Related Manuals for ESAB Arc 4000i
Summary of Contents for ESAB Arc 4000i
- Page 1 Aristot Origot Arc 4000i, Mig U4000i, Mig 4000i, Tig 4000i Service manual 0740 800 191 080229 Valid for serial no. 803- -xxx- -xxxx...
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Page 2: Table Of Contents
........Arc 4000i valid for serial number 803- -xxx- -xxxx . - Page 3 ........Connections and control devices, Arc 4000i .
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Page 4: Read This First
Mig U4000i, Mig 4000i, Tig 4000i and Arc 4000i with serial no. 803--xxx--xxxx. Note! Mig U4000i, Mig 4000i, Tig 4000i and Arc 4000i with serial number 105- -xxx- -xxxx to 802- -xxx- -xxxx differ from the description in this manual. For those machines there is... -
Page 5: Introduction
INTRODUCTION 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. -
Page 6: Technical Data
TECHNICAL DATA Mig U4000i Mains voltage 400V ±10%, 3∼ 50 Hz Mains supply 2.0 MVA sc min Primary current MIG/MAG 25 A 27 A 20 A No- -load power demand when in the energy--saving mode, 6.5 min. after welding 60 W Voltage/current range MIG/MAG 8 -- 60 V / 16 -- 400 A... -
Page 7: Mig 4000I
Mig 4000i Mains voltage 400V ±10%, 3∼ 50 Hz Mains supply 2.0 MVA sc min Primary current (MIG/MAG) 25 A (MMA) 27 A No- -load power demand when in the energy--saving mode, 6.5 min. after welding 60 W Voltage/current range (MIG/MAG) 8 -- 60 V / 16 -- 400 A (MMA) -
Page 8: Tig 4000I
Tig 4000i Mains voltage 400V ±10%, 3∼ 50 Hz Mains supply 2.0 MVA sc min Primary current (TIG) 20 A (MMA) 27 A No- -load power in the energy--saving mode, 6.5 min. after welding 60 W Voltage/current range (TIG) 8 -- 60 V / 4 -- 400 A (MMA) 16 -- 400 A Permissible load at TIG... -
Page 9: Arc 4000I
Arc 4000i Mains voltage 400 V ±10%, 3∼ 50 Hz Mains supply 2.0 MVA sc min Primary current I 27 A No- -load power in energy--saving mode 6.5 min. after welding 50 W Setting range 16 A -- 400 A... -
Page 10: 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 11 Component Description XT.. Terminal blocks. MMC module. Wire numbers 100--199. See description on page 22. Mains module. Wire numbers 200--299. 2AP1 EMC suppressor board. See diagram on page 23. 2FU1 Fuse, 4 A slow blow (anti--surge). 2FU2 Fuse, 6.3 A, slow blow (anti--surge). 2FU3 Fuse, 3.15 A, slow blow (anti--surge).
- Page 12 Component Description 15BR1 Rectifier bridge. See the description of 15AP1:1 on page 26 and the assembly instructions on page 59. 15D1, 15D2 Rectifier and freewheel diode modules. Each module consists of two diodes. 15D1 rectifies the welding current. During the time interval between two voltage pulses from transformer 15TM1, the freewheel diodes 15D2 maintain the welding current from inductor 15L3.
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Page 13: Mmc Option For Mig Machines
MMC option for MIG machines CAN bus distribution board AP3 connected to Mig 4000i The MIG machines are normally delivered without MMC module. If the accessory ’MMC kit’ is used, the MMC module can be moved from the wire feed unit to the power source. S0740 800 191/E080229/P78 - - 13 - - cu19_00... -
Page 14: Mig U4000I Valid For Serial Number 803- -Xxx- -Xxxx
Mig U4000i valid for serial number 803--xxx--xxxx S0740 800 191/E080229/P78 - - 14 - - cu19_00... - Page 15 S0740 800 191/E080229/P78 - - 15 - - cu19_00...
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Page 16: Mig 4000I Valid For Serial Number 803- -Xxx- -Xxxx
Mig 4000i valid for serial number 803--xxx--xxxx S0740 800 191/E080229/P78 - - 16 - - cu19_00... - Page 17 S0740 800 191/E080229/P78 - - 17 - - cu19_00...
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Page 18: Tig 4000I Valid For Serial Number 803- -Xxx- -Xxxx
Tig 4000i valid for serial number 803--xxx--xxxx S0740 800 191/E080229/P78 - - 18 - - cu19_00... - Page 19 S0740 800 191/E080229/P78 - - 19 - - cu19_00...
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Page 20: Arc 4000I Valid For Serial Number 803- -Xxx- -Xxxx
Arc 4000i valid for serial number 803--xxx--xxxx S0740 800 191/E080229/P78 - - 20 - - cu19_00... - Page 21 S0740 800 191/E080229/P78 - - 21 - - cu19_00...
