ESAB ER 1 Manual de usuario
Service manual
0463 480 001 GB 20170607 Valid for: 716-xxx-xxxx
ER 1, ER 1F
Remote controls
TABLE OF CONTENTS
0463 480 001 © ESAB AB 2017
READ THIS FIRST.................................................................................... 3
BEFORE STARTING SERVICE................................................................ 4
Service aid ................................................................................................ 4
ESAB Tools ............................................................................................... 4
INTRODUCTION....................................................................................... 5
TECHNICAL DATA .................................................................................. 6
WIRING DIAGRAM................................................................................... 7
Component description ........................................................................... 7
Block diagram........................................................................................... 7
SOFTWARE .............................................................................................. 9
ERROR CODES........................................................................................ 10
Error code decriptions ............................................................................. 10
Err 4 or No response from ER1 or ER1F .............................................. 10
TROUBLESHOOTING .............................................................................. 12
Unable to set current with ER1 .............................................................. 12
Push is not detected on ER1 .................................................................. 12
LCD behaviour on ER1............................................................................ 12
Unable to increase current with ER 1F................................................... 12
Status indications on circuit boards ...................................................... 14
Remote control board 21AP1 – Indication of operational status ............ 14
DISASSEMBLY AND REASSEMBLY ...................................................... 15
ER 1 ........................................................................................................... 15
ER 1F ......................................................................................................... 17
SPARE PARTS AND ACCESSORIES ..................................................... 18
Rights reserved to alter specifications without notice.
READ THIS FIRST
0463 480 001 -3- © ESAB AB 2017
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.
The circuit boards are divided into numbered blocks. 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" chapter
in this manual.
This manual contains details of design changes that have been made up to and including
April 2017.
The manual is valid for:
• ER 1 Handheld remote control 0445 536 880 (4 pin cable) with serial number
716-xxx-xxxx
• ER 1 Handheld remote controls 0445 536 881, 0445536882 and 0445536883 (6
pin cable) with serial number 716-xxx-xxxx
• ER 1F Remote control, foot pedal 0445 550 880 (4 pin cable) with serial number
716-xxx-xxxx
• ER 1F Remote control, foot pedal 0445 550 881 and 0445550882 (6 pin cable) with
serial number 716-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 ER 1 and ER 1F are designed and tested in accordance with the standards stated in
the instruction manual. On completion of service or repair work, it is the responsibility of the
person(s) performing the work to ensure that the product still complies with the requirements
of the involved standards.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
BEFORE STARTING SERVICE
0463 480 001 -4- © ESAB AB 2017
BEFORE STARTING SERVICE
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 610x610mm /
24×24in.)
• 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
ESAB Tools
Checkmaster 9000
Ordering no. 0740 505 881
ESAB test box TB 1
Ordering no. 0460 868 880
INTRODUCTION
0463 480 001 -5- © ESAB AB 2017
INTRODUCTION
The remote control ER 1 can be used to control current, arc force and memory selection. The
available functions and number of memories depend on the power source the remote control
is connected to.
The foot pedal ER 1F can be used to control current. It also has a trigger function, which can
be used for weld start.
For symbols and functionality, see Instruction manual.
Wires/cables within modules are marked 100 - 6999.
Wires/cables between modules are marked 7000 - 7999.
Components outside modules are marked C1 - C99 (C=capacitor), 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
TECHNICAL DATA
0463 480 001 -6- © ESAB AB 2017
TECHNICAL DATA
ER 1 ER 1F
Operating voltage 12–24VDC 12–24VDC
Dimensions L×W×H 205×59×38mm±10%
(8.0×2.3×1.5in.±10%)
225×152×82mm±10%
(8.9×6.0×3.2in.±10%)
Weight unit with 5 meter
(16.4 ft) cable
475g (1.05lb) 2250g (4.96lb)
Operating temperature -20 to +60°C (-4to140°F) -20 to +60°C (-4to140°F)
Transportation temperature -40to +80°C (-40to176°F) -40to +80°C (-40to176°F)
Enclosure class IP53 IP23
WIRING DIAGRAM
0463 480 001 -7- © ESAB AB 2017
WIRING DIAGRAM
Component description
Component Description
21XS2 LCD
21XS3 Encoder
21AP1 Control board
21XS1 Remote interconnection cable
Block diagram
NOTE!
21AP1 is same but used with different configuration for remote control ER1 and
foot pedal ER1F.
ER 1
WIRING DIAGRAM
0463 480 001 -8- © ESAB AB 2017
ER 1F
SOFTWARE
0463 480 001 -9- © ESAB AB 2017
SOFTWARE
The software in ER1 and ER1F consists of three parts: system software (application
software), secondary bootloader and primary bootloader.
The software is updated using the USB port on the power source. For information about
software update, see power source service manual.
ERROR CODES
0463 480 001 - 10 - © ESAB AB 2017
ERROR CODES
Error code decriptions
The error code is used to indicate that a fault has occurred in the equipment. Errors are
indicated by the text "Err" and the error code number flashing alternately in the power source
display.
For error codes, see power source service manual. Additional error codes and suggested
service technician actions for error codes are described in the sub-sections below.
Err 4 or No response from ER1 or ER1F
No response from the remote control ER1, foot pedal ER1F or Err 4 on power source.
Service technician actions:
1. Check if cable has a 4 pin or 6 pin connector. Follow the adequate instructions
depending on the cable.
2. Check if the cable is cut or damaged.
3. Check the continuity in the cable.
4 pin cable configuration Connector
numbering
Color Connector Function On PCBA
Black 1 0 V CN1, MTA156 Pin 1
Red 2 +12 V CN1, MTA156 Pin 2
Blue 3 CAN L CN8, Pin 1
White 4 CAN H CN8, Pin 2
Shield Metal cup Shield ER1: To cable mounting plate
ER1F: To PCBA mounting
plate
6 pin cable configuration Connector
numbering
Color Connector Function On PCBA
Black 2 0 V CN1, MTA156 Pin 1
Red/Grey 1 +12 V CN1, MTA156 Pin 2
Blue 3 CAN L CN8, Pin 1
White 4 CAN H CN8, Pin 2
Shield Metal cup Shield ER1: To cable mounting plate
ER1F: To PCBA mounting
plate
Test points for measurements
Test point number Value (in V DC)
TP35, TP2 11.25 V ≤ V ≤ 11.85 V
TP1 4.5 V ≤ V ≤ 5.5 V
TP6 3.13 ≤ V ≤ 3.47
ER 1F: TP12 2.75 ≤ V ≤ 2.90
Este manual sirve para los siguientes modelos
1
Tabla de contenidos
Otros manuales de Mando a distancia de ESAB
