatory to
clean it regularly. How often depends on:
• the welding process
• the arc time
• the working environment
• the surrounding environment, that is grinding etc.
Tools needed for the cleaning procedure:
• torx screwdriver, T25 and T30
• dry compressed air at a pressure of 4 bar
• protective equipment like ear plugs, safety glasses, masks, gloves and safety shoes
CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared workspace.
0740 800 221 - 67 - © ESAB AB 2015

Cleaning procedure
1. Disconnect the mains supply.

2. Wait for 4 minutes to discharge the capacitors.
3. Remove the side panels on the power source.
4. Remove the top panel on the power source.
5. Remove the plastic cover between the heat sink and fan (b).
6. Clean the power source with dry compressed air (4 bar) as follows:
a) The upper rear part.
b) From the rear panel through the secondary heat sink.
c) The inductor, transformer and current sensor.
d) The power components side, from the rear side behind PCB 15AP1.
e) The PCBs at both sides.
7. Make sure that there is no dust left on any part.
8. Install the plastic cover between the heat sink and the fan (2) and make sure it is correctly
fitted against the heat sink.
9. Do a test of the power source according to IEC 60974-4, follow the procedure in section
"After repair, inspection and test".
10 Install the top panel on the power source.
.
11 Install the side panels on the power source.
.
12 Connect the mains supply.
.
After repair, inspection and test

After repair, inspection and test shall be carried out according to manufacturers instructions
and local regulations. The after repair, inspection and test consists of:
• Visual inspection (see Section “Visual inspection”, page 69)
• Electrical test (see Section “Electrical test”, page 70)
• Functional test (see Section “Functional test”, page 73 )
The inspection and test shall be documented in a test report, (see Section “Test report”,
page 74).
A signed and dated label shall be attached to the equipment after an approved test.
0740 800 221 - 68 - © ESAB AB 2015

Visual inspection
WARNING!
Disconnect the welding power source from the mains supply and make sure the
DC bus capacitors are discharged before inspection. The DC bus capacitor
During visual inspection, each safety related function judged as relevant by the test
personnel, shall be checked for correct operation.
During visual inspection, the following listed items shall be checked:
1. Torch/electrode holder, welding current return clamp
○ missing or defective insulation
○ defective connections
○ defective, damaged switches
○ other damage
2. Mains supply
○ defective, damaged cable
○ deformed, faulty plug
○ broken or thermally damaged plug pins
○ ineffective cable anchorage
○ cables and plugs unsuitable for the intended use and performance
3. Welding circuit
○ defective damaged cable
○ deformed, faulty or thermally damaged coupler/sockets
○ ineffective cable anchorage
○ cables and coupler unsuitable for the intended use and performance
4. Enclosure
○ missing or damaged parts
○ unauthorised modifications
○ cooling openings blocked or missing air filters
○ signs of overload and improper use
○ missing or defective protective covers (for example, gas cylinder holder)
○ missing or defective lifting means, holder etc.
○ conductive objects placed in the enclosure
5. Controls and indicators
○ defective switches, meters and lamps
○ incorrect fuses accessible from outside of the enclosure
6. General condition
○ cooling liquid circuit leakage or incorrect cooling liquid level
○ defective gas hoses and connections
○ poor legibility of markings and labelling
○ other damage or signs of improper use
0740 800 221 - 69 - © ESAB AB 2015

Electrical test
WARNING!
Disconnect the welding power source from the mains supply and make sure the
DC bus capacitors are discharged before test. The DC bus capacitor discharge
time is at least 2 minutes!
1. Check continuity of the protective circuit. Minimum measuring current 0.2A.

Measure the resistance of the protective circuit from the protective earth connection in the
mains plug to different conductive parts (for example screws) of the enclosure of the
power source.
During the measurement the cable shall be bent, flexed and twisted along the whole
length in order to detect interruptions in the protective conductor.
○ Required value for cables up to 5 m, max 0.3 Ω.
2. Check the insulation resistance. Use an insulation tester with the measurement voltage
set to 500 VDC.
a) Preparations before insulation resistance test
– Remove the cover plates of the power source.
– Supply circuit:
- Switch on the Mains switch 2QF1 (mains plug disconnected from the mains).
– Welding circuit:
- Short-circuit the welding outlets XS1, XS2.
- Connector XS3: Short-circuit sockets D,E,H,J,K,L,T,U,V to each other and to the
welding outlet XS2.
- Connector XS4: Short-circuit sockets F,G,H to each other and to the welding
outlet XS2.
– 42VAC circuit:
- Connector XS3: Short-circuit sockets A,B,F to each other, and in measurements
b–d below also short-circuit sockets A,B,F to the welding outlet XS2.
b) Supply circuit – Welding circuit Measure from the supply pins in the mains plug to
the welding outlets XS1, XS2.
– Required value not less than 5 MΩ.
c) Welding circuit – Protective circuit Measure from the welding outlets XS1, XS2 to
the protective earth connection in the mains plug.
– Required value not less than 2.5 MΩ.
d) Supply circuit – Protective circuit Measure from the supply pins in the mains plug
to the protective earth connection in the mains plug.
e) 42VAC – Welding circuit Disconnect sockets A,B,F in connector XS3 from the
welding outlet XS2 again! Measure from connector XS3, sockets A,B,F to the welding
outlet XS2.
f) Restoration after insulation resistance test Remove all short circuit cable sets
which have been added for the insulation resistance test. Turn the mains switch of the
welding power source to OFF position.
0740 800 221 - 70 - © ESAB AB 2015

