ESAB Tig 4300i AC/DC User manual

Origo™

Service manual

0740 800 178 GB 20190814

Valid for: serial no. 710-xxx-xxxx to 950-xxx-xxxx

Tig 4300i AC/DC

TABLE OF CONTENTS

0740 800 178 © ESAB AB 2019

1

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

2

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

3

TECHNICAL DATA ................................................................................... 7

4

WIRING DIAGRAMS................................................................................. 9

4.1 Component description ......................................................................... 9

4.2 Tig 4300i AC/DC, dc power block.......................................................... 12

4.3 Tig 4300i AC/DC, ac power block.......................................................... 14

5

DESCRIPTION OF OPERATION.............................................................. 15

5.1 AP2 Interference suppressor board ..................................................... 15

5.2 1 Control panel ....................................................................................... 15

5.3 2AP1 Interference suppressor board (EMC board) ............................. 16

5.4 5 Cooling unit.......................................................................................... 16

5.5 15 The power module............................................................................. 17

5.6 15AP1 Power board................................................................................ 18

5.6.1 15AP1:1 Mains rectifier bridge and charging circuit ............................. 18

5.6.2 15AP1:2 Switching circuit..................................................................... 19

5.6.3 15AP1:3 Overvoltage and undervoltage protection.............................. 19

5.6.4 15AP1 Component positions................................................................ 20

5.7 15AP2 Gate driver board ....................................................................... 20

5.7.1 15AP2:1 Gate driver stages ................................................................. 21

5.7.2 15AP2:2 Overvoltage and undervoltage protection.............................. 21

5.7.3 15AP2 Component positions................................................................ 22

5.8 18AP1 AC control board ........................................................................ 23

5.8.1 18AP1:1 Power supply ......................................................................... 24

5.8.2 18AP1:2 CAN bus ................................................................................ 24

5.8.3 18AP1:3 Temperature monitoring......................................................... 25

5.8.4 18AP1:4 Arc voltage monitoring........................................................... 26

5.8.5 18AP1:5 Fan control............................................................................. 27

5.8.6 18AP1:6 Switch driver .......................................................................... 28

5.8.7 18AP1 Component positions................................................................ 29

5.9 18AP2 AC power board.......................................................................... 30

5.9.1 18AP2:1 Switching circuits ................................................................... 30

5.9.2 18AP2:2 Temperature monitoring......................................................... 30

5.9.3 18AP2 Component positions................................................................ 32

5.10 18AP3 Connection board....................................................................... 33

5.10.1 18AP3 Component positions................................................................ 34

5.11 20AP1 Control board.............................................................................. 35

5.11.1 20AP1:1 Power supply ......................................................................... 36

5.11.2 20AP1:2 Fan control............................................................................. 36

5.11.3 20AP1:3 The CAN bus ......................................................................... 37

TABLE OF CONTENTS

0740 800 178 © ESAB AB 2019

5.11.3.

1

Starting sequence ............................................................................. 37

5.11.3.

2

Communication interruptions............................................................. 38

5.11.3.

3

Terminating resistors ......................................................................... 38

5.11.4 20AP1:4 Temperature monitoring......................................................... 39

5.11.5 20AP1:5 Overvoltage and undervoltage protection.............................. 39

5.11.6 20AP1:6 Communication with relay board 20AP2 ............................... 39

5.11.7 20AP1:7 Gate pulses ........................................................................... 39

5.11.8 20AP1:8 Current sensor....................................................................... 40

5.11.9 20AP1:9 Arc voltage feedback ............................................................. 40

5.11.9.

