ESAB Tig 3001i Aristo Origo™ User manual

Aristo™, Origo™

Service manual

0740 800 196 GB 20180918

Valid for: serial no. 833-xxx-xxxx to 039-xxx-xxxx

Mig 3001i, Tig 3001i

TABLE OF CONTENTS

0740 800 196 © ESAB AB 2018

1

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

2

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

3

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

4

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

4.1 Component description ......................................................................... 10

4.2 Mig 3001i, valid from serial no. 833-xxx-xxxx to 039-622-xxxx .......... 12

4.3 Mig 3001i, valid from serial no. 039-623-xxxx ...................................... 14

4.4 Tig 3001i .................................................................................................. 16

5

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

5.1 1 MMC unit .............................................................................................. 18

5.2 2AP1 Interference suppressor board and main rectifier .................... 19

5.3 10AP1 Tig board ..................................................................................... 20

5.3.1 10AP1:1 Power supply ......................................................................... 20

5.3.2 10AP1:2 Communication with the control board .................................. 20

5.3.3 10AP1:3 Gas valve............................................................................... 20

5.3.4 10AP1:4 HF generator ......................................................................... 21

5.3.5 10AP1:5 TIG Torch switch.................................................................... 21

5.3.6 10AP1:6 Signal transfer 20AP1 - 20AP2.............................................. 21

5.3.7 10AP1 Component positions................................................................ 21

5.4 15 The power module............................................................................. 22

5.5 15AP1 Power board................................................................................ 22

5.5.1 15AP1:1 Internal power supply ............................................................ 23

5.5.2 15AP1:2 Temperature monitoring......................................................... 23

5.5.3 15AP1:3 Overvoltage and undervoltage protection.............................. 24

5.5.4 15AP1:4 Charging circuit...................................................................... 25

5.5.5 15AP1:5 Gate driver stages and switching circuits .............................. 26

5.5.6 15AP1:6 Fan control............................................................................. 27

5.5.7 15AP1 Component positions................................................................ 27

5.6 15AP2 Secondary board ........................................................................ 28

5.6.1 15AP2:1 Diode modules....................................................................... 28

5.6.2 15AP2:2 Temperature monitoring......................................................... 28

5.6.3 15AP2 Component positions................................................................ 30

5.7 20AP1 Control board.............................................................................. 31

5.7.1 20AP1:1 Power supply ......................................................................... 32

5.7.2 20AP1:2 Fan control............................................................................. 33

5.7.3 20AP1:3 The CAN bus ......................................................................... 34

5.7.3.1 Communication interruptions............................................................. 35

5.7.3.2 Terminating resistors ......................................................................... 35

5.7.4 20AP1:4 Temperature monitoring......................................................... 36

5.7.5 20AP1:5 Overvoltage and undervoltage protection.............................. 36

5.7.6 20AP1:6 Relay driver stages................................................................ 37

TABLE OF CONTENTS

0740 800 196 © ESAB AB 2018

5.7.7 20AP1:7 Gate pulses ........................................................................... 37

5.7.8 20AP1:8 Current sensor....................................................................... 37

5.7.9 20AP1:9 Arc voltage feedback ............................................................. 38

5.7.9.1 Open-circuit voltage control............................................................... 39

5.7.10 20AP1:10 Control panel interface circuits ............................................ 40

5.7.11 20AP1 Circuit board versions............................................................... 40

5.7.12 20AP1 Component positions, version 1 ............................................... 42

5.7.13 20AP1 Component positions, version 2 ............................................... 43

5.8 20AP2 Relay board................................................................................. 44

5.8.1 20AP2:1 Power supply ......................................................................... 44

5.8.2 20AP2:2 Power supply to the cooling unit............................................ 44

5.8.3 20AP2:3 Cooling water monitoring....................................................... 45

5.8.4 20AP2:4 Gas pressure monitoring ....................................................... 46

5.8.5 20AP2 Component positions................................................................ 46

5.8.6 20AP2 Circuit diagram ......................................................................... 47