3. Check the no-load voltage.

Use the ESAB test box TB 1, and a voltmeter indicating mean values. If the welding
power source has an activated VRD function, proceed to step 4.
a) Connect the positive (XS1) and negative (XS2) welding outlets to the positive and
negative terminals (VIN) of the TB 1.
b) Connect a voltmeter to VPEAK of the TB 1.
c) Connect the welding power source to the mains supply.
d) Turn the control knob of the TB 1 anti-clockwise to 0.2.
e) Turn the mains switch of the welding power source to ON position.
f) Set the welding process selector switch in MMA position and the current control on
the power source to 20A.
g) Slowly turn the control knob of the TB 1 clockwise from 0.2 to 5.2 while checking the
voltmeter for the highest value.
– Measured value must not exceed 113 V.
h) Turn the mains switch of the welding power source to OFF position.
i) Disconnect the welding power source from the mains supply.
4. Check the no-load voltage with VRD activated.
Use the ESAB test box TB 1, and a voltmeter indicating mean values. This test is only
conducted when the VRD function is activated.
a) Connect the positive (XS1) and negative (XS2) welding outlets to the positive and
negative terminals (VIN) of the TB 1.
b) Connect a voltmeter to VPEAK of the TB 1.
c) Connect the welding power source to the mains supply.
d) Turn the control knob of the TB 1 anti-clockwise to 0.2.
f) Set the welding process selector switch in MMA position and the current control on
the power source to 20A.
g) Slowly turn the control knob of the TB 1 clockwise from 0.2 to 5.2 while checking the
voltmeter for the highest value.
– Measured value must not exceed 35 V.
h) Check that the LED indicates active VRD function by a steady green light.
i) Turn the mains switch of the welding power source to OFF position.
j) Disconnect the welding power source from the mains supply.
0740 800 221 - 71 - © ESAB AB 2015

Test box TB 1
Circuit diagram of the TB 1
0740 800 221 - 72 - © ESAB AB 2015

Functional test
1. Each safety related function judged as relevant by the test personnel shall be checked
for correct operation.
Conformity shall be checked by operating the device and by checking whether the
welding power source operates correctly.
2. Check the supply circuits on/off switching device.
a) Disconnect the welding power source from the mains supply and make sure the DC
capacitors are discharged.
b) Remove the cover.
c) Turn the mains switch of the welding power source to OFF position.
d) Measure resistance from the supply pins of the mains plug to the mains rectifier
15BR1 on the Power board 15AP1.
– Measure L1-15BR1:L1. Required value, open circuit
f) Measure resistance between the supply pins L1,L3 in the mains plug, and from the
supply pin L2 in the mains plug to the mains rectifier 15BR1 on the Power board
15AP1.
– Measure L1-L3. Required value, less than 0.5Ω
– Measure L2-15BR2:L2. Required value, less than 0.5Ω
g) Turn the mains switch of the welding power source to OFF position.
h) Reassemble the cover.
3. Check LEDs and display segments.
a) Connect the welding power source to the mains supply.
b) Turn the mains switch of the welding power source to ON position.
– The LEDs and display segments (except for the two decimal points on the right
end displays) will be illuminated for about a second to indicate correct function.
4. Check the function of the welding power source by welding.
5. Disconnect the welding power source from the mains supply.
6. Write the test report. (See Section “Test report”, page 74.)
7. If the unit passes all the tests, attach appropriate label with signature and date of
the test.
0740 800 221 - 73 - © ESAB AB 2015

Test report
Company: Location:
Equipment:Arc welding power source Serial number:
Manufacturer:ESAB Type:
Testing equipment:
VISUAL INSPECTION Passed □