1

Open-circuit voltage control............................................................... 41

5.11.10 20AP1 Circuit board versions............................................................... 42

5.11.11 20AP1 Component positions, version 1 ............................................... 43

5.11.12 20AP1 Component positions, version 2 ............................................... 44

5.12 20AP2 Relay board................................................................................. 45

5.12.1 20AP2:1 Power supply ......................................................................... 45

5.12.2 20AP2:2 External shutdown ................................................................. 45

5.12.3 20AP2:3 Starting sequence.................................................................. 46

5.12.4 20AP2:4 Power supply to the cooling unit............................................ 47

5.12.5 20AP2:5 Cooling water monitoring....................................................... 47

5.12.6 20AP2:6 Gas valve............................................................................... 48

5.12.7 20AP2:7 HF starting device.................................................................. 48

5.12.8 20AP2:8 TIG Starting ........................................................................... 49

5.12.9 20AP2:9 Gas flow monitoring............................................................... 49

5.12.1

0

20AP2 Component positions................................................................ 49

5.12.11 20AP2 Circuit diagram ......................................................................... 50

6

REMOTE CONTROLS .............................................................................. 51

7

FAULT CODES ......................................................................................... 52

7.1 Fault log................................................................................................... 52

7.2 Fault codes.............................................................................................. 52

7.3 Fault code description ........................................................................... 52

7.3.1 Power source ....................................................................................... 52

7.3.2 AC unit.................................................................................................. 55

8

SERVICE INSTRUCTIONS....................................................................... 57

8.1 What is ESD? .......................................................................................... 57

8.2 Service aid .............................................................................................. 57

8.3 Dismantling............................................................................................. 58

8.4 Service traps........................................................................................... 58

8.5 Checking the IGBT transistors.............................................................. 59

8.6 Mounting components on the heat sink............................................... 61

TABLE OF CONTENTS

0740 800 178 © ESAB AB 2019

8.7 Checking the gate signals from AC control board 18AP1.................. 62

8.8 Checking the IGBT modules of AC power board 18AP2 .................... 62

8.9 Soft starting ............................................................................................ 66

8.9.1 Checking the gate pulses from circuit board 20AP1 ............................ 66

8.9.2 Checking the gate pulses from circuit board 15AP2 ............................ 68

8.9.3 Measurements...................................................................................... 69

8.10 Checking the overvoltage and undervoltage threshold values ......... 70

8.11 Calibrating the current sensor signal................................................... 71

8.12 Calibration of the arc voltage display .................................................. 72

8.13 2TC2, auxiliary transformer with 10 A MCB ......................................... 73

9

SPARE PARTS ......................................................................................... 75

Rights reserved to alter specifications without notice.

1 READ THIS FIRST

0740 800 178

- 5 -

1 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 AND

ACCESSORIES" chapter in this manual.

This manual contains details of all design changes that have been made up to and including

June 2010.

The manual is valid for: Tig 4300i AC/DC with serial no. 710-xxx-xxxx and 950-xxx-xxxx.

Tig 4300i AC/DC has been designed and tested in accordance with international and

European standards IEC/EN 60974. On completion of service or repair, the service

organisation that has performed the work must make sure that the equipment still

complies with the above standards.

WARNING!

Many parts of the power source are at mains voltage.

2 INTRODUCTION

0740 800 178

- 6 -

2 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.

Schematic diagram of the power source

The modules have the following main functions:

1 MMC module

The control panel and welding data unit, which control the power source functions.

2 Mains module

Mains interference suppressor, mains inductor, mains switch, control power transformers and

contactor.

15 Power module

This module is a forward converter inverter, operating at a switching frequency of 27 kHz.

IGBT transistors are used as the switching elements. All power semiconductors are built into

modules in order to ensure a robust design suitable for use in the demanding welding

environment.

18 AC module

The AC module controls and handles the AC switching IGBTs.

20 Processor board module (controller module)

This is the control board, 20AP1, with a microprocessor, that monitors and controls the

voltage and current. This board also contains storage of welding data in the welding data

unit. The control board is served by relay board 20AP2, which handles input and output

signals to/from the control board.

Further information on the modules can be found in the component and function descriptions.