6

REMOTE CONTROLS .............................................................................. 48

7

FAULT CODES ......................................................................................... 49

7.1 Fault log................................................................................................... 49

7.2 Summary of fault codes......................................................................... 49

7.3 Fault code description ........................................................................... 50

7.3.1 Power source ....................................................................................... 50

8

SERVICE INSTRUCTIONS....................................................................... 53

8.1 What is ESD? .......................................................................................... 53

8.2 Service aid .............................................................................................. 53

8.3 Checking power board 15AP1............................................................... 54

8.4 Checking secondary board 15AP2 ....................................................... 57

8.5 Soft starting ............................................................................................ 59

8.6 Mounting components on the heat sink............................................... 64

8.6.1 Thermal paste ...................................................................................... 64

8.6.2 Rectifier bridge 2BR1 ........................................................................... 64

8.6.3 Power board 15AP1 with semicunductor modules............................... 64

8.6.4 Diode modules 15D1, 15D2 and secondary board 15AP2................... 65

8.7 Calibrating the current sensor signal................................................... 66

8.8 MIG power sources, calibration of the arc voltage feedback............. 67

8.9 TIG power sources, calibration of the arc voltage feedback ............. 69

9

CONNECTION OF TERMINATING RESISTORS..................................... 70

9.1 Mig 3001i ................................................................................................. 70

9.1.1 Power source without MMC ................................................................. 70

9.1.2 Power source without MMC and with remote control ........................... 71

9.1.3 Power source with MMC ...................................................................... 71

9.1.4 Power source with MMC and remote control ....................................... 71

TABLE OF CONTENTS

0740 800 196 © ESAB AB 2018

9.1.5 Power source with MMC and wire feeder with MMC............................ 71

9.1.6 Power source with MMC, wire feeder with MMC and remote control... 71

9.2 Tig 3001i .................................................................................................. 72

9.2.1 Power source with MMC ...................................................................... 72

9.2.2 Power source with MMC and remote control ....................................... 72

10

IN-SERVICE INSPECTION AND TESTING.............................................. 73

10.1 General requirements ............................................................................ 73

10.2 Periodic inspection and test.................................................................. 73

10.3 After repair, inspection and test ........................................................... 73

10.4 Visual inspection .................................................................................... 73

10.5 Electrical test .......................................................................................... 74

10.6 Functional test ........................................................................................ 76

11

TEST REPORT ......................................................................................... 78

12

SPARE PARTS ......................................................................................... 79

Rights reserved to alter specifications without notice.

1 READ THIS FIRST

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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" chapter

in this manual.

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

June 2016.

The manual is valid for:

Mig 3001i with serial number 833-xxx-xxxx, 950-xxx-xxxx, 039-xxx-xxxx

Tig 3001i with serial number 840-xxx-xxxx, 950-xxx-xxxx, 039-xxx-xxxx

The Mig 3001i and Tig 3001i are designed and tested in accordance with international

and European standards IEC/EN 60974.

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.

WARNING!

Many parts of the power source are at mains voltage.

2 INTRODUCTION

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2 INTRODUCTION

Mig 3001i is a welding power source intended for MIG/MAG welding, as well as for welding

with powder filled cored wire (FCAW-S), TIG welding and for welding with coated electrodes

(MMA).

Tig 3001i is a TIG welding power source, which can also be used for MMA welding.

Cooling unit. Mig 3001i and Tig 3001i can be supplied with or without cooling unit. The

cooling unit can be retro fitted. Installation kit for the cooling unit is available as an accessory,

see the spare parts list.

Control panels, welding process parameters are controlled via the control panel. See the

separate instruction and service manuals for a detailed description of the panels.



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 block 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.

The modules have the following main functions:

1 MMC module

The control panel and display.

2 Mains module

Mains interference suppressor, mains switch, auxiliary transformer.

10 TIG module

Comprises all TIG functions.

15 Power module

This module is a dual forward inverter, operating at a switching frequency of 2 x 40 kHz.

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

modules.

20 Processor board module (controller module)

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

voltage and current.

2 INTRODUCTION

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Block diagram of the Mig 3000i.