ELECTRICAL TEST Limit Measured values
Protective conductor ≤ 0.3 Ω
resistance
Insulation resistance:
• Input circuit/Welding ≥ 5 MΩ
circuit (500 VDC)
• Welding circuit/Protective ≥ 2.5 MΩ
circuit (500 VDC)
• Input circuit/Protective ≥ 2.5 MΩ
circuit (500 VDC)
No-load voltage:
• without VRD Vpeak ≤113 VDC
• with VRD activated Vpeak ≤35 VDC
Electrical test Passed □
FUNCTIONAL TEST Passed □
Remarks
Date
Tested by Signature
Testing company
0740 800 221 - 74 - © ESAB AB 2015

SPARE PARTS AND ACCESSORIES
SPARE PARTS AND ACCESSORIES
For spare parts, see 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

Spare parts list 0459 839 084 Warrior™ 400i CC/CV, Warrior™ 500i CC/CV
Instruction manual 0463 340 Warrior™ 400i CC/CV, Warrior™ 500i CC/CV
(BR SA GB)
Instruction manual 0463 341 Warrior™ 500i CC/CV (US CAN SA RU)
0740 800 221 - 75 - © ESAB AB 2015

ESAB subsidiaries and representative offices
Europe NORWAY North and South America SOUTH KOREA

AS ESAB ESAB SeAH Corporation
AUSTRIA Larvik ARGENTINA Kyungnam
ESAB Ges.m.b.H Tel: +47 33 12 10 00 CONARCO Tel: +82 55 269 8170
Vienna-Liesing Fax: +47 33 11 52 03 Buenos Aires Fax: +82 55 289 8864
Tel: +43 1 888 25 11 Tel: +54 11 4 753 4039
Fax: +43 1 888 25 11 85 POLAND Fax: +54 11 4 753 6313 UNITED ARAB EMIRATES
ESAB Sp.zo.o. ESAB Middle East FZE
BELGIUM Katowice BRAZIL Dubai
S.A. ESAB N.V. Tel: +48 32 351 11 00 ESAB S.A. Tel: +971 4 887 21 11
Heist-op-den-Berg Fax: +48 32 351 11 20 Contagem-MG Fax: +971 4 887 22 63
Tel: +32 15 25 79 30 Tel: +55 31 2191 4333
Fax: +32 15 25 79 44 PORTUGAL Fax: +55 31 2191 4440
ESAB Lda
Africa
BULGARIA Lisbon CANADA EGYPT
ESAB Kft Representative Office Tel: +351 8 310 960 ESAB Group Canada Inc. ESAB Egypt
Sofia Fax: +351 1 859 1277 Missisauga, Ontario Dokki-Cairo
Tel: +359 2 974 42 88 Tel: +1 905 670 02 20 Tel: +20 2 390 96 69
Fax: +359 2 974 42 88 ROMANIA Fax: +1 905 670 48 79 Fax: +20 2 393 32 13
ESAB Romania Trading SRL
THE CZECH REPUBLIC Bucharest MEXICO SOUTH AFRICA
ESAB VAMBERK s.r.o. Tel: +40 316 900 600 ESAB Mexico S.A. ESAB Africa Welding & Cutting
Vamberk Fax: +40 316 900 601 Monterrey Ltd
Tel: +420 2 819 40 885 Tel: +52 8 350 5959 Durbanvill 7570 - Cape Town
Fax: +420 2 819 40 120 RUSSIA Fax: +52 8 350 7554 Tel: +27 (0)21 975 8924
LLC ESAB
DENMARK Moscow USA
Aktieselskabet ESAB Tel: +7 (495) 663 20 08 ESAB Welding & Cutting Distributors
Herlev Fax: +7 (495) 663 20 09 Products For addresses and phone
Tel: +45 36 30 01 11 Florence, SC numbers to our distributors in
Fax: +45 36 30 40 03 SLOVAKIA Tel: +1 843 669 44 11 other countries, please visit our
ESAB Slovakia s.r.o. Fax: +1 843 664 57 48 home page
FINLAND Bratislava
ESAB Oy Tel: +421 7 44 88 24 26 www.esab.com
Helsinki Fax: +421 7 44 88 87 41
Asia/Pacific
Tel: +358 9 547 761 AUSTRALIA
Fax: +358 9 547 77 71 SPAIN
ESAB South Pacific
ESAB Ibérica S.A.
Archerfield BC QLD 4108
GREAT BRITAIN Alcalá de Henares (MADRID)
Tel: +61 1300 372 228
ESAB Group (UK) Ltd Tel: +34 91 878 3600
Fax: +61 7 3711 2328
Waltham Cross Fax: +34 91 802 3461
Tel: +44 1992 76 85 15 CHINA
Fax: +44 1992 71 58 03 SWEDEN
Shanghai ESAB A/P
ESAB Sverige AB
ESAB Automation Ltd Shanghai
Gothenburg
Andover Tel: +86 21 2326 3000
Tel: +46 31 50 95 00
Tel: +44 1264 33 22 33 Fax: +86 21 6566 6622
Fax: +46 31 50 92 22
Fax: +44 1264 33 20 74 INDIA
ESAB International AB
FRANCE Gothenburg ESAB India Ltd
ESAB France S.A. Tel: +46 31 50 90 00 Calcutta
Cergy Pontoise Fax: +46 31 50 93 60 Tel: +91 33 478 45 17
Tel: +33 1 30 75 55 00 Fax: +91 33 468 18 80
Fax: +33 1 30 75 55 24 SWITZERLAND
ESAB AG INDONESIA
GERMANY Dietikon P.T. ESABindo Pratama
ESAB GmbH Tel: +41 1 741 25 25 Jakarta
Solingen Fax: +41 1 740 30 55 Tel: +62 21 460 0188
Tel: +49 212 298 0 Fax: +62 21 461 2929
Fax: +49 212 298 218 UKRAINE
ESAB Ukraine LLC JAPAN
HUNGARY Kiev ESAB Japan
ESAB Kft Tel: +38 (044) 501 23 24 Tokyo
Budapest Fax: +38 (044) 575 21 88 Tel: +81 45 670 7073
Tel: +36 1 20 44 182 Fax: +81 45 670 7001
Fax: +36 1 20 44 186 MALAYSIA
ITALY ESAB (Malaysia) Snd Bhd
ESAB Saldatura S.p.A. USJ
Bareggio (Mi) Tel: +603 8023 7835
Tel: +39 02 97 96 8.1 Fax: +603 8023 0225
Fax: +39 02 97 96 87 01 SINGAPORE
THE NETHERLANDS ESAB Asia/Pacific Pte Ltd
ESAB Nederland B.V. Singapore
Amersfoort Tel: +65 6861 43 22
Tel: +31 33 422 35 55 Fax: +65 6861 31 95
Fax: +31 33 422 35 44
www.esab.com