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Page 22: Description Of Operation
MMC modules for the Tig 4000i The power source is supplied with control panel TA4 or control panel TA6. MMC modules for the Arc 4000i The power source is supplied with control panel A2 or control panel A4. S0740 800 191/E080229/P78... -
Page 23: 2Ap1 Interference Suppressor Board (Emc Board)
2AP1 Interference suppressor board (EMC board) Circuit diagram and component positions, 2AP1 S0740 800 191/E080229/P78 - - 23 - - ct32_02... - Page 24 5 Cooling unit Component description, water cooling unit Start and run capacitor for the fan motor, 5 mF 450 V AC. Start and run capacitor for the pump motor, 3 mF 400V. 5EV1 Fan motor, 230 V AC. Pump motor, 230 V AC. Microswitch for the water lock connection.
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Page 25: 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 26: 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 27: 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 29. -
Page 28: 15Ap1 Component Positions
15AP1 Component positions S0740 800 191/E080229/P78 - - 28 - - ct32_15... -
Page 29: 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 30: 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 31: 15Ap2 Component Positions
15AP2 Component positions WARNING! 0 V on this circuit board is at mains voltage. S0740 800 191/E080229/P78 - - 31 - - ct32_15... -
Page 32: 20Ap1 Control Board
This description is valid for machines supplied with circuit board 0487 201 880. Mig U4000i, Mig 4000i, Tig 4000i and Arc 4000i with serial no. 803--xxx--xxxx are supplied with this circuit board. Spare part boards When replacing the board, do not forget to move the “terminal D jumper”... -
Page 33: 20Ap1:2 Fan Control
Uan 5 V internal reference voltage on 20AP1. Uref 2.5 V internal reference voltage on 20AP1. 20AP1:2 Fan control When the mains power supply is turned on, the fans are off. After about 4 seconds they start and run at full speed, for a short moment, before shutting down until welding starts. -
Page 34: 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 35: 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 36: 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 34. If a CAN remote control with terminating resistor, or an external terminating resistor, is connected to the power source, the internal terminating resistor must be disconnected from the power source. -
Page 37: 20Ap1:6 Communication With Relay Board 20Ap2
20AP1:6 Communication with relay board 20AP2 See page 42, 20AP2 relay board. 20AP1:7 Gate pulses See page 29, 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 38: 20Ap1:9 Arc Voltage Feedback For Universal And Mig Machines
20AP1:9 Arc voltage feedback for Universal and MIG machines 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 39 Methods of measuring the arc voltage Various methods of measurement are available by transferring a link between contacts Y1, Y2 and Y3. When delivered, the link is fitted between Y2 and Y3. The link must be connected between Y2 and Y3 for MMA and TIG welding. Welding with the filler wire positive: voltage sensing from the wire.
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Page 40: 20Ap1:9 Arc Voltage Feedback For Tig And Mma Machines
20AP1:9 Arc voltage feedback for TIG and MMA machines Circuit diagram of the arc voltage input The arc voltage input senses the welding voltage at the power source’s welding current terminals. Contacts Y2 and Y3 must be linked. The signal from the arc voltage input is used as an input signal to the welding process controller: from it, the controller calculates in real time how much current must flow in the circuit in the next instant. -
Page 41: 20Ap1 Component Positions
20AP1 Component positions S0740 800 191/E080229/P78 - - 41 - - cu19_20_1... -
Page 42: 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 controller circuit board 20AP1. Link BY3 tells the processor on the controller board what version of the relay board is in use. -
Page 43: 20Ap2:3 Starting Sequence
20AP2:3 Starting sequence Schematic diagram of the power source starting circuits Starting sequence: 1. Turning main switch 2QF1 from 0 to 1 closes contacts a--1 and c--3, this energises the relay contacts on RE1 -- RE3. 2. Turning 2QF1 to the START position closes contacts 2--b and 4--d. 3. -
Page 44: 20Ap2:4 Power Supply To The Cooling Unit
20AP2:4 Power supply to the cooling unit The cooling water pump is controlled by the software in the welding data unit via circuit board 20AP1. The wiring diagram of the cooling unit is shown on page 24. 20AP2:5 Cooling water monitoring in MIG welding mode Water lock and flow guard in a MIG machine Microswitch 5S1 in the water lock connector closes when a cooling water hose is connected to the blue water connector... - Page 45 Starting the welding equipment The MMC panel senses whether microswitch 13S1 in the wire feed unit is closed. If 13S1 is closed, the panel generates a command to start the pump. If water flow is not detected within 15 seconds, the pump is stopped. If welding does not start within 6.5 minutes, the pump is stopped.