3 TECHNICAL DATA

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3 TECHNICAL DATA



Mig 3001i Tig 3001i

Mains voltage 400 V ±10%, 3~ 50/60 Hz 400 V ±10%, 3~ 50/60 Hz

Mains supply S

sc min

1.4 MVA S

sc min

1.4 MVA

Primary current

I

max

MIG/MAG 17 A

I

max

TIG

3)

14 A 13 A

I

max

MMA 18 A 19 A

No-load power demand

when in the energy-saving

mode, 6.5 min. after welding

30 W 30 W

Setting range

MIG/MAG 16 A / 14.8 V - 300 A / 29.0 V

TIG

3)

4 A / 10.2 V - 300 A / 22.0 V 4-300 A

MMA 16 A / 20.6 V - 300 A / 32.0 V 16-300 A

Permissible load at

MIG/MAG

35% duty cycle 300 A / 29 V

60% duty cycle 240 A / 26 V

100% duty cycle 200 A / 24 V

Permissible load at TIG

3)

35% duty cycle 300 A / 22 V 300 A / 22 V

60% duty cycle 240 A / 19.6 V 240 A / 19.6 V

100% duty cycle 200 A / 18 V 200 A / 18 V

Permissible load at MMA

35% duty cycle 300 A / 32 V 300 A / 32 V

60% duty cycle 230 A / 29.2 V 230 A / 29.2 V

100% duty cycle 190 A / 27.6 V 190 A / 27.6 V

Power factor at maximum

current

MIG/MAG 0.90

TIG

3)

0.89 0.89

MMA 0.90 0.90

Efficiency at maximum

current

MIG/MAG 82.3 %

TIG

3)

75.9 % 81 %

MMA 85.7 % 84 %

3 TECHNICAL DATA

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Mig 3001i Tig 3001i

Open-circuit voltage

without VRD function

1)

67 V DC 67 V DC

VRD function deactivated

2)

60 V DC 60 V DC

VRD function activated

2)

< 35 V < 35 V

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

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

Continual sound preassure

at no-load

<70 dB <70 dB

Dimensions l × w × h 652 × 249 × 423 mm 652 × 249 × 423 mm

with cooling unit 714 × 249 × 693 mm 714 × 249 × 693 mm

Weight 33 kg 33.5 kg

with cooling unit 53.5 kg 54 kg

Insulation class

transformer

H H

Enclosure class IP23 IP23

Application class

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 control panel has this function.

3)

Valid for a power source controlled from a U6 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 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.

4 WIRING DIAGRAM

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4 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

4.1 Component description

Component Description

1 MMC module. Wire numbers 100-199. This module is described in a

separate service manual for the control panels. See "1 MMC unit", page

18.

2 Mains module. Wire numbers 200-299.

2AP1, 2BR1 Interference suppressor board with main rectifier. Power sources with cooling

unit have a different version of the suppressor board than power sources

without cooling unit. See wiring and component positions diagram in "2AP1

Interference suppressor board and main rectifier", page19and the

assembly instructions for the rectifier in "Mounting components on the heat

sink", page64.

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).

2FU4 Fuse, slow blow (anti-surge). Tig: 5 A, Mig: 10 A

2L1 - 2L4 Ferrite ring cores.

2QF1 Main On / Off switch.

2TC1 Auxiliary transformer.

3 Primary inductor module. Wire numbers 300-399.

5 Cooling unit, CoolMidi 1000. Wire numbers 500-599.

The CoolMidi 1000 is described in a separate service manual with filename

0740 800 195.

4 WIRING DIAGRAM

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3L1 Primary inductor.

7L1, 7L2 Ferrite ring cores, fitted to each end of cable 7200.

10 TIG module. Wire numbers 1000-1199

10AP1 TIG board. See the description in "10AP1 Tig board", page20.

10C1, 10C2 Interference suppression capacitors.

10EV1 Fan, 24 V DC. See the description of 20AP1:2 in "20AP1:2 Fan control",

page33.

10TV1 HF transformer. See HF generator in "10AP1:4 HF generator", page21.

10L1 Ferrite ring core.

10YV1 Gas valve. See in "10AP1:3 Gas valve", page20.