2 Esab Warrior 400 I 500 I

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2 Esab Warrior 400 I 500 I

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Warrior™ 400i CC/CV

Warrior™ 500i CC/CV

READ THIS FIRST................................................................................................ 4

TECHNICAL DATA ............................................................................................... 7

WIRING DIAGRAM ............................................................................................... 9

0740 800 221 © ESAB AB 2015

20AP1:11 Wire feeder interface ....................................................................... 44

FAULT INDICATIONS ......................................................................................... 48

IN-SERVICE INSPECTION AND TESTING........................................................ 67

SPARE PARTS AND ACCESSORIES ............................................................... 75

0740 800 221 © ESAB AB 2015

READ THIS FIRST

0740 800 221 -4- © ESAB AB 2015

Design structure of the power source

0740 800 221 -5- © ESAB AB 2015

Block diagram of the Warrior 400i/500i CC/CV power sources

0740 800 221 -6- © ESAB AB 2015

0740 800 221 -7- © ESAB AB 2015

Warrior 400i CC/CV Warrior 500i CC/CV Warrior 500i CC/CV

0740 800 221 -8- © ESAB AB 2015

0740 800 221 -9- © ESAB AB 2015

0740 800 221 - 10 - © ESAB AB 2015

0740 800 221 - 11 - © ESAB AB 2015

Warrior 400i/500i CC/CV

0740 800 221 - 12 - © ESAB AB 2015

0740 800 221 - 13 - © ESAB AB 2015

Warrior component positions

0740 800 221 - 14 - © ESAB AB 2015

0740 800 221 - 15 - © ESAB AB 2015

Right view, power modules

0740 800 221 - 16 - © ESAB AB 2015

Warrior internal voltage map

Principle diagram of the Warrior 400i/500i CC/CV internal power supplies

0740 800 221 - 17 - © ESAB AB 2015

1AP1 MMC board

1AP1:1 Power supply

0740 800 221 - 18 - © ESAB AB 2015

1AP1:2 Display and LEDs

0740 800 221 - 19 - © ESAB AB 2015

0740 800 221 - 20 - © ESAB AB 2015

1AP1 Component positions

0740 800 221 - 21 - © ESAB AB 2015

2AP1 Mains filter board

0740 800 221 - 22 - © ESAB AB 2015

2AP1 Component positions

15AP1 Power board

0740 800 221 - 23 - © ESAB AB 2015

15AP1:1 Power supply

0740 800 221 - 24 - © ESAB AB 2015

0740 800 221 - 25 - © ESAB AB 2015

15AP1:2 DC bus and precharge circuit

0740 800 221 - 26 - © ESAB AB 2015

15AP1:3 IGBT drives

0740 800 221 - 27 - © ESAB AB 2015

15AP1:4 Primary current

0740 800 221 - 28 - © ESAB AB 2015

15AP1:5 DC bus voltage monitoring

This circuit monitors over- and undervoltage on the DC bus.