Related Manuals for ESAB Aristo Origo Arc 4001i
Summary of Contents for ESAB Aristo Origo Arc 4001i
- Page 1 Aristot Origot Arc 4001i Mig 4001i Service manual 0740 800 197 100621 Valid for serial no. 833-xxx-xxxx 852-xxx-xxxx...
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Page 2: Table Of Contents
READ THIS FIRST ..............INTRODUCTION . - Page 3 What is ESD? ..............Service aid .
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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 schematic 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.
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Page 6: Technical Data
TECHNICAL DATA Mig 4001i Arc 4001i 400 V $10%, 3∼ 50/60 Hz 400 V $10%, 3∼ 50/60 Hz Mains voltage Mains supply 2.2 MVA 2.2 MVA sc min sc min Primary current MIG/MAG 26 A 26 A 20 A 20 A 27 A 27 A No-load power in energy-saving mode... -
Page 7: Wiring Diagram
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. 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 Component Description XT.. Terminal blocks. MMC module. Wire numbers 100-199. See description on page 14. Mains module. Wire numbers 200-299. 2AP1 EMC suppressor board. See diagram on page 15. 2FU1 Fuse, 0.5 A slow blow (anti-surge). 2FU2 Fuse, 3.15 A slow blow (anti-surge). 2FU3 Fuse, 4 A slow blow (anti-surge).
- Page 9 Component Description 15Q1, 15Q2 IGBT transistors. See the description of 15AP1:2 on page 18 and the installation instructions on page 49. 15ST1 Thermal overload cutout, in the winding of main transformer TM1. See the description of 20AP1:4 on page 27. 15ST2 Thermal overload cutout, mounted on the heat sink for the IGBT modules.
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Page 10: Arc 4001I
Arc 4001i S0740 800 197/E100621/P74 - 10 - ca42_00... - Page 11 S0740 800 197/E100621/P74 ca42_00 - 11 -...
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Page 12: Mig 4001I
Mig 4001i S0740 800 197/E100621/P74 - 12 - ca42_00... - Page 13 S0740 800 197/E100621/P74 ca42_00 - 13 -...
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Page 14: Description Of Operation
DESCRIPTION OF OPERATION This description of operation 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. AP2 Interference suppressor board Component positions and circuit diagram for circuit board AP2 The circuit board removes interference signals. -
Page 15: 2Ap1 Interference Suppressor Board (Emc Board)
2AP1 Interference suppressor board (EMC board) Circuit diagram and component positions, 2AP1 S0740 800 197/E100621/P74 ca42_02 - 15 -... -
Page 16: 15 The Power Module
15 The power module The power module converts 3-phase 400 V to the welding voltage. It consists of a single forward inverter, operating at a switching frequency of 27 kHz. The mains rectifier bridge 15BR1, the IGBT transistors 15Q1 and 15Q2 and the diode modules 15D1 and 15D2 are all mounted on a heat sink. -
Page 17: 15Ap1 Power Board
15AP1 Power board The power board carries the mains rectifier, the smoothing capacitors, the charging circuit and the switching circuit. Circuit board connectors marked NC are not connected. 15AP1:1 Mains rectifier bridge and charging circuit When the mains power supply is turned on, smoothing capacitors C13-C16 are charged via rectifier bridge BR2. -
Page 18: 15Ap1:2 Switching Circuit
15AP1:2 Switching circuit The power module switching components consist of IGBT transistors 15Q1 and 15Q2, operating at a switching frequency of 27 kHz. The transistors must never be energised when the gate connections are removed. The gate pulse waveforms and duration are vital for correct operation. See also page 20. -
Page 19: 15Ap1 Component Positions
15AP1 Component positions S0740 800 197/E100621/P74 ca42_15 - 19 -... -
Page 20: 15Ap2 Gate Driver Board
15AP2 Gate driver board The gate driver board carries circuitry for gate driving and overvoltage and undervoltage protection. 15AP2:1 Gate driver stages WARNING! Dangerous voltage - mains voltage. Never measure the gate signals when the power source is connected to the mains supply. The pulse frequency is 27 kHz, with a maximum pulse width of 39.0 - 40.8 % of the cycle width. -
Page 21: 15Ap2:2 Overvoltage And Undervoltage Protection
15AP2:2 Overvoltage and undervoltage protection WARNING! Dangerous voltage. Mains voltage on circuit boards 15AP1 and 15AP2 when connected to the 400 V supply. 0 V on power board 15AP1 and gate driver board 15AP2 is connected to the mains supply. 0 V on the power board and gate driver board is galvanically isolated from 0 V on controller board 20AP1. -
Page 22: 15Ap2 Component Positions
15AP2 Component positions WARNING! 0 V on this circuit board is at mains voltage. S0740 800 197/E100621/P74 - 22 - ca42_15... -
Page 23: 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 24: 20Ap1:1 Power Supply
