ESAB Aristo Mig 3001i Service Manual
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ESAB Aristo Mig 3001i Service Manual

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Aristot Origot
Mig 3001i
Tig 3001i
Service manual
0740 800 196
101019
Valid for serial no. 833-xxx-xxxx to 039-xxx-xxxx

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Summary of Contents for ESAB Aristo Mig 3001i

  • Page 1 Aristot Origot Mig 3001i Tig 3001i Service manual 0740 800 196 101019 Valid for serial no. 833-xxx-xxxx to 039-xxx-xxxx...

  • Page 2: Table Of Contents

    READ THIS FIRST ..............INTRODUCTION .
  • Page 3 20AP2 Circuit diagram ............REMOTE CONTROLS .

  • Page 4: Read This First

    READ THIS FIRST Maintenance and repair work should 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.
  • Page 5 Design structure of the power source The power source is transistor-controlled, operating on the inverter principle. It consists of a number of function modules, as shown in the block diagram below. Each module has a module number, which is always included as the first part of the name/identification of components in the module.

  • Page 6: Technical Data

    TECHNICAL DATA Mig 3001i Tig 3001i 400 V $10%, 3 ∼ 50/60 Hz 400 V $10%, 3 ∼ 50/60 Hz Mains voltage Mains supply 1.4 MVA 1.4 MVA sc min sc min Primary current MIG/MAG 16 A 13 A 13 A 19 A 19 A No-load power demand when in the...
  • Page 7 2) Valid for power sources with VRD specification on the rating plate. The VRD function is explained in the instruction manual for the control panel, if the control panel has this function. Mains supply, S sc min Minimum short circuit power on the network in accordance with IEC 61000-3-12 Duty cycle The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a cer­...

  • Page 8: 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.
  • Page 9 Component Description TIG module. Wire numbers 1000-1199 10AP1 TIG board. See the description on page 16. 10C1, 10C2 Interference suppression capacitors. 10EV1 Fan, 24 V DC. See the description of 20AP1:2 on page 27. 10TV1 HF transformer. See HF generator on page 16. 10L1 Ferrite ring core.

  • Page 10: Mig 3001I

    Mig 3001i S0740 800 196/E101019/P76 - 10 - ca41_00...
  • Page 11 Placement of the circuit boards, Mig 3001i S0740 800 196/E101019/P76 ca41_00 - 11 -...

  • Page 12: Tig 3001I

    Tig 3001i Placement of the circuit boards, Tig 3001i S0740 800 196/E101019/P76 - 12 - ca41_00...
  • Page 13 S0740 800 196/E101019/P76 ca41_00 - 13 -...

  • Page 14: Description Of Operation

    DESCRIPTION OF OPERATION This description of operation describes the function of circuit boards and other components in the power source. It is divided into sections, numbered to correspond to the circuit board numbers and divisions into function blocks. 1 MMC unit The MMC unit can either be fitted to the wire feed unit and/or the power source.

  • Page 15: 2Ap1 Interference Suppressor Board And Main Rectifier

    2AP1 Interference suppressor board and main rectifier Circuit diagram, 2AP1 R7, R8 and R9 are varistors that clip the voltage peaks exceeding about 1100 V. The varistors do not conduct when the voltage is below 575 V AC RMS, this corresponds to a peak voltage of 810 V.

  • Page 16: 10Ap1 Tig Board

    10AP1 Tig board The TIG board is fitted to the Tig 3001i. Sections 10AP1:1 to 10AP1:6 refer to the wiring diagram on page 12. Circuit diagram of the TIG functions 10AP1:1 Power supply 42 V AC is supplied from transformer 2TC1. 10AP1:2 Communication with the control board The processor on circuit board 20AP1 controls the gas valve and the HF...

  • Page 17: 10Ap1:5 Tig Torch Switch

    10AP1:5 TIG torch switch The torch switch is supplied at 42 V AC. This voltage is rectified and energizes optocoupler IC1 when the torch switch is closed. 10AP1:6 Signal transfer 20AP1 - 20AP2 Power supply and signal transfer for 20AP2, see 20AP2:1 on page 37. 10AP1 Component positions S0740 800 196/E101019/P76...

  • Page 18: 15 The Power Module

    15 The power module The power module converts the rectified 3-phase 400 V to the welding voltage. It consists of a dual forward inverter, operating at a switching frequency of 2 x 40 kHz. The mains rectifier bridge 2BR1, the IGBT modules IC3 and IC8 and the diode modules 15D1 and 15D2 are all mounted on a heat sink.

