ESAB Mig 4002cw Service Manual
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ESAB Mig 4002cw Service Manual

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See also: Instruction Manual
Mig 4002cw, Mig 4002c
Mig 5002cw, Mig 5002c
Mig 6502cw, Mig 6502c
   
Origo
Service manual
0349 300 080
101229
Valid for serial no.
740,743,741,744,742,745,801,802,803,804,806,805- -xxx- -xxxx

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  • Page 1 Mig 4002cw, Mig 4002c Mig 5002cw, Mig 5002c Mig 6502cw, Mig 6502c     Origo Service manual 0349 300 080 101229 Valid for serial no. 740,743,741,744,742,745,801,802,803,804,806,805- -xxx- -xxxx...

  • Page 2: Table Of Contents

    ..............ESAB Administration Tool (ESAT) .
  • Page 3 INSTRUCTIONS ..............SAFETY .

  • Page 4: Read This First

    This manual contains details of all design changes that have been made up to and including December 2010. The Origo Mig 4002cw, Mig 4002c, Mig 5002cw, Mig 5002c, Mig 6502cw, Mig 6502c are designed and tested in accordance with European standard EN 60974- -1 and EN 60974- -10.

  • Page 5: Technical Data

    TECHNICAL DATA Origo Mig 4002cw Mains voltage 230/400--415/500 V 3∼ 50 Hz 230/440--460 V 3∼ 60 Hz Permissible load at 60 % duty cycle Mig/Mag: 400 A / 34 V; MMA: 400 A / 36 V 100% duty cycle Mig/Mag: 310 A / 30 V; MMA: 310 A / 33 V...
  • Page 6 Enclosure class IP 23 Application classification Origo Mig 6502cw Mains voltage 230/400--415/500 V 3∼ 50 Hz 230/440--460 V 3∼ 60 Hz Permissible load at 60 % duty cycle Mig/Mag: 650 A / 44 V; MMA: 650 A / 44 V 100% duty cycle Mig/Mag: 500 A / 39 V;...
  • Page 7 This page is left blank intentionally. - - 7 - - 1sxx02cw...

  • Page 8: Wiring Diagram

    WIRING DIAGRAM WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic S S S S sensitive devices. Use proper static- -proof bags and boxes. S S S S Component description 9 pole terminal block PF20 Suppression circuit board Main ON/OFF switch...

  • Page 9: Origotm Mig 4002C / 5002C / 6502C Block Diagram

    ACH10 Driver/relays circuit board Chopper module Connector, r Amphenol 10 pole or Burndy 12 pole (obsolete). For connection to/from the wire feed unit Origo Mig 4002c / 5002c / 6502c block diagram - - 9 - - 1sxx02cw...
  • Page 10 Mig 4002cw, 5002cw, 6502cw, 400 - - 415 V - - 10 - - 1sxx02cw...
  • Page 11 Mig 4002cw, 5002cw, 6502cw, 400 - - 415 V - - 11 - - 1sxx02cw...
  • Page 12 Mig 4002c, 5002c, 6502c, 400 - - 415 V - - 12 - - 1sxx02cw...
  • Page 13 Mig 4002c, 5002c, 6502c, 400 - - 415 V - - 13 - - 1sxx02cw...
  • Page 14 Mig 4002cw, 5002cw, 6502cw, 230 - - 500 V - - 14 - - 1sxx02cw...
  • Page 15 Mig 4002cw, 5002cw, 6502cw, 230 - - 500 V - - 15 - - 1sxx02cw...
  • Page 16 Mig 4002c, 5002c, 6502c, 230 - - 500 V - - 16 - - 1sxx02cw...
  • Page 17 Mig 4002c, 5002c, 6502c, 230 - - 500 V - - 17 - - 1sxx02cw...

  • Page 18: 230V / 400- -415V / 440- -460V / 500V

    ? 230V / 400- -415V / 440- -460V / 500V ? - - 18 - - 1sxx02cw...

  • Page 19: Burndy 23 <- -> Amphenol 19

    Burndy 23 <- -> Amphenol 19 Burndy 23 Amphenol 19 Signals Start contact Artificial ground Arc voltage +15VB Data display Clock display Load display Crater fill Water connection monitoring Water connection monitoring - - 19 - - 1sxx02cw...

