ESAB Tig 3000i User manual

Origo™, Aristo®

Service manual

0740 800 172 GB 20180918

Valid for: serial no. 535-xxx-xxxx to 209-xxx-xxxx

Mig L3000i, Mig C3000i,

Tig3000i, Tig 3000i AC/DC

TABLE OF CONTENTS

0740 800 172 © ESAB AB 2018

1

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

2

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

3

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

4

WIRING DIAGRAM................................................................................... 11

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

4.2 Mig L3000i ............................................................................................... 14

4.3 Mig C3000i, valid from serial no. 613-xxx-xxxx to 209-622-xxxx ....... 16

4.4 Mig C3000i, valid from serial no. 209-623-xxxx ................................... 18

4.5 Tig 3000i .................................................................................................. 20

4.6 Tig 3000i AC/DC...................................................................................... 22

5

DESCRIPTION OF OPERATION.............................................................. 24

5.1 1 MMC module ........................................................................................ 24

5.2 2AP1 Interference suppressor board and main rectifier .................... 25

5.3 10AP1 Tig board ..................................................................................... 27

5.3.1 10AP1:1 Power supply ......................................................................... 27

5.3.2 10AP1:2 Communication with the control board .................................. 27

5.3.3 10AP1:3 Gas valve............................................................................... 27

5.3.4 10AP1:4 HF generator ......................................................................... 27

5.3.5 10AP1:5 TIG Torch switch.................................................................... 28

5.3.6 10AP1 Component positions................................................................ 28

5.4 13AP1 Wire feeder control board.......................................................... 28

5.4.1 13AP1:1 Power supply ......................................................................... 29

5.4.2 13AP1:2 Start / Stop............................................................................. 29

5.4.3 13AP1:3 Gas valve............................................................................... 30

5.4.4 13AP1:4 Motor driving / braking ........................................................... 30

5.4.5 13AP1:5 Pulse generator input ............................................................ 31

5.4.6 13AP1:6 The CAN bus ......................................................................... 31

5.4.7 13AP1:7 Arc voltage sensing ............................................................... 32

5.4.8 13AP1:8 Monitoring the ELP ................................................................ 32

5.4.9 13AP1 Component positions................................................................ 33

5.5 15 The power module............................................................................. 34

5.6 15AP1 Power board................................................................................ 34

5.6.1 15AP1:1 Internal power supply ............................................................ 35

5.6.2 15AP1:2 Temperature monitoring......................................................... 35

5.6.3 15AP1:3 Overvoltage and undervoltage protection.............................. 36

5.6.4 15AP1:4 Charging circuit...................................................................... 37

5.6.5 15AP1:5 Gate driver stages and switching circuits .............................. 38

5.6.6 15AP1:6 Fan control............................................................................. 39

5.6.7 15AP1 Component positions................................................................ 40

5.7 15AP2 Secondary board ........................................................................ 41

5.7.1 15AP2:1 Diode modules....................................................................... 41

TABLE OF CONTENTS

0740 800 172 © ESAB AB 2018

5.7.2 15AP2:2 Temperature monitoring......................................................... 42

5.7.3 15AP2 Component positions................................................................ 43

5.8 18AP1 AC control board ........................................................................ 44

5.8.1 18AP1:1 Power supply ......................................................................... 45

5.8.2 18AP1:2 CAN bus ................................................................................ 46

5.8.3 18AP1:3 Temperature monitoring......................................................... 47

5.8.4 18AP1:4 Arc voltage monitoring........................................................... 48

5.8.5 18AP1:5 Fan control............................................................................. 48

5.8.6 18AP1:6 Switch driver .......................................................................... 49

5.8.7 18AP1 Component positions................................................................ 50

5.9 18AP2 AC power board.......................................................................... 51

5.9.1 18AP2:1 Switching circuits ................................................................... 51

5.9.2 18AP2:2 Temperature monitoring......................................................... 52

5.9.3 18AP2:3 Fan control............................................................................. 52

5.9.4 18AP2 Component positions................................................................ 53

5.10 20AP1 Control board.............................................................................. 54

5.10.1 20AP1:1 Power supply ......................................................................... 55

5.10.2 20AP1:2 Fan control............................................................................. 56

5.10.3 20AP1:3 The CAN bus ......................................................................... 57

5.10.3.