  • Page 19: 15Ap1 Power Board

    15AP1 Power board The power board carries the charging circuit, the gate driver circuit, the switching circuit and the overvoltage and undervoltage protection circuits. WARNING! Dangerous voltage - mains voltage. Never make any measurements on this board when the machine is connected to the mains supply. On pages 46 and 50 there are instructions on how to check the power board.

  • Page 20: 15Ap1:3 Overvoltage And Undervoltage Protection

    15AP1:3 Overvoltage and undervoltage protection WARNING! Dangerous voltage. Mains voltage on circuit board 15AP1 when connected to the 400 V supply. 0 VA on power board 15AP1 is connected to the mains supply. 0 VA is galvanically isolated from 0 V. The overvoltage and undervoltage protection generates a fault signal if the voltage across capacitors 15C1 and 15C2 falls outside the permitted interval of 300 - 715 V DC, which is equivalent to a mains voltage of 212 - 505 V AC.

  • Page 21: 15Ap1:4 Charging Circuit

    15AP1:4 Charging circuit When the mains power supply is turned on, smoothing capacitors 15C1 and 15C2 charge up via resistors R15 and R16. When there are gate pulses present at pulse transformer TR2, transistor Q19 pulls the 'shutdown' signal to 0VA. PWM circuit IC2 generates gate pulses to the thyristor in IGBT module IC8, the thyristor short-circuits resistors R15 and R16.

  • Page 22: 15Ap1:5 Gate Driver Stages And Switching Circuits

    15AP1:5 Gate driver stages and switching circuits WARNING! Dangerous voltage - mains voltage. Never measure the gate signals when the power source is connected to the mains supply. The gate pulse frequency is 40 kHz. See page 50 for screen traces of waveforms and measurement instructions.

  • Page 23: 15Ap1 Component Positions

    15AP1 Component positions S0740 800 196/E101019/P76 ca41_15_1 - 23 -...

  • Page 24: 15Ap2 Secondary Board

    15AP2 Secondary board The secondary board is fitted on the main transformers 15TM1, 15TM2 and the diode modules 15D1, 15D2. On page 48 there are instructions on how to check the secondary board. 15AP2:1 Diode modules The diode modules comprises two diodes each, rectifier and freewheel diode. During the time interval between two voltage pulses, the freewheel diode maintain the welding current from inductor 15L3.

  • Page 25: 15Ap2 Component Positions

    15AP2 Component positions Note! There are two versions of 15AP2. The second version of the board includes filter components (R33, C13 and D6) that are important for the VRD function. Any of the circuit board versions can be used for power sources without VRD specification on the rating plate. S0740 800 196/E101019/P76 ca41_15_2 - 25 -...

  • Page 26: 20Ap1 Control Board

    20AP1 Control board The processor on the control board monitors and controls the various functions of the power source. It obtains information on welding data and welding processes from the welding data unit. Depending on the type of control panel, the power source control board is set up for combi mode or power source mode.

  • Page 27: 20Ap1:1 Power Supply

    20AP1:1 Power supply +24 V Internal and external power supply. +15 V Internal power supply on 20AP1. -15 V Internal power supply on 20AP1. +5 V Internal power supply on 20AP1. +2.5 V Internal power supply on 20AP1. Uan 5 V internal reference voltage on 20AP1. Uref 2.5 V internal reference voltage on 20AP1.

  • Page 28: 20Ap1:3 The Can Bus

    20AP1:3 The CAN bus A standardised communication (CAN - Controller Area Network) bus is used for communication between the units of the machine. Communication speed is 400 kbit/s. The CAN bus is connected in parallel to the connectors CAN_A and CAN_B. The +12V_Can and 0V_Can power supply is unregulated and is galvanically isolated from other parts of the control board.

  • Page 29: Communication Interruptions

    Starting sequence On power-up, the board's CAN controller reads in the bus speed from the micro processor: 400 kbit/s. The circuit board displays the starting sequence from power-up. LED1 lights red. Then LED1, LED2 and LED3 lights green. When the board has been initiated, and the power source is in the application program, LED1 flashes continously with a green light.