  • Page 20: Description Of Operation

    DESCRIPTION OF OPERATION CB0 Control circuit 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 board in the MMC control panel. CB0:1 Circuit board identity The control board has a machine ID, a hardware ID and a unit type number.

  • Page 21: Cb0:3 The Can Bus

    CB0:3 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 22: Terminating Resistors

    Terminating resistors In order to avoid communication interference, the ends of the CAN bus must be terminated by resistive loads. One end of the CAN bus is at the control panel, which incorporates a terminating resistor. The other end is in the power source and it must be fitted with a terminating resistor.

  • Page 23: Cb0:5 Current Sensor

    CB0:5 Current sensor The current signal supplied to contact S3 on circuit board CB0 is 200 mA at 400 A, and is linearly proportional to the welding current. Measuring the voltage between contacts S3 and S4 on circuit board CB0 must show 0.195 V at 100 A of welding current.

  • Page 24: Cb0:5.1 Calibrating The Current Sensor Signal

    CB0:5.1 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. Measure the shunt voltage using a calibrated multimeter.

  • Page 25: Cb0:6 Arc Voltage Input Mig/Mag

    CB0:6 Arc voltage input Mig/Mag The arc voltage input senses the welding voltage regardless of the welding polarity or welding method. If sensing via the welding filler wire is turned on, the voltage present on filler wire will be used; if not, the voltage at the power source terminals is used instead.

  • Page 26: Cb0:6.1 Calibration Of The Arc Voltage Feedback

    Welding with the filler wire positive or negative, without external sensing from the wire or workpiece. Y2 -- Y3 must be linked. The input signal is measured between inputs W5 and W2 (the voltage at the power source terminals), as there is no connection to X1.
  • Page 27 Welding with the filler wire positive: voltage sensing from the wire This is the most common arrangement of arc voltage sensing. The control panel must show the same voltage value as shown on the external voltmeter 0.6 V. Adjust the display value by means of potentiometer R87. Welding with the filler wire negative: voltage sensing from the wire The control panel must show the same voltage value as shown on the external voltmeter 0.6 V.

  • Page 28: Cb0:7 Arc Voltage Input In Mma Process

    Welding with the filler wire positive or negative: no external sensing from the wire or workpiece The external voltmeter shows a value 0.2 -- 1.6 V higher than the value shown on the control panel. Do not adjust the value shown on the control panel: this is already adjusted from 1.

  • Page 29: Cb0 Components Positions

    CB0 Components positions - - 29 - - 1sxx02cw...

  • Page 30: Ach10 Driver/Relays Board

    ACH10 Driver/relays board That board co--operates with CB0 and realises following functions: driving transistors in chopper module monitoring of voltage across capacitors in chopper module driving cooling fan, water pump, and mains relay. All function units are described below. ACH10:1 Circuit diagram ACH10:2 Power supply Power supply unit provides two stabilized voltages: +14V and --10V that supply PWM driver, voltage comparator and some of relays.

  • Page 31: Ach10:3 Pwm Driver

    ACH10:3 PWM driver Input stage Control board provides PWM signal that drives transistors Q01 and Q02 in chopper module. Transistors work in push--pull mode. Signal frequency on Q01 and Q02 gates is about 10kHz. Those two transistors have common load R23 on ACH10 board.

  • Page 32: Ach10:4 Pre Charging Voltage Sense

    ACH10:4 Pre charging voltage sense For softer turning--on of main transformer T1 -- chopper module rectifier capacitors battery is pre--charged before energising contactor K1. Voltage on capacitors is sensed by comparator A:3A, and optocoupler V6 is turned on when sensed voltage is more than 44V -- this is signalized by LED diode V4.

  • Page 33: Ach10:5 Mains Contactor Circuit, Energy Saving

    ACH10:5 Mains contactor circuit, energy saving Mains contactor K1 is controlled by microcontroller on board CB0 via transistors Q42, Q31 and relay K1 on ACH10 board. RC snubber element C9 suppress over--voltages transients during turning--off the K1. Energy saving If welding source is not used in MIG process longer than 15 minutes, the microcontroller turns off the contactor K1 and source is in energy saving mode.