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

description in "15 The power module", page22.

15AP1 Power board. See the description in "15AP1 Power board", page22.

15AP2 Filter board with rectifier modules. See the description in "15AP2 Secondary

board", page28.

15AP3 Current sensor. See the description of 20AP1:8 in "20AP1:8 Current sensor",

page37.

15C1, 15C2 Smoothing capacitors.

15D1, 15D2 Rectifier and freewheel diode modules. Each module consists of two diodes.

During the time interval between the voltage pulses from transformers 15TM1

and 15TM2, the freewheel diodes maintain the welding current from inductor

15L3.

See in "Rectifier bridge 2BR1", page64for assembly instructions for the

diode modules.

15EV1, 15EV2 Fans, 24 V DC. See the description of 20AP1:2 in "20AP1:2 Fan control",

page33.

15L3 Inductor.

15TM1,

15TM2

Main transformers.

20AP1 Controller circuit board. See the description in "20AP1 Control board", page

31.

20AP2 Relay board. See the description in "20AP2 Relay board", page44.

The relay board is only fitted to power sources with cooling unit.

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 WIRING DIAGRAM

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4.2 Mig 3001i, valid from serial no. 833-xxx-xxxx to 039-622-xxxx

4 WIRING DIAGRAM

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Placement of the circuit boards, Mig 3001i

4 WIRING DIAGRAM

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4.3 Mig 3001i, valid from serial no. 039-623-xxxx

4 WIRING DIAGRAM

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Placement of the circuit boards, Mig 3001i

4 WIRING DIAGRAM

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4.4 Tig 3001i

Placement of the circuit boards, Tig 3001i

4 WIRING DIAGRAM

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5 DESCRIPTION OF OPERATION

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5 DESCRIPTION OF OPERATION

This section 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 1 MMC unit

The MMC unit can either be fitted to the wire feed unit and/or the power source.

The MMC unit consists of an operator's control panel and a welding data board with a

welding data unit. In some applications the welding data unit is a part of the power source

control board, then there is no welding data board included in the MMC unit.

The power source, the wire feed unit and the welding data unit each have their own

microprocessor for control, with the welding data unit being the central unit in the system. In

addition to storing and issuing welding data, it also exercises overall control of the system as

a whole.



MMC unit for the Mig 3001i

A24 is a MMC unit with welding data board.

The Mig 3001i can also be delivered without MMC unit.

A24

MMC units for the Tig 3001i

TA23 and TA24 are MMC units without welding data board. The welding data unit is a part

of the power source control board.

TA23 TA24

The MMC units are described in separate instruction and service manuals.

5 DESCRIPTION OF OPERATION

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5.2 2AP1 Interference suppressor board and main rectifier

Circuit diagram, 2AP1

R7, R8 and R9 are varistors that clip the voltage peaks exceeding about 1100 V. The

varistors do not conduct when the voltage is below 575 V AC RMS, this corresponds to a

peak voltage of 810 V.

Terminal F is not fitted to suppressor boards used in power sources without cooling unit.

From serial no. 039-xxx-xxxx all suppressor boards are supplied with terminal F.

Main rectifier 2BR1 is fitted on the heat sink. See the fitting instruction in "Rectifier bridge

2BR1", page64.



Component positions, 2AP1 with terminal F



5 DESCRIPTION OF OPERATION

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Component positions, 2AP1 without terminal F



5.3 10AP1 Tig board

The TIG board is fitted to the Tig 3001i. Sections 10AP1:1 to 10AP1:6 refer to the wiring

diagram in "Tig 3001i", page16.

Circuit diagram of the TIG functions

5.3.1 10AP1:1 Power supply

42 V AC is supplied from transformer 2TC1.

5.3.2 10AP1:2 Communication with the control board

The processor on circuit board 20AP1 controls the gas valve and the HF generator.

The processor senses the start signal from the torch switch when optocoupler IC1 is

energized.

5.3.3 10AP1:3 Gas valve

When the torch switch is operated, relay RE1 closes and energizes the gas valve. When the

torch switch is released and the gas post-flow time has elapsed, the gas valve is deactivated.

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