  • Page 30: 20Ap1:4 Temperature Monitoring

    One end of the CAN bus is in the power source and it must be fitted with a terminating resistor, R28 in the circuit diagram on page 28. The terminating resistor can be disconnected by removing the jumper from terminal D. Terminal D, version 2 of 20AP1 Terminal D, version 1 of 20AP1 See page 61 for examples on how to connect the terminating resistors in...

  • Page 31: 20Ap1:5 Overvoltage And Undervoltage Protection

    20AP1:5 Overvoltage and undervoltage protection See 15AP1:3 on Page 20. 20AP1:6 Relay driver stages The relay driver stages are only used in the Tig 3001i and Mig 3001i with water cooling unit. For more information see: “10AP1 Tig board” on page 16 and “20AP2 Relay board”...

  • Page 32: 20Ap1:9 Arc Voltage Feedback

    20AP1:9 Arc voltage feedback Circuit diagram of the arc voltage input The arc voltage input senses the welding voltage regardless of the welding polarity or welding method. If sensing via the welding filler wire is connected, it is this voltage that will be used: if not, the voltage at the power source's terminals is used.

  • Page 33: Open-Circuit Voltage Control

    Open-circuit voltage control The open-circuit voltage control is active when: there is an open welding circuit and no arc. The open-circuit voltage control is inactive when: the HF ignition is activated during TIG welding with HF. there is contact between electrode and workpiece. there is an arc.

  • Page 34: 20Ap1:10 Control Panel Interface Circuits

    When there is contact between electrode and workpiece. The power source produces a current of about 24 A. When the electrode is lifted from the workpiece. The arc strikes, the open-circuit voltage control is deactivated and the current increases to 30 A. When the arc voltage exceeds 8 V, the current increases / decreases to the set current.

  • Page 35: 20Ap1 Component Positions, Version

    20AP1 Component positions, version 1 S0740 800 196/E101019/P76 ca41_20_1 - 35 -...

  • Page 36: Ap1 Component Positions, Version 2

    20AP1 Component positions, version 2 S0740 800 196/E101019/P76 - 36 - ca41_20_1...

  • Page 37: 20Ap2 Relay Board

    20AP2 Relay board The relay board handles hardware-connected inputs and outputs to/from control board 20AP2. In the event of a relay fault, the entire board must be replaced. 20AP2:1 Power supply The relay board is supplied at +24 V from control circuit board 20AP1. Power supply of the relay board for MIG power sources Power supply of the relay board for TIG power sources 20AP2:2...

  • Page 38: 20Ap2:3 Cooling Water Monitoring

    The ELP switch in the water lock connector closes when a cooling water hose is connected to the blue water connector on the cooling unit. The pump stops if the switch opens. (ELP stands for ESAB Logic Pump.) The contact in the flow guard closes when the water flow rate exceeds 0.7 l/minute.

  • Page 39: 20Ap2:4 Gas Pressure Monitoring

    20AP2:4 Gas pressure monitoring Terminals CN5: 1 and 2 are intended for use with a gas pressure monitor. The processor reacts to voltage flanks from the input. The power sources are not normally fitted with gas pressure monitors, which means that this input must be short-circuited by a jumper. If the jumper is open, fault code 32 is displayed.

  • Page 40: Remote Controls

    REMOTE CONTROLS A number of remote control units can be connected to the power sources, these are described in a separate service manual. FAULT CODES Fault codes are used in order to indicate and identify a fault in the equipment. Fault log All faults that occur when using the welding equipment are documented as error messages in the fault log.

  • Page 41: Fault Code Description

    Fault Description Welding Power Wire Remote code data source feed control unit unit unit Lost contact with the power source Memory error in data memory High inductance in the welding circuit Transmitter buffer overflow Receiver buffer overflow Program operating fault Out of wire Stack overflow No cooling water flow...
  • Page 42 Code Description, power source 5 V power supply too low The unregulated power supply voltage (+30 V) is too low: the smoothing capacitors cannot keep the voltage up enough for the processor to continue to operate. The processor stops all normal activities, expecting to be shut down.
  • Page 43 Something has prevented the processor from performing its normal program duties. The program restarts automatically. The current welding process will be stopped. This fault does not disable any functions. This fault should never occur in reality. Contact ESAB if the fault does occur. Stack overflow The stack memory is full.

  • Page 44: Service Instructions

    SERVICE INSTRUCTIONS CAUTION ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic- sensitive 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.
  • Page 45 The software update is made from a PC, it has to be managed by a trained serviceman. For this a PC program called ESAT, ESAB Software Administration Tool, is needed. The PC is connected to the welding equipment by a cable connector and a CAN reader. From the ESAT it is possible to update the software.

