ESAB Warrior™ 400i cc/cv Warrior™ 500i cc/cv User manual

Service manual

0464 523 001 GB 20150602 Valid for: serial no. 324-, 339-, 405-xxx-xxxx

Warrior™400iCC/CV

Warrior™500iCC/CV

TABLE OF CONTENTS

0464 523 001 © ESAB AB 2015

READ THIS FIRST................................................................................................ 5

INTRODUCTION................................................................................................... 6

Design structure of the power source ...............................................................6

Working principle ................................................................................................. 6

TECHNICAL DATA ............................................................................................... 8

WIRING DIAGRAM............................................................................................. 10

Component description..................................................................................... 11

Warrior 400i/500i CC/CV ....................................................................................13

Warrior component positions ...........................................................................15

DESCRIPTION OF OPERATION........................................................................ 18

Warrior internal voltage map.............................................................................18

1AP1 MMC board................................................................................................19

1AP1:1 Power supply....................................................................................... 19

1AP1:2 Display and LEDs................................................................................ 20

1AP1:3 Encoder ............................................................................................... 20

1AP1:4 Selectors .............................................................................................21

1AP1 Component positions..............................................................................22

2AP1 Mains filter board .....................................................................................23

2AP1 Component positions..............................................................................24

15AP1 Power board ........................................................................................... 25

15AP1:1 Power supply..................................................................................... 26

15AP1:2 DC bus and precharge circuit............................................................ 28

15AP1:3 IGBT drives ....................................................................................... 29

15AP1:4 Primary current.................................................................................. 30

15AP1:5 DC bus voltage monitoring ................................................................ 31

15AP1:6 DC bus ripple protection.................................................................... 32

15AP1:7Temperature monitoring ....................................................................33

15AP1:8 Torch.................................................................................................. 33

15AP1:9 Fan and cooler .................................................................................. 34

15AP1 Component positions............................................................................35

15AP2 Capacitor board......................................................................................36

15AP2 Component positions............................................................................36

15AP3 Filter board ............................................................................................. 37

15AP3 Component positions............................................................................37

20AP1 Control board ......................................................................................... 38

20AP1:1 Power supply..................................................................................... 38

20AP1:2 DC bus monitoring.............................................................................41

20AP1:3 Primary current.................................................................................. 41

20AP1:4 Secondary current ............................................................................. 42

20AP1:5 Arc voltage ........................................................................................ 43

20AP1:6 Current regulator ...............................................................................44

20AP1:7 PWM circuit .......................................................................................45

TABLE OF CONTENTS

0464 523 001 © ESAB AB 2015

20AP1:8 Gate drives ........................................................................................ 46

20AP1:9 Digital inputs/outputs ......................................................................... 47

20AP1:10 Remote interface ............................................................................. 47

20AP1:11 Wire feeder interface ....................................................................... 48

20AP1:12 MMC interface ................................................................................. 49

20AP1:13 Processor and miscellaneous circuits .............................................50

20AP1 Component positions............................................................................51

FAULT INDICATIONS ......................................................................................... 52

Fault descriptions ..............................................................................................52

SERVICE INSTRUCTIONS................................................................................. 55

What is ESD?......................................................................................................55

Service aid .......................................................................................................... 55

Special tools ....................................................................................................... 56

Mounting components on the heat sink ..........................................................56

Tightening torque for screw joints on power components............................57

Power On/Off sequence.....................................................................................59

Checking the IGBT transistor modules............................................................60

Measurement with the IGBT modules connected to the power

board ............................................................................................................ 61

Measurement with the IGBT modules disconnected from the power

board ............................................................................................................ 62

Checking the precharge power resistors R4, R5, R304, R305 .......................62

Checking the primary rectifier bridge ..............................................................63

Checking the secondary rectifier diodes.........................................................64

Soft start ............................................................................................................. 65

AC power supply – preparations before soft starting .......................................66

DC power supply – preparations before soft starting ....................................... 67

Checking the IGBT gate pulses ....................................................................... 69

Checking the main transformer primary voltage .............................................. 70

Checking the welding outlet voltage.................................................................70

Restoring the power source after soft starting ................................................. 70

Calibrating the arc voltage ................................................................................71

Calibrating the welding current ........................................................................72

Activating the VRD-function .............................................................................72

IN-SERVICE INSPECTION AND TESTING........................................................ 74

General requirements ........................................................................................ 74

Periodic inspection and test .............................................................................74

Cleaning instruction .......................................................................................... 74

After repair, inspection and test .......................................................................75

Visual inspection................................................................................................76

TABLE OF CONTENTS

0464 523 001 © ESAB AB 2015

Electrical test...................................................................................................... 77

Functional test.................................................................................................... 80

Test report...........................................................................................................81

SPARE PARTS AND ACCESSORIES ............................................................... 82

Rights reserved to alter specifications without notice.