  • Page 34: Ach10:7 Cooling Liquid Pump

    ACH10:7 Cooling liquid pump Water pump is controlled by microcontroller on board CB0 via transistors Q47,Q36, relay K2 on ACH10 board. ACH10:8 Flow guard When liquid -- cooled torch is connected to wire feeder, board CB0 senses voltage on pin B10, that pin is pulled up by R34 on board ACH10. Contact in the flow guard closes when the liquid flow rate exceeds 0.7 l/minute.

  • Page 35: Ach10 Components Positions

    ACH10 Components positions - - 35 - - 1sxx02cw...

  • Page 36: Pf20 Suppression Circuit Board

    PF20 Suppression circuit board PF20:1 Circuit diagram PF20:2 Components positions REMOTE CONTROLS Remote control M1 can be connected to the power sources, these are described in a separate service manual with filename / ordering no. xxx. - - 36 - - 1sxx02cw...

  • Page 37: Fault Codes

    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. When the fault log is full, the oldest message will automatically erase when the next fault occurs.

  • Page 38: Fault Code Description, Power Source

    Fault Description Control Power Wire fe- Remote code panel source ed unit control unit Memory error in data memory Memory allocation error Transmitter buffer overflow Receiver buffer overflow Program operating fault Out of wire Stack overflow No cooling liquid flow No reply from the display unit No gas flow Incompatible units...
  • Page 39 Fault Description code 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 40 The program restarts automatically. The current welding process will be stopped. This fault does not disable any functions. This fault should never occur. Action: Contact ESAB if the fault does occur. Stack overflow The stack memory is full. This fault should never occur: the fault code is intended as an aid during development work.

  • Page 41: Service Instructions

    SERVICE INSTRUCTIONS WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic S S S S sensitive devices. Use proper static- -proof bags and boxes. S S S S What is ESD? A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electrostatic Discharge.

  • Page 42: Service Aid

    To make an update of the system, you will also need an application program upgrade. This program will be sent to registered ESAT users by e--mail or be downloaded from ESAB web site. ESAT has it’s own instruction manual 0458 885 174.

  • Page 43: Antistatic Service Kit

    CAN connection Antistatic service kit Ordering no. 0740 511 001 The kit makes it easier to protect sensitve components from electrostatic discharge. Contents: Conductive mat (size 610 x 610 mm) 1.5 metre long ground cable with a crocodile clip Adjustable wrist strap and cable with inbuilt protective resistor Antistatic service kit Checking PWM signal...
  • Page 44 Without load in MMA process duty cycle is about 90%. - - 44 - - 1sxx02cw...
  • Page 45 Output PWM signal from ACH10 can be checked on V16 (condition -- no load on output). Amplitudes should be about +14V and -- 9V, frequency 20kHz ±0,5kHz, duty cycle about 90%. - - 45 - - 1sxx02cw...

  • Page 46: Checking Thermal Cutout

    In MIG/Mag process, without pressing the switch on the torch -- PWM signal is not generated -- output signal should be about --9V which means that chopper transistors are off. Checking thermal cutout Thermal cutouts are normally closed and form a loop. When either of the thermal cutouts opens, a fault must be indicated.

  • Page 47: Checking Flow Guard (Only Machines With Flow Guard Sensor)

    Checking Flow guard (only machines with Flow Guard sensor) Esab Logic Pump switch on feeder must be ”on” -- in Mig/Mag process. Turn of the plug from X4.1--X4.2 on ACH10. When switch on torch is pressed -- an error message should be displayed -- welding process is stopped.

  • Page 48: Checking Pre Charging Circuit

    Checking pre charging circuit After few second from turning the power on led diode V4 should light up, and contactor K1 should switch on. If not, an error message should be displayed (error nr 5). Check the pre--charging circuit , If voltage on chopper capacitors is more than 45V V4 should light on.