1

Communication interruptions............................................................. 58

5.10.3.

2

Terminating resistors ......................................................................... 59

5.10.4 20AP1:4 Temperature monitoring......................................................... 60

5.10.5 20AP1:5 Overvoltage and undervoltage protection.............................. 60

5.10.6 20AP1:6 Relay driver stages................................................................ 60

5.10.7 20AP1:7 Gate pulses ........................................................................... 60

5.10.8 20AP1:8 Current sensor....................................................................... 61

5.10.9 20AP1:9 Arc voltage feedback ............................................................. 62

5.10.9.

1

Open-circuit voltage control............................................................... 63

5.10.1

0

20AP1:10 Control panel interface circuits ............................................ 64

5.10.11 20AP1 Circuit board versions............................................................... 65

5.10.1

2

20AP1 Component positions, version 1 ............................................... 66

5.10.1

3

20AP1 Component positions, version 2 ............................................... 67

5.11 CAN adapter option Mig C3000i ............................................................ 68

5.11.1 Connection instructions ........................................................................ 69

6

REMOTE CONTROLS .............................................................................. 70

7

FAULT CODES ......................................................................................... 71

7.1 Fault log................................................................................................... 71

7.2 Summary of fault codes......................................................................... 71

TABLE OF CONTENTS

0740 800 172 © ESAB AB 2018

7.3 Fault code description ........................................................................... 72

7.3.1 Power source ....................................................................................... 72

7.3.2 AC unit.................................................................................................. 75

7.3.3 Wire feed unit ....................................................................................... 77

8

SERVICE INSTRUCTIONS....................................................................... 79

8.1 What is ESD? .......................................................................................... 79

8.2 Service aid .............................................................................................. 79

8.3 Special tools ........................................................................................... 80

8.4 Checking power board 15AP1............................................................... 81

8.5 Checking secondary board 15AP2 ....................................................... 83

8.6 Checking the IGBT modules of AC power board 18AP2 .................... 86

8.7 Checking the gate signals to AC power board 18AP2 ........................ 88

8.8 Soft starting ............................................................................................ 90

8.9 Mounting components on the heat sink............................................... 95

8.9.1 Thermal paste ...................................................................................... 95

8.9.2 Rectifier bridge 2BR1 ........................................................................... 95

8.9.3 Power board 15AP1 with semicunductor modules............................... 96

8.9.4 Diode modules 15D1, 15D2 and secondary board 15AP2................... 97

8.9.5 AC power board 18AP2 with IGBT modules ........................................ 98

8.10 Calibrating the current sensor signal................................................... 99

8.11 MIG machines, calibration of the arc voltage feedback ..................... 100

8.12 DC TIG machines, calibration of the arc voltage feedback ................ 102

8.13 AC TIG machines, calibration of the arc voltage display ................... 103

9

SPARE PARTS ......................................................................................... 104

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:

AristoMig 300, ESABMig 300i, AristoMig C300 and ESABMig C300i with serial no.

535-xxx-xxxx.

Mig L3000i with serial no. 613-xxx-xxxx and 802-xxx-xxxx.

Mig C3000i with serial no. 613-xxx-xxxx, 802-xxx-xxxx, 950-xxx-xxxx, 039-xxx-xxxx and

209-xxx-xxxx.

Tig 3000i with serial no. 612-xxx-xxxx and 802-xxx-xxxx.

Tig 3000i AC/DC with serial no. 612-xxx-xxxx, 802-xxx-xxxx and 039-xxx-xxxx.



The Mig L3000i, Mig C3000i, Tig 3000i, Tig 3000i AC/DC, AristoMig 300, ESABMig 300i,

AristoMig C300 and ESABMig C300i are designed and tested in accordance with

applicable international and European standards series 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.