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Page 46: 20Ap2:5 Cooling Water Monitoring In Tig Welding Mode
20AP2:5 Cooling water monitoring in TIG welding mode Microswitch 5S1 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. Contact 5SL1 in the flow guard closes when the water flow rate exceeds 0.7 l/minute. -
Page 47: 20Ap2:6 Tig Gas Valve
20AP2:6 TIG Gas valve Gas valve 10YV1 is controlled by the processor on circuit board 20AP1. It can be activated via service function no. 10. 20AP2:7 TIG HF starting device The 10AP1 HF starting device is controlled by the processor on circuit board 20AP1. -
Page 48: 20Ap2:9 Gas Flow Monitor
20AP2:9 Gas flow monitor MIG and TIG machines Terminals G4 and G5 are intended for use with a gas flow monitor. The processor reacts to voltage flanks from the input. The MIG and TIG machines are not normally fitted with gas flow monitors, which means that this input must be short--circuited by a link. -
Page 49: 20Ap2 Circuit Diagram
20AP2 Circuit diagram S0740 800 191/E080229/P78 - - 49 - - cu19_20_2... -
Page 50: Fault Log
REMOTE CONTROLS A number of remote control units can be connected to the power sources, these are described in a separate service manual with filename 0740 800 170. 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 51: Fault Code Description, Power Source
Fault Description Welding Power Wire feed Remote code data unit source unit control unit Lost contact with the power source Memory error in data memory 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... - Page 52 Code Description 5 V power supply too low The unregulated power supply voltage 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. Action: Turn off the mains power supply to reset the unit.
- Page 53 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 54 S0740 800 191/E080229/P78 - - 54 - - emptypage...
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Page 55: 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 56: Service Aid
The software update is made from a PC, it has to be managed by a trained serviceman. For this a computer 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 in power source, wire feeder and control panel. -
Page 57: Dismantling
Dismantling When dismantling the power source, start as follows: Remove the screws securing the cover and the rear handle. Pull the cover backwards and lift it off. Remove the side plates. Service traps The following are a number of points where it is easy to make a mistake and damage the equipment. -
Page 58: 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 59: 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 60: Soft Starting
Soft starting We recommend soft starting of the machine 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 61 Connect an oscilloscope to the SST 2 across terminals GND2 and P2, as shown on page 60. 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.
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Page 62: 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 machine must be in soft starting mode when checking the gate pulses, see page 60. 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 63: 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 64: 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 65: Calibrating The Current Sensor Signal
Calibrating the current sensor signal If the power source has a TIG function, remove fuse 2FU5 from transformer 2TC2. This disconnects the supply to the HF ignition unit (see the wiring diagram). Connect the power source to a resistive load. Connect a calibrated shunt in series with the load. -
Page 66: Mig Machines, Calibration Of The Arc Voltage Feedback
MIG machines, 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 short--circuiting link across connectors Y2 -- Y3: see the circuit diagram above. - Page 67 Welding with the filler wire positive: voltage sensing from the wire This is the commonest 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 68: Dc Tig Machines, Calibration Of The Arc Voltage Feedback
DC TIG machines, 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 69: Instructions
INSTRUCTIONS This chapter is an extract from the instruction manuals for the Mig U4000i, Mig 4000i, Arc 4000i and Tig 4000i. SAFETY CAUTION! Read and understand the instruction manual before installing or operating. INSTALLATION The installation must be executed by a professional. -
Page 70: Mains Power Supply
Mains power supply Rating plate with supply connection data Check that the unit is connected to the correct mains power supply voltage, and that it is protected by the correct fuse sizes. A protective earth connection must be made, in accordance with regulations. Recommended fuse sizes and minimum cable area Mains voltage 400 V 3μ... - Page 71 When welding with water--cooled MIG/--guns on all wire feed units, it is recommended to connect a separate cooling unit for the 2 extra guns. We recommend connecting the guns in parallel. Two wire feed units A connection kit is required when connecting two wire feed units, see accessory part of the spare parts list.
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Page 72: Operation
Connection for cooling water from the wire feed unit -- RED Main power supply switch, 0 / 1 / START * ELP = ESAB Logic Pump, see Cooling unit on page 75. S0740 800 191/E080229/P78 - - 72 - -... -
Page 73: Connections And Control Devices, Mig 4000I
Main power supply switch, 0 / 1 / START Connection for cooling water from the wire feed unit -- RED Connections and control devices, Arc 4000i Welding current cable connector (+) White indicating lamp, mains power supply Connector for remote control adapter... -
Page 74: Connections And Control Devices, Tig 4000I
Connections and control devices, Tig 4000i Connection for cooling water from the TIG Main power supply switch, 0 / 1 / START torch -- RED Connection with water lock for cooling wa- White indicating lamp -- Power supply ON ter to the TIG torch -- BLUE Cooling water filler Orange indicating lamp -- Overheating Connection for return cable (+) -
Page 75: Fan Control
Cooling unit Water connection (TIG welding) The cooling unit is equipped with a detection system ELP (ESAB Logic Pump) which checks that the water hoses are connected. The power source On/Off switch must be in the “0” position (Off) when connecting a water--cooled TIG torch. -
Page 76: Maintenance
MAINTENANCE Regular maintenance is important for safe, reliable operation. Only those persons who have appropriate electrical knowledge (authorized personnel) may remove the safety plates. Note! All guarantee undertakings from the supplier cease to apply if the customer himself attempts any work in the product during the guarantee period in order to rectify any faults. Cleaning the air filter Release the cover plate with the dust filter (1). -
Page 77: 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 U4000i & Mig 4000i 0459 839 019 Tig 4000i 0459 839 022 Arc 4000i 0459 839 023 NOTES S0740 800 191/E080229/P78 - - 77 - - notes... - Page 78 ESAB subsidiaries and representative offices Europe Asia/Pacific Representative offices NORWAY 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...