3 TECHNICAL DATA

0740 800 178

- 7 -

3 TECHNICAL DATA

Tig 4300iw AC/DC

Mains voltage 400V ±10%, 3~ 50Hz

Mains supply

S

sc min

2.6MVA

Z

max

0.24Ohm

Primary current

I

max

TIG

25A

I

max

MMA

32A

No-load power in energy-saving mode 6.5 min.

after welding

75W

Voltage/current range

TIG AC*/DC 4–430A

MMA 16–430A

Permissible load at TIG

30% duty cycle 430A / 27.2V

60% duty cycle 350A / 24.0V

100% duty cycle 315A / 22.6V

Permissible load at MMA

30% duty cycle 430A / 37.2V

60% duty cycle 330A / 33.2V

100% duty cycle 300A / 32.0V

Power factor at maximum current

TIG 0.89

MMA 0.89

Efficiency at maximum current

TIG 76%

MMA 80%

Open-circuit voltage U

0

max

without VRD function

1)

83V

U

0L

"Live TIG" , VRD function deactivated

2)

60V

MMA, VRD function deactivated

2)

60V

VRD function activated

2)

<35V

Operating temperature range -10 to +40°C (+14 to +104°F)

Transportation temperature -20 to +55°C (-4 to +131°F)

Dimensions l × w × h 625×394×776mm

(24.6×15.5×30.5in.)

Continual sound pressure at no-load <70db(A)

Weight 95kg (209.4lb)

Insulation class H

3 TECHNICAL DATA

0740 800 178

- 8 -

Tig 4300iw AC/DC

Enclosure class IP23

Application class

*) The minimum current during AC welding depends on the alloy used for the aluminium

plates and their surface cleanliness.

1)

Valid for power sources without VRD specification on the rating plate.

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 panel has that function.

Cooling unit

Cooling power 2.0kW at 40°C (104°F) temperature

difference and flow 1.0l/min (0.26gpm)

Coolant ESAB ready mixed coolant

Liquid quantity 5.5l (1.45gal)

Maximum water flow 2.0l/min (0.53gpm)

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, or below.

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.

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.

4 WIRING DIAGRAMS

0740 800 178

- 9 -

4 WIRING DIAGRAMS

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

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

4.1 Component description

Component Description

AP2 Interference suppressor board. See diagram "Tig 4300i AC/DC, dc power

block" in this chapter.

D1 LED, orange, for overtemperature indication.

D2 Indicating LED, white. Indicates power on.

XP.. Plug connector.

XS.. Socket connector.

XT.. Terminal block.

1 MMC module with control panel. Wire numbers 100-199. The control panel

is described in a separate manual.

2 Mains module. Wire numbers 200-299.

2AP1 EMC suppressor board.

2FU1 Fuse, 4 A, slow blow (anti-surge).

2FU2 Fuse, 6.3 A, slow blow (anti-surge).

4 WIRING DIAGRAMS

0740 800 178

- 10 -

2FU3 Fuse, 3.15 A, slow blow (anti-surge).

2FU4 Fuse, 8 A glass-tube fuse, slow blow (anti-surge).

From serial no. 710-903-5789, the 8 A glass-tube fuse is replaced by a 10 A

Micro Circuit Breaker, fitted to the rear panel of the power source, see

section "2TC2, auxiliary transformer" in chapter "Service instructions".

2FU5 Fuse, 2 A, slow blow (anti-surge).

2FU6 Fuse, 0.1 A, slow blow (anti-surge).

2KM1 Main contactor. See section "20AP2:3 Starting sequence" in chapter

"Description of operation".

2QF1 Main switch. See section "20AP2:3 Starting sequence" in chapter

"Description of operation".

2TC1 Auxiliary transformer.

2TC2 Auxiliary transformer.

There are two versions of the transformer, see section "2TC2, auxiliary

transformer" in chapter "Service instructions".

3 Primary inductor module. Wire numbers 300-399.

3L1 Primary inductor.