WARNING!

Many parts of the power source are at mains voltage.

2 INTRODUCTION

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2 INTRODUCTION

The AristoMig and ESABMig power sources are renamed:

New name Old name

Mig L3000i AristoMig 300 / ESABMig 300i

Mig C3000i AristoMig C300 / ESABMig C300i



There are two different product families, Aristo and Origo, to which the power sources

belong. The product family is depending on the type of control panel that is used. The control

panels are not described in this manual, this manual describes the power sources: Mig

L3000i, Mig C3000i, Tig 3000i and Tig 3000i AC/DC



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.

13 Wire feeder module

Comprises all wire feeder 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.

18 AC module

Comprises all AC TIG functions.

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 C3000i.

3 TECHNICAL DATA

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3 TECHNICAL DATA

Mig L3000i, Mig C3000i

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

Primary current

I

max

MIG/MAG (21 A) 17 A

I

max

MMA (23 A) 18 A

I

max

TIG

3)

14 A

No-load power demand when in the

energy-saving mode, 6.5 min. after welding

30 W

Setting range

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

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

TIG

3)

4 A / 10.2 V - 300 A / 22.0 V

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 MMA

30% duty cycle 300 A / 32 V

60% duty cycle 230 A / 29.2 V

100% duty cycle 190 A / 27.6 V

Permissible load at TIG

3)

35 % duty cycle 300 A / 22 V

60 % duty cycle 240 A / 19.6 V

100 % duty cycle 200 A / 18 V

Power factor at maximum current

MIG/MAG (0.70) 0.90

MMA (0.73) 0.87

TIG

3)

0.89

Efficiency at maximum current

MIG/MAG (84 %) 82.3 %

MMA (83 %) 85.7 %

TIG

3)

75.9 %

Open-circuit voltage U

0

without VRD function

1)

MIG/MAG: 70 - 80 V MMA: 57 - 67 V

VRD function deactivated, only Mig C3000i

2)

60 V DC

VRD function activated, only Mig C3000i

2)

< 35 V

Operating temperature -10 to +40°C

Constant A-weighed sound pressure < 70 dB

3 TECHNICAL DATA

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Dimensions l × w × h

Mig L3000i 652 × 249 × 423 mm

Mig C3000i 652 × 412 × 423 mm

Weight

Mig L3000i (26.5 kg) 29 kg

Mig C3000i (38 kg) 40.5 kg

Insulation class transformer H

Enclosure class IP23C

Application class

Mig C3000i

Torch connection EURO

Max. diameter wire bobbin 300 mm

Wire feed speed 0.8 - 25.0 m/min

Wire dimension

Fe & Ss 0.6 - 1.2 mm

Al 1.0 - 1.2 mm

Cored wire 0.8 - 1.2 mm

Shielding gas All types intended for MIG/MAG welding

max pressure 5 bar

Motor current Imax 3.5 A

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



Tig 3000i AC/DC Tig 3000i

Mains voltage 400 V, ±10%, 1-3~ 50/60 Hz 400 V, ±10%, 3~ 50/60 Hz

Primary current

I

max

TIG 18 A (19 A) 14 A

I

max

MMA 22 A (23 A) 19 A

No-load power demand

when in the energy-saving

mode, 6.5 min. after welding

26 W 30 W

Setting range

TIG, AC* / DC 4-300 A 4-300 A

MMA 16-300 A 16-300 A

Permissible load at TIG, AC/DC

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

3 TECHNICAL DATA

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Tig 3000i AC/DC Tig 3000i

Permissible load at MMA

35% duty cycle 300 A / 32 V -

60% duty cycle 230 A / 29.2 V -

100% duty cycle 190 A / 27.6 V -

Power factor at maximum current

TIG - (0.65) 0.89

TIG AC 0.85 -

TIG DC 0.90 -

MMA 0.91 (0.73) 0.90

Efficiency at maximum current

TIG - (77%) 82%

TIG AC 71% -

TIG DC 71% -

MMA 76% (83%) 84%

Open-circuit voltage

MMA 58 V 57-67 V

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

Constant A-weighted sound

pressure

<70 dB <70 dB

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

Insulation class

transformer

H H

Enclosure class IP 23 IP 23

Application class

Data in brackets (x x x x) are valid for power sources without primary inductor.