  • Page 49: Checking Liquid Pump Circuit

    speed is low, temperature sensor B3 is open -- voltage between X7:2--X7:1 should be about 13V. Checking liquid pump circuit Check if relay K2 on ACH10 closes when ELP switch on wire feeder is up. When K2 on ACH10 is closed voltage on diode V11 should be about 24V. Be Careful! High Mains Voltage is on X6 connector.

  • Page 50: Checking The Led Indicators On Board Cb0

    Checking the LED Indicators on board CB0 The indications are two coloured LED--indicators, red and green. One indicator can have three indication states, off, red on, and green on. Three indicators are used which means that 9 states can be indicated. The following events will be indicated: Event Indicator...

  • Page 51: Checking Chopper Block V0

    Checking chopper block V0 Chopper is assembled form three main blocks: input rectifier, capacitors bank and output IGBT stage. Chopper module schematic diagram: There are three types of chopper modules, each one for particular power source: OrigoMig 4002c/4002cw OrigoMig 5002c/5002cw OrigoMig 6502c/6502cw Differences lay within heatsinks dimensions, type and number of power IGBT modules, capacitance of capacitors, type of rectifier diodes.
  • Page 52 Views - - 52 - - 1sxx02cw...

  • Page 53: Overview Test

    Overview test Each block consist of at least two serviceable parts. The first step of control is taking overview and checking if any parts are looking abnormal. Broken parts can have marks of thermal damage, change of colors or shape. If after that checking nothing was find out next step is electrical testing.

  • Page 54: Checking Of Output Stage

    For easy disassembly unscrew both rectifier heatsinks from capacitors side and plastic shelf with AC terminals and disassemble two M6 screws down the heatsink on opposite side. Important note - - all diode threads have to be covered with very thin layer of No. 2 Electro Joint Compound before replacing.

  • Page 55: Replacing Of Damaged Transistors

    Replacing of damaged transistors In order to replace damaged transistor following items have to be disassembled: diode rectifiers output terminal DC--link terminals unconnected from modules Important note -- IGBT module is symmetrical except two plastic pins for positioning PCB. During replacement check if ”+” ”--” marked side of module is placed on capacitors side and ant the end is connected to DC--link terminals.

  • Page 56: Instructions

    5002c/5002cw and 6502c/6502cw. SAFETY Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding equipment. The following recommen- dations should be observed in addition to the standard regulations that apply to the workplace.

  • Page 57: Installation

    INSTALLATION The installation must be executed by a professional. WARNING! This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user’s responsibility to take adequate precautions. Lifting instructions The power supply should be lifted by means of its lifting eye.

  • Page 58: Assembly Of Components

    Assembly of components WARNING! During transport, the rear wheels of the power source are in their forward position. Before use, place the wheels in their rear position. - - 58 - - 2sxx02cw...

  • Page 59: Mains Power Supply

    A protective earth connection must be made, in accordance with regulations. Rating plate with supply connection data Recommended fuse sizes and minimum cable areas 50Hz Mig 4002cw, 4002c Mig 5002cw, 5002c Mig 6502cw, 6502c Mains voltage 230/400--415/500 V...

  • Page 60: Operation

    OPERATION General safety regulations for the handling of the equipment appear from page 56. Read through before you start using the equipment! WARNING - - TIPPING RISK! Fasten the equipment -- particularly if the ground is uneven or sloping. Connections and control devices Mains supply switch Control cable socket (from / to wire feeder) Indicating lamp, power supply ON...

  • Page 61: Water Connection

    Water connection Feed has a sensor ELP, ESAB Logic Pump, that senses if the The Aristo /Origo water hoses of the welding gun are connected. When a water cooled welding gun is connected, the water pump starts. When connecting the cooling water hoses to/from the Feed wire feed unit, the mains ON/OFF switch of the Mig must be in the OFF position.

  • Page 62: Fault Tracing

    Check that the correct welding wires are being used. Check the main power supply fuses. ORDERING OF SPARE PARTS Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication. - - 62 - -...

  • Page 63: Notes

    NOTES - - 63 - - notes...
  • Page 64 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...

This manual is also suitable for:

Mig 5002cwMig 4002cMig 5002cMig 6502cwMig 6502c

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