20AP1:1 Power supply +24 V Power supply to relay board 20AP2. +15 V Internal power supply on 20AP1 and power supply to the pulse transformers on 15AP2. -15 V Internal power supply on 20AP1. +5 V Internal power supply on 20AP1. +2.5 V Internal power supply on 20AP1. -
Page 25: 20Ap1:3 The Can Bus
20AP1:3 The CAN bus A standardised communication (CAN - Controller Area Network) bus is used for communication between the welding equipment units. 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 26: Starting Sequence
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 27: 20Ap1:4 Temperature Monitoring
Terminal D, version 2 of 20AP1 Terminal D, version 1 of 20AP1 See page 59 for examples on how to connect the terminating resistors in different equipment configurations. 20AP1:4 Temperature monitoring Principle diagram of the temperature monitoring circuits Thermal cutout switch 15ST1 is fitted under the winding of main transformer 15TM1, and opens at a temperature of 130°C. -
Page 28: 20Ap1:6 Communication With Relay Board 20Ap2
20AP1:6 Communication with relay board 20AP2 See page 35, 20AP2 relay board. 20AP1:7 Gate pulses See page 20, 15AP2:1 gate driver stage. 20AP1:8 Current sensor The current signal supplied to contact S3 on circuit board 20AP1 is 200 mA at 400 A, and is linearly proportional to the current. -
Page 29: 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 30: 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 31: 20Ap1:10 Control Panel Interface Circuits
When the current exceeds 8 A the hot start current is activated. When the arc voltage exceeds 52 V, welding stops and the open-circuit voltage control is activated. TIG welding mode Live TIG start The power source generates open-circuit voltage. When there is contact between electrode and workpiece. -
Page 32: 20Ap1 Component Positions, Version
20AP1 Component positions, version 1 S0740 800 197/E100621/P74 - 32 - ca42_20_1... - Page 33 20AP1 Component positions, version 2 S0740 800 197/E100621/P74 ca42_20_1 - 33 -...
- Page 34 S0740 800 197/E100621/P74 - 34 - emptypage...
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Page 35: 20Ap2 Relay Board
20AP2 Relay board The relay board handles hardware-connected inputs and outputs to/from control board 20AP2. The relays provide the necessary galvanic insulation. 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. Link BY3 tells the processor on the control board what version of the relay board is in use. -
Page 36: 20Ap2:3 Starting Sequence
20AP2:3 Starting sequence Schematic diagram of the power source starting circuits Starting sequence: Turning main switch 2QF1 from 0 to 1 closes contacts a-1 and c-3, this energises the relay contacts on RE1 - RE3. Turning 2QF1 to the START position closes contacts 2-b and 4-d. The control board is energised from the control current transformer. -
Page 37: 20Ap2:4 Power Supply To The Cooling Unit
The ELP switch in the water lock connector closes when a cooling water hose is connected to the blue water connector on the front of the cooling unit. The pump stops if the switch opens. (ELP stands for ESAB Logic Pump.) Starting the welding equipment The welding data unit senses whether the ELP switch is closed. -
Page 38: 20Ap2:9 Gas Pressure Monitoring
Welding stop The welder releases the welding torch trigger switch. Welding stops. The water pump continues to run for a further 6.5 minutes. If welding is restarted while the pump is still running, the pump will continue to run as required, i.e. the 6.5 minute shutdown countdown is interrupted. 20AP2:9 Gas pressure monitoring Terminals G4 and G5 are intended for use with a gas pressure sensor monitor. -
Page 39: 20Ap2 Component Positions
20AP2 Component positions The circuit diagram and component positions shows all the components with which the board may be fitted: the exact choice of components varies, depending on in which machine the board is used. Spare part circuit boards are delivered with all components fitted. S0740 800 197/E100621/P74 ca42_20_2 - 39 -... -
Page 40: 20Ap2 Circuit Diagram
20AP2 Circuit diagram S0740 800 197/E100621/P74 - 40 - ca42_20_2... -
Page 41: 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 42: Fault Code Description, Power Source
Fault Description Welding Power Wire feed Remote code data unit source unit control unit Memory allocation error Transmitter buffer overflow Receiver buffer overflow Program operating fault Out of wire Stack overflow No cooling water flow No reply from the display unit No gas flow Incompatible units Fault code description, power source... - Page 43 Code Description Intermediate DC voltage outside limits The DC voltage from the main rectifier, 15BR1, is too high or too low. Too high a voltage can be due to severe transients on the mains power supply or to a weak power supply (high inductance of the supply).