READ THIS FIRST

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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.

Use the wiring diagram as a form of index for the description of operation. The circuit boards

are divided into numbered blocks, which are described individually in more detail in the

description of operation. 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

June 2013.

The manual is valid for: Warrior 500i CC/CV, 380 - 415 V 0465 350 883

Warrior 400i CC/CV, 380 - 415 V 0465 350 884

Warrior 500i CC/CV, VRD 415 V 0465 350 885

Warrior 400i CC/CV, VRD 415 V 0465 350 886

From serial no. 339-XXX-XXXX Warrior 400i CC/CV and Warrior 500i CC/CV (CE version)

will fulfill the Australian standard AS 1674.2 – 2003 regarding the output no load voltage for

category C environment when VRD 35V is activated. Filter board 15AP3 and resistor 15R1

are needed for this and have been added.

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 Warrior 400i CC/CV and Warrior 500i CC/CV are designed and tested in

accordance with international standard IEC 60974-1. 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 above standard.

CAUTION!

Read and understand the instruction manual before

installing or operating.

INTRODUCTION

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INTRODUCTION

Design structure of the power source

The Warrior power source is transistor-controlled, operating on the inverter principle. It

consists of a number of function modules. Each module has a module number, which is

always included as the first part of the name/identification of components in the module.

The modules have the following main functions:

1 MMC module

The MMC board including two three-digit displays, and two LEDs. Attached to the MMC

board are two selector switches, one potentiometer and one encoder.

2 Mains module

Mains filter board, primary inductor, mains switch, auxiliary transformer

15 Power module

Power board including primary rectifier and IGBT transistor modules. Capacitor board, main

transformer, secondary inductor, secondary diode modules.

20 Control module

The control board, with a microprocessor, that monitors and controls the welding process.

Working principle

The mains input voltage range is three-phase 380±10% VAC to 415±10% VAC at rated load.

The auxiliary transformer 2T1 has multiple primary connections and has to be correctly

connected depending on the mains voltage.

The primary rectifier creates the DC bus voltage by rectifying the input AC voltage.

The primary inverter of the Warrior power source is a 4-transistor IGBT fullbridge, operating

at a switching frequency of 22 kHz. All power semiconductors are built into modules.

The primary inverter output is connected to a main transformer with a 7:1 turns ratio.

The main transformer output is connected to a secondary rectifier which contains four diode

modules.

The Warrior power source is rated 400A/36VDC or 500A/40VDC at 60% duty cycle.

INTRODUCTION

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Block diagram of the Warrior 400i/500i CC/CV power sources

TECHNICAL DATA

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TECHNICAL DATA

Warrior 400i CC/CV Warrior 500i CC/CV

Mains voltage 380-415 V ±10%,

3~ 50/60 Hz

380-415 V ±10%,

3~ 50/60 Hz

Mains supply S

scmin

6.4 MVA 7.2 MVA

Mains supply Z

max

0.025 Ω 0.022 Ω

Primary current I

max

MIG/MAG 28 A 37 A

TIG 23 A 30 A

MMA 28 A 38 A

No-load power in energy-saving

mode 6.5 min. after welding 30 W 30 W

Setting range

MIG/MAG 16 A/15 V - 400 A/34 V 16 A/15 V - 500 A/39 V

TIG 5 A/10 V - 400 A/26 V 5 A/10 V - 500 A/30 V

MMA 16 A/20 V - 400 A/36 V 16 A/20 V - 500 A/40 V

Permissible load at MIG/MAG

60 % duty cycle 400 A/34 V 500 A/39 V

100% duty cycle 300 A/29 V 400 A/34 V

Permissible load at TIG

60 % duty cycle 400 A/26 V 500 A/30 V

100% duty cycle 300 A/22 V 400 A/26 V

Permissible load at MMA

60 % duty cycle 400 A/36 V 500 A/40 V

100% duty cycle 300 A/32 V 400 A/36 V

Power factor at maximum current 0.91 0.91

Efficiency at maximum current 88 % 89 %

Electrode types Basic

Rutile

Cellulosic

Basic

Rutile

Cellulosic

Open-circuit voltage

VRD 35 V deactivated 56 V DC peak 56 V DC peak

VRD 35 V activated 28 V DC peak 28 V DC peak

Apparent power at maximum

current

18.0 kVA 24.6 kVA

Active power at maximum

current

16.4 kW 22.5 kW

Operating temperature -10 to +40°C -10 to +40°C

Transportation temperature -20 to +55°C -20 to +55°C

Constant sound pressure when

idling

<70 db (A) <70 db (A)

TECHNICAL DATA

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Warrior 400i CC/CV Warrior 500i CC/CV

Dimensions l × w × h 712 × 325 × 470 mm 712 × 325 × 470 mm

Weight 58.5 kg 58.5 kg

Insulation class H H

Enclosure class IP 23 IP 23

Application class

Mains supply, S

sc min

Minimum short circuit power on the network in accordance with IEC 61000-3-12.