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

plates and their surface cleanliness.

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 IP 23S is intended for indoor and outdoor use; however, should not be

operated in precipitation.

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 module",

page24.

2 Mains module. Wire numbers 200-299.

2AP1, 2BR1 Interference suppressor board with main rectifier. See diagram in "2AP1

Interference suppressor board and main rectifier", page25 and the

assembly instructions for the rectifier in "Rectifier bridge 2BR1", page

95.

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, 5 A, slow blow (anti-surge).

2L1 - 2L4 Ferrite ring cores.

2L5 - 2L6 Ferrite ring cores, used from serial number xxx-551-xxxx.

2QF1 Main On / Off switch.

2TC1 Auxiliary transformer.

3 Primary inductor module. Wire numbers 300-399.

3L1 Primary inductor. From serial number 802-xxx-xxxx all power sourcess are

equipped with the inductor. For earlier power sources it is an option.

10 TIG module. Wire numbers 1000-1199

10AP1 TIG board. See the description in "10AP1 Tig board", page27.

4 WIRING DIAGRAM

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10C1, 10C2 Interference suppression capacitors.

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

page56.

10TV1 HF transformer. See HF generator in "10AP1:4 HF generator", page27.

10L1 Ferrite ring core.

10YV1 Gas valve. See "10AP1:3 Gas valve", page27.

13 Wire feeder module. Wire numbers 1300-1499.

13AP1 Wire feeder controller circuit board. See the description in "13AP1 Wire

feeder control board", page28.

13C5 Interference suppression capacitor.

13G1 Pulse generator. Incorporated in motor 13M1.

See the description in "13AP1:5 Pulse generator input", page31.

13L1, 13L2 Ferrite ring cores.

13M1 Motor with pulse generator.

13YV1 Solenoid valve. See the description in "13AP1:3 Gas valve", page30.

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

and description in "15 The power module", page34.

15AP1 Power board. See the description in "15AP1 Power board", page34.

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

Secondary board", page41.

15AP3 Current sensor. See the description in "20AP1:8 Current sensor", page

61.

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 "Mounting components on the heat sink", page95 for assembly

instructions for the diode modules.

15D3, 15D4,

15D5

Transient voltage suppressors, only fitted to the Tig 3000i AC/DC.

The suppressors must always be fitted, otherwise the diode modules 15D1

and 15D2 will be damaged when AC welding is active.

15EV1, 15EV2 Fans, 24 V DC. See the description in "20AP1:2 Fan control", page56.

15L3 Inductor.

15TM1, 15TM2 Main transformers.

18 AC module. Wire numbers 1800-1999.

18AP1 AC control board. See the description in "18AP1 AC control board", page

44.

18AP2 AC power board. See the description in "18AP2 AC power board", page

51.

4 WIRING DIAGRAM

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18EV1, 18EV2 Fans, 24 V DC. See the description in "18AP1:5 Fan control", page48.

18L1 Inductor.

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

page54.

20L1 Ferrite ring core. Not used from serial no. xxx-601-xxxx, does not need to

be replaced if broken.

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 L3000i

4 WIRING DIAGRAM

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4 WIRING DIAGRAM

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4.3 Mig C3000i, valid from serial no. 613-xxx-xxxx to 209-622-xxxx

4 WIRING DIAGRAM

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4 WIRING DIAGRAM

0740 800 172

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4.4 Mig C3000i, valid from serial no. 209-623-xxxx

4 WIRING DIAGRAM

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4 WIRING DIAGRAM

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4.5 Tig 3000i

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