- Page 44 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.
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Page 45: 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 46 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.
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Page 47: Service Traps
Service traps The following are a number of points where it is easy to make a mistake and damage the equipment. Main On/Off switch, 2QF1 Don't get the cable cores mixed up. Connect all the cores to the switch in accordance with their numbers and the terminal numbers on the switch, all as shown in the circuit diagram for the power source. -
Page 48: Checking The Igbt Transistors
Checking the IGBT transistors Check the IGBT transistors with the diode test mode of a multimeter. 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. -
Page 49: Mounting Components On The Heat Sink
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 very thin, even layer of thermal paste 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. -
Page 50: Soft Starting
Soft starting We recommend soft starting of the power source after replacing control circuit board 20AP1, relay board 20AP2 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. - Page 51 Test points for gate pulses from 20AP1 Compare the waveform of the gate pulses with the diagram below. The waveform shape must be as in the diagram. Pulses from 20AP1 to 15AP2 when the output of 20AP1 is connected to 15AP2. Measure the pulse frequency, it must be 27 kHz $0.5 kHz.
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Page 52: Checking The Gate Pulses From Circuit Board 15Ap2
Checking the gate pulses from circuit board 15AP2 WARNING! During normal operation there is mains voltage on circuit board 15AP2. The power source must be in soft starting mode when checking the gate pulses, see page 50. Connect an oscilloscope with the probe to TC1 and the screen to TC2. CAUTION! If you short circuit TC1 and TC2, the gate driver board will be destroyed. -
Page 53: Measurements
Measurements Circuit diagram for soft starting measurements Start the power source. Measure the voltage on 15BR1. It should be about 15 V DC. See the circuit diagram above. Measure the voltage between the negative terminal on capacitor C16 and the positive terminal on capacitor C14, on circuit board 15AP1. -
Page 54: Checking The Overvoltage And Undervoltage Threshold Values
Checking the overvoltage and undervoltage threshold values WARNING! Dangerous voltages. Mains voltage on circuit board 15AP1 and 15AP2 when the power source is connected to the 400 V supply. Disconnect the machine from the mains, and follow the instructions below. Disconnection from the mains supply Remove wires 261, 262 and 263 from terminal block A on circuit board 15AP1. -
Page 55: 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, or use ESAT to set a current reference. Set a welding current of 400 A. Load the power source so that the voltage across the load is 35 - 37 V. -
Page 56: 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 Connect a wire feed unit to the power source. - Page 57 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.
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Page 58: Mma Power Sources, Calibration Of The Arc Voltage Feedback
MMA 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 59: 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 over all control of the system. -
Page 60: 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 61: 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 62: 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 63: 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 64: Electrical Test
2KM1. 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 65 Connect the positive (3) and negative (4) welding outlets to the positive and negative terminals (DC of the TB 1. Connect a voltmeter to V of the TB 1. PEAK Connect the welding power source to the mains supply. Turn the control knob of the TB 1 anti-clockwise to 0.2. Turn the mains switch of the the welding power source to ON.
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Page 66: 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 devices Disconnect the welding power source from the mains supply. - Page 67 Turn the mains switch of the the welding power source to OFF. m. Reassemble the cover. Check signal and control lamps Check the function of the display indicators by turning on the unit and visually check the front panel. The LED test starts with all LEDs dark, then the diodes are turned on and off, one at a time, until all diodes have been tested.
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Page 68: Test Report
Test report Company: Location: Arc welding power source Serial number: Equipment: 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 69: Instructions
INSTRUCTIONS This chapter is an extract from the instruction manuals for the Mig 4001i and Arc 4001i. 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 70: 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. Recommended fuse sizes and minimum cable area Mig 4001i &... -
Page 71: Connections And Control Devices Arc 4001I
Connections and control devices Arc 4001i Mains power supply switch, 0 / 1 / Start Connection (-) MMA: return cable or welding cable TIG: torch MIG/MAG: return cable Control panel, Connection (+) see separate instruction manual MMA: welding cable or return cable TIG: return cable MIG/MAG: welding cable Connection for remote control unit... -
Page 72: Tig Welding
TIG welding ”Live TIG-start” With “Live TIG start” the tungsten electrode is placed against the workpiece. When the electrode is then lifted away from the workpiece again the arc is struck at a limited current level. (12-15 A). MAINTENANCE Regular maintenance is important for safe, reliable operation. Only personnel with the appropriate electrical skills (authorised staff) may remove safety plates. -
Page 73: Welding Torch
Check that the correct current value is set. Check that the correct electrodes are being used. 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 4001i... - Page 74 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...