Mains supply, Z

max

Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP23 is intended for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

WIRING DIAGRAM

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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.

Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors

XS1 - XS99 (S = socket), XP1 - XP99 (P = plug), 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

WIRING DIAGRAM

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Component description

Component Description

1 MMC module. Wire numbers 100-199.

1AP1 Display board

1G1 Encoder

1R1 Potentiometer 10kΩ (inductance/arc force selection)

1S1 Switch selector, three positions (electrode type)

1S3 Switch selector, five positions (process type)

2 Mains module. Wire numbers 200-299.

2AP1 Mains filter board

2L1, 2L2, 2L3 Ferrite cores

2L4 Primary inductor

2QF1 Mains switch

2T1 Auxiliary transformer, with multiple input windings

Input voltage windings:

• 380V

• 400V

• 415V

• 440V (not used in this version)

• 460V (not used in this version)

• 575V (not used in this version)

Output voltages:

• 20V (primary)

• 40V (secondary)

• 42V (secondary)

15 Power module. Wire numbers 1500-1699.

15AP1 Power board

15AP2 Capacitor board

15AP3 Filter board

(added from serial no. 339-XXX-XXXX)

15BR1 Primary rectifier bridge, 3 phase

15C1 Capacitor 0.1µF

15C2 Capacitor 0.1µF

15C3 Capacitor 0.1µF

15CS1 Secondary current sensor, 1:2000

15EV1 Fan, 24VDC

15FU1 Automatic fuse 10A

15L1 Secondary inductor

15L2-15L9 Ferrite ring cores

WIRING DIAGRAM

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Component Description

15PM1, 15PM2 IGBT power transistor modules. Each module consists of two

transistors and two freewheel diodes.

15PM3, 15PM4, 15PM5,

15PM6

Secondary rectifier diode modules. Each module consists of two

diodes.

15R1 Resistor 150 ohm, 50 W (added from serial no. 339-XXX-XXXX)

15ST2 Temperature switch, on the primary heatsink

15ST3 Temperature switch, on the secondary heatsink

15T1 Main transformer, 7:1 turns ratio

20 Control module. Wire numbers 2000-2099.

20AP1 Control board

20C1 Capacitor 0.1µF

XS.. Socket (sleeve)

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling

electrostaticsensitive devices.

• Use proper static-proof bags and boxes.

WIRING DIAGRAM

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Warrior 400i/500i CC/CV

WIRING DIAGRAM

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WIRING DIAGRAM

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Warrior component positions

Left view

WIRING DIAGRAM

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Right view

WIRING DIAGRAM

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Right view, power modules

DESCRIPTION OF OPERATION

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DESCRIPTION OF OPERATION

This section 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.

Warrior internal voltage map

Principle diagram of the Warrior 400i/500i CC/CV internal power supplies

DESCRIPTION OF OPERATION

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1AP1 MMC board

The user interface contains a circuit board with two three-digit LED displays and two LEDs.

Two selector switches, one potentiometer and one encoder are connected to the MMC

board.

1AP1:1 Power supply

The MMC board is supplied at 24VDC and 15VDC from the control board 20AP1. An

illuminated LED D4 indicates that +5V is OK.

+24V (±0.1V ) is converted to +5V by the switching circuit IC5, D5, L1.

+15V (±0.5V) supplies the selector switches 1S1 and 1S3, the potentiometer 1R1 and the

encoder 1G1.

+5V (4.6±0.2V ) supplies the displays, the LEDs and the logic circuitry. The actual voltage is

not really 5V but 4.6V.

DESCRIPTION OF OPERATION

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1AP1:2 Display and LEDs

The displays and LEDs are controlled by the LED drivers IC1-IC3. The data to the LED

drivers is received from the control board 20AP1 over a three-line serial bus through the IC4

buffer circuits. The normal data speed is about 1kHz.

An illuminated LED D8 indicates a thermal error, which means that one or both of the

temperature switches 15ST2-15ST3 have tripped. An illuminated LED D9 indicates that VRD

is active.

The three-digit display DY1-DY3 shows the arc voltage The three-digit display DY4-DY6

shows the welding current.

NOTE!

The decimal points of displays DY3 and DY6 are not connected.

At power on, all the display segments (except for DY3 and DY6 dots) and the LEDs are

illuminated for about one second, to indicate correct function.

1AP1:3 Encoder

The panel encoder 1G1 generates two square wave pulse trains when turned. Square

waveA is90° phase shifted relative to square waveB. This phase shift is necessary for the

processor to determine in which direction the encoder is being turned.

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ESAB Warrior™ 400i cc/cv Warrior™ 500i cc/cv User manual

ESAB Warrior™ 400i cc/cv Warrior™ 500i cc/cv User manual

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