  • Page 46: Checking Power Board 15Ap1

    Checking power board 15AP1 Disconnect the power source from the mains and follow the instructions below. The numbers of the instructions refer to the diagrams on this and next page. The thyristor in IC8 is connected in parallel with resistors R16 and R15. The resistance must be 24 ohm.
  • Page 47 Power board 15AP1, measuring points S0740 800 196/E101019/P76 ca41f2pwr - 47 -...

  • Page 48: Checking Secondary Board 15Ap2

    Checking secondary board 15AP2 Disconnect the machine from the mains and follow the instructions below. The item numbers below refer to the circuit and component position diagrams on this and next page. Checking the diode modules Remove the screws marked 1a and 1b. see this and next page.
  • Page 49 Secondary board 15AP2, measuring points S0740 800 196/E101019/P76 ca41f2pwr - 49 -...

  • Page 50: Soft Starting

    Soft starting We recommend soft starting of the machine after replacing control circuit board 20AP1 or circuit boards or components in the power module. This supplies the power module with a low DC voltage in order to avoid injury to persons or damage to components. It is also a good idea to use soft starting when fault tracing in the power module.
  • Page 51 Gate pulses from 20AP1. Measure with the screen (gnd) connected to +24 V. The pulse frequency must be 40 kHz $1 kHz. The pulse duration must be 41-44% of the cycle time, measured at -10 V of the negative pulse, as shown in the graph to the right.
  • Page 52 12. Secondary side of the main transformers Measure with the probe connected to T11 and T22 respectively. The shape of the pulses must be as in the graph to the right. 13. Measure the output voltage from the welding current terminals, XS1 and XS2. It must be about 2.9 to 3.1 V.
  • Page 53 Soft starting measuring points, power board 15AP1 S0740 800 196/E101019/P76 ca41f2soft - 53 -...

  • Page 54: Mounting Components On The Heat Sink

    Mounting components on the heat sink Thermal paste Apply thermal conducting paste to the components before fitting them to the heat sink. See the spare parts list for the order number for thermal paste. Use only the paste recommended by us. Start by cleaning the heat sink from dirt and old thermal paste.

  • Page 55: Power Board 15Ap1 With Semicunductor Modules

    Power board 15AP1 with semicunductor modules Clean the heat sink and apply thermal conducting paste to the semiconductor modules as described on page 54. Fit the board and tighten the screws that are securing the IGBT modules to the heat sink to a torque of 2.5 Nm, and then further tighten them to 4.5 Nm.

  • Page 56: Diode Modules 15D1, 15D2 And Secondary Board 15Ap2

    Diode modules 15D1, 15D2 and secondary board 15AP2 Fit the diode modules to secondary board 15AP2. Tighten the connection screws to a torque of 4.5 Nm, see the picture below. Solder pins 3 and 4 of the diode modules to circuit board 15AP2. Fitting of diode modules 15D1 and 15D2 to circuit board 15AP2 Clean the heat sink and apply thermal conducting paste to the diode modules as described on page 54.

  • Page 57: Calibrating The Current Sensor Signal

    Calibrating the current sensor signal Connect the power source to a resistive load. Connect a calibrated shunt in series with the load. Set the power source to MMA mode. Set a welding current of 100 A. Load the power source so that the voltage across the load is 24 V. Circuit diagram for the current calibration Measure the shunt voltage using a calibrated multimeter.

  • Page 58: Mig Power Sources, Calibration Of The Arc Voltage Feedback

    MIG power sources, calibration of the arc voltage feedback The arc voltage input can be calibrated using trimming potentiometers R87 and R103 on circuit board 20AP1. The board has been calibrated in the factory: further adjustment should not normally be necessary. Circuit diagram of the arc voltage input Check that there is a jumper across connectors Y2 - Y3: see the circuit diagram above.
  • Page 59 Welding with the filler wire positive: voltage sensing from the wire This is the most common arrangement of arc voltage sensing. V = external voltmeter. R = load resistor. The control panel must show the same voltage value as shown on the external voltmeter $0.6 V.