5 Water cooling module. Wire numbers 500-599

The wiring diagram for the cooling module is in section "5 Cooling unit" in this

chapter. The power supply to the cooling water pump and fan is controlled by

the power source software. See the description in section "20AP2:4" and

"20AP2:5" in chapter "Description of operation".

10 TIG module. Wire numbers 1000-1199

10AP1 HF starting device. See the description in section "20AP2:7 HF starting

device" in chapter "Description of operation".

10C1 Interference suppression capacitor, 47 nF 250 V.

10TV1 HF transformer.

10YV1 Gas valve. See the description in section "20AP2:7 HF starting device" in

chapter "Description of operation".

15 Power module. Wire numbers 1500-1699. See the schematic diagram in

section "15 The power module" in chapter "Description of operation".

15AP1 Power board.

15AP2 Gate driver board.

15AP3 Current sensor. See the description in section "20AP1:8 Current sensor" in

chapter "Description of operation".

15BR1 Rectifier bridge. See section "15AP1:1 Mains rectifier" in chapter

"Description of operation" and the assembly instructions in section "Fitting

instructions" in chapter "Service instructions".

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.

4 WIRING DIAGRAMS

0740 800 178

- 11 -

See section "Fitting instructions" in chapter "Service instructions" for

assembly instructions for the diode modules.

15EV1, 15EV2 Fans, 24 V DC. See the description in section "20AP1:4 Power supply" in

chapter "Description of operation".

15L1, 15L2 2 + 2 ferrite rings. Reduce transient voltages produced when the diode

modules 15D1 and 15D2 turn off.

15L3 Inductor

15Q1, 15Q2 IGBT transistors. See section "15AP1:2 Switching circuit" in chapter

"Description of operation" and section "Fitting instructions" in chapter

"Service instructions".

15ST1 Thermal overload cutout, in the winding of main transformer TM1. See

section "20AP1:4 Temperature monitoring" in chapter "Description of

operation".

15ST2 Thermal overload cutout, mounted on the heat sink for the IGBT modules.

See section "20AP1:4 Temperature monitoring" in chapter "Description of

operation" and section "Fitting instructions" in chapter "Service instructions".

15TM1 Main transformer.

18 AC module. Wire numbers 1800-1999.

18AP1 AC control board. See the description in section "18AP1 AC control board" in

chapter "Description of operation".

18AP2 AC power board. See the description in section "18AP2 AC power board" in

chapter "Description of operation".

18EV1, 18EV2 Fans, 24 V DC. See the description in section "18AP1:5 Fan control" in

chapter "Description of operation".

20AP1 Control board.

20AP2 Relay board.

4 WIRING DIAGRAMS

0740 800 178

- 12 -

4.2 Tig 4300i AC/DC, dc power block

4 WIRING DIAGRAMS

0740 800 178

- 13 -

4 WIRING DIAGRAMS

0740 800 178

- 14 -

4.3 Tig 4300i AC/DC, ac power block

5 DESCRIPTION OF OPERATION

0740 800 178

- 15 -

5 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.

5.1 AP2 Interference suppressor board

Component positions and circuit diagram for circuit board AP2

The circuit board reduces interference signals from the TIG torch.

R1, and C1-C3 are not used in this application.

5.2 1 Control panel

Control panel TA24 AC/DC is used for the Tig 4300i AC/DC

The control panel consists of an operator's control panel and a display board.

The control panel is connected with a cable to the control board of the power source.

The control panel is described in separate instruction and service manuals.

5 DESCRIPTION OF OPERATION

0740 800 178

- 16 -

5.3 2AP1 Interference suppressor board (EMC board)

Circuit diagram and component positions, 2AP1

5.4 5 Cooling unit

Component description, water cooling unit

5C1 Start and run capacitor for the fan motor, µ5 F 450 V AC.

5C2 Start and run capacitor for the pump motor, 3 µF 400V.