  • Page 60: Tig Power Sources, Calibration Of The Arc Voltage Feedback

    TIG power sources, calibration of the arc voltage feedback The arc voltage input can be calibrated using trimming potentiometer R87 on circuit board 20AP1. The board has been calibrated in the factory: further adjustment should not normally be necessary. Use an accurately calibrated external voltmeter to measure the voltage at the welding current terminals.

  • Page 61: Connection Of Terminating Resistors

    CONNECTION OF TERMINATING RESISTORS Abbrevations used in this chapter MMC = Man Machine Communication The MMC unit is a control panel with display, in some cases it also incorporates a welding data board, see WDU below. WDU = Welding Data Unit. The welding data unit handles the overall control of the system.

  • Page 62: Power Source Without Mmc And With Remote Control

    Power source without MMC and with remote control MMC & WDU Power source Wire feed unit Remote control Feasible MMC units are: MA23, MA24, MA6 and U6 MMC & Power source Wire feed unit Remote control Feasible MMC unit is: U8 Power source with MMC MMC &...

  • Page 63: Power Source With Mmc And Wire Feeder With Mmc

    Power source with MMC and wire feeder with MMC MMC & WDU MMC & WDU Power source Wire feed unit Feasible MMC unit for the power source is: A24. Feasible MMC units for the wire feed unit are: MA23, MA24, MA6 and U6 Power source with MMC, wire feeder with MMC and remote control MMC &...

  • Page 64: 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.

  • Page 65: Visual Inspection

    Visual inspection Disconnect the welding power source from the mains supply. 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: Torch/electrode holder, welding current return clamp.

  • Page 66: Electrical Test

    Turn the mains switch of the the welding power source to OFF. Check the no-load voltage. Use the ESAB testbox TB 1. If the welding power source has an activated VRD function then proceed to step 5. Connect the positive (3) and negative (4) welding outlets to the positive and negative terminals (DC of the TB 1.
  • Page 67 Set the welding power souce to MMA-welding. Set the welding current control on the welding power souce to maximum. Check the voltage with the voltmeter. Measured value shall not exceed 35 V. Check that the LED indicates active VRD function by a steady green light. Turn the mains switch of the the welding power source to OFF.

  • Page 68: Functional Test

    Functional test 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. Check the supply circuits on/off switching device Disconnect the welding power source from the mains supply.

  • Page 69: Test Report

    Test report Company: Location: Arc welding power source Equipment: Serial number: ESAB Manufacturer: Type: Testing equipment: VISUAL INSPECTION PASSED ELECTRICAL TEST Limit Measured values Protective conductor resistance ≤ 0.3 Ω É É É É É É É É É É É É É É É É É É É...

  • Page 70: Instructions

    INSTRUCTIONS This chapter is an extract from the instruction manuals for the Mig 3001i and Tig 3001i. SAFETY CAUTION! Read and understand the instruction manual before installing or operating. INSTALLATION Lifting instructions Location Position the welding power source such that its cooling air inlets and outlets are not obstructed.

  • Page 71: Operation

    Make sure that the welding power source is connected to the correct supply voltage and that it is protected by the correct fuse rating. A protective earth connection must be made in accordance with regulations. NOTE! The welding power source is designed for connection to a 400 volt system with four conductors.

  • Page 72: Connections And Control Devices Tig 3001I

    Connections and control devices Tig 3001i Control panel, Connection (-) TIG: Welding torch see separate instruction manual MMA: Welding cable or return cable Connection CAN for remote control unit Connection (+) TIG: Return cable MMA: Return cable or welding cable Connection for start signal from the Mains voltage switch welding torch...

  • Page 73: Tig Welding With Mig 3001I

    TIG welding with Mig 3001i ”Live TIG-start” At a ”Live TIG-start” the tungsten electrode is placed against the workpiece. When the electrode is then lifted away from workpiece, the arc is struck at a limited current level (12 - 15 A). MAINTENANCE Regular maintenance is important for safe, reliable operation.

  • Page 74: Fault-Tracing

    Check that the correct wire or electrode is used. Check the mains power supply fuses. SPARE PARTS The spare parts list is published in a separate document that can be downloaded from the internet: www.esab.com Product Filename Mig 3001i 0459 839 031...
  • Page 75 S0740 800 196/E101019/P76 emptypage - 75 -...
  • Page 76 ESAB subsidiaries and representative offices Europe NORWAY Asia/Pacific Representative offices AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna-Liesing Sofia Shanghai Fax: +47 33 11 52 03 Tel: +43 1 888 25 11...

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