5EV1 Fan motor, 230 V AC.

5M1 Pump motor, 230 V AC.

5S1 Microswitch for the water lock connection.

5SL1 Water flow guard. The contact closes for flow rates of 0.7 l/min and over.

NOTE!

This is an accessory.

5ST1 Temperature sensor switch. Closes at 45°C, opens at 35°C.

5 DESCRIPTION OF OPERATION

0740 800 178

- 17 -

Wiring diagram for the cooling unit

The power supply to cooling water pump 5M1 and fan 5EV1 is controlled by the power

source software in the welding data unit. See section "20AP2:5 Cooling water monitoring" in

this chapter. The fan is connected in parallel with the pump, and is controlled by temperature

sensor switch 5ST1.

5.5 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. Circuit board 15AP1 links them

together. It also carries a smaller circuit board, 15AP2, which provides the functions for the

gate drivers and overvoltage and undervoltage protection.

Block diagram of the power module

If the IGBT transistors 15Q1 and 15Q2, or circuit boards 15AP1, 15AP2 or 20AP1, are

replaced, the gate pulse waveforms must be checked afterwards and the power source must

be soft-started. See section "Soft starting" in chapter "Service instructions".

5 DESCRIPTION OF OPERATION

0740 800 178

- 18 -

See the instructions in section "Fitting instructions" in chapter "Service instructions"

concerning mounting of the components on the heat sink (15Q1, 15Q2, 15BR1, 15D1 and

15D2).

WARNING!

The power module is live at mains voltage. 0 V in the power module is connected to

mains voltage.

5.6 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.

5.6.1 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. Contactor 2KM1 closes after about twelve seconds and connects the

mains supply to rectifier bridge 15BR1. See section "20AP2:3 Starting sequence" in this

chapter for a more detailed description of the starting sequence.

Component description:

BR2 Rectifier for charging current.

C1, C2 Capacitors, restricting the inrush charging current to rectifier bridge BR2. The

current while capacitors C13 - C16 are charging is about 0.7 A.

C13 - C16 Smoothing capacitors, with a total capacitance of 1000 µF.

R5, R10 Discharging resistors for C1 and C2.

R1 Load-limiting resistor (10 Ω) for the charging current to C13 - C16.

R8, R9 Potential divider and discharge resistors for C13 - C16.

R11 - R13 Varistors. Limit voltage peaks that exceeds about 1000 V.

The varistors do not conduct when the voltage is below 480 V AC RMS, this

corresponds to a peak voltage of 680 V.

5 DESCRIPTION OF OPERATION

0740 800 178

- 19 -

Component description:

R14 Varistor.

15BR1 Main rectifier for mains voltage.

5.6.2 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 section

"15AP2 Gate driver board" in this chapter.

If an IGBT transistor (15Q1, 15Q2) has failed, both transistors must be replaced. Failure of

either transistor always subjects rectifier bridge 15BR1 to a high current surge, which

substantially reduces its life. We therefore recommend that the rectifier bridge should also be

replaced if the transistors have failed. See chapter "Service instructions" for instructions on

checking the IGBT transistors.

Diode modules 15D1 and 15D2 each contain two diodes. Both they and the IGBT transistors

must be mounted in accordance with the instructions in the section "Mounting components

on the heat sink" in the chapter "Service instructions".

5.6.3 15AP1:3 Overvoltage and undervoltage protection

The voltage protection function monitors the voltage across smoothing capacitors C13-C16.

See page 21 for a description of operation.

5 DESCRIPTION OF OPERATION

0740 800 178

- 20 -

CAUTION!

Do not mix up contacts B and D on circuit board 15AP2.

5.6.4 15AP1 Component positions

5.7 15AP2 Gate driver board

The gate driver board carries circuitry for gate driving and overvoltage and undervoltage

protection.

Page is loading ...

ESAB Tig 4300i AC/DC User manual

Related papers

Other documents