ESAB Mig 4004i Pulse User manual

Aristo®, Origo™

Service manual

0740 800 217 GB 20180831

Valid for: serial no. 145-, 240-, 550-, 806-xxx-xxxx

Mig4004i, Mig5004i,

Mig4004iPulse, Mig4004iA44,

Mig4004iPulseWeldCloud™

TABLE OF CONTENTS

0740 800 217 © ESAB AB 2018

1

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

2

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

3

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

4

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

4.1 Component description ......................................................................... 12

4.2 Diagram ................................................................................................... 14

4.3 Placement of the components .............................................................. 16

5

DESCRIPTION OF OPERATION.............................................................. 17

5.1 1 MMC unit .............................................................................................. 17

5.1.1 1AP1 MMC control board ..................................................................... 17

5.1.1.1 1AP2 MMC panel .............................................................................. 18

5.2 2 Mains module....................................................................................... 18

5.2.1 2AP1 Interference suppressor board (EMC-board).............................. 18

5.2.2 2AP2 Rectifier board ............................................................................ 19

5.2.2.1 2AP2 Block diagram.......................................................................... 19

5.2.2.2 2AP2:1 Voltage regulator .................................................................. 20

5.2.2.3 2AP2:2 Pulse generator .................................................................... 20

5.2.2.4 2AP2:3 Thyristor driver...................................................................... 21

5.2.2.5 2AP2:4 Charging circuit..................................................................... 21

5.2.2.6 2AP2:5 Mains supply monitoring....................................................... 22

5.2.2.7 2AP2 Component positions............................................................... 23

5.2.3 2AP3 Power supply board.................................................................... 24

5.2.3.1 2AP3 Block diagram.......................................................................... 24

5.2.3.2 2AP3:1 Power supply ........................................................................ 24

5.2.3.3 2AP3:2 +25V PWM driver ................................................................. 25

5.2.3.4 2AP3:3 +25V power supply ............................................................... 25

5.2.3.5 2AP3:4 +12V power supply ............................................................... 26

5.2.3.6 2AP3 Component positions............................................................... 27

5.2.4 2AP4 Filter board ................................................................................. 28

5.2.4.1 2AP4 Block diagram.......................................................................... 29

5.2.4.2 2AP4 Component position................................................................. 29

5.3 5 Cooling unit.......................................................................................... 30

5.3.1 5AP1 Block diagram............................................................................. 30

5.4 15 The power module............................................................................. 30

5.4.1 15AP1 Power board ............................................................................. 31

5.4.1.1 15AP1 Block diagram........................................................................ 31

5.4.1.2 15AP1:1 Gate drivers ........................................................................ 33

5.4.1.3 15AP1:2 Switching circuit.................................................................. 34

5.4.1.4 15AP1:3 Overvoltage and undervoltage protection........................... 35

5.4.1.5 15AP1:4 Temperature protection....................................................... 36

5.4.1.6 15AP1:5 Fan control.......................................................................... 37

TABLE OF CONTENTS

0740 800 217 © ESAB AB 2018

5.4.1.7 15AP1:6 Voltage regulator ................................................................ 37

5.4.1.8 15AP1:7 Supply circuit ...................................................................... 37

5.4.1.9 15AP1 Component positions............................................................. 38

5.5 20 Control module .................................................................................. 39

5.5.1 20AP1 Control board............................................................................ 39

5.5.1.1 20AP1 Block diagram........................................................................ 40

5.5.1.2 20AP1:1 Power supply ...................................................................... 41

5.5.1.3 20AP1:2 Fan control.......................................................................... 41

5.5.1.4 20AP1:3 CAN bus ............................................................................. 42

5.5.1.5 20AP1:4 Temperature monitoring...................................................... 44

5.5.1.6 20AP1:5 Overvoltage and undervoltage protection........................... 44

5.5.1.7 20AP1:6 Rectifier board interface ..................................................... 44

5.5.1.8 20AP1:7 Gate pulses ........................................................................ 44

5.5.1.9 20AP1:8 Output current sensors ....................................................... 45

5.5.1.1

0

20AP1:9 Arc voltage feedback .......................................................... 46

5.5.1.1

1

20AP1:10 Primary current sensor ..................................................... 48

5.5.1.1

2

20AP1:11 LED board interface .......................................................... 48

5.5.1.1

3

20AP1:12 Cooling unit interface........................................................ 49

5.5.1.1

4

20AP1:10 External shutdown ............................................................ 49

5.5.1.1

5

20AP1 Component positions............................................................. 50

5.5.2 20AP2 LED board ................................................................................ 51

6

REMOTE CONTROLS .............................................................................. 53

7

ERROR CODES........................................................................................ 54

8

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

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

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

8.3 Service traps........................................................................................... 58

8.4 Disassembling and reassembling the power source.......................... 59

8.5 Checking the input rectifier ................................................................... 60

8.6 Checking the rectifier module ............................................................... 61

8.7 Checking the IGBT transistors.............................................................. 62

8.8 Checking the transistor module............................................................ 63

8.9 Checking the output diodes .................................................................. 65

8.10 Mounting components on the heat sinks............................................. 68

8.11 Soft starting ............................................................................................ 69

8.12 Checking the gate pulses from circuit board 20AP1 .......................... 70

8.13 Checking the gate pulses from circuit board 15AP1 .......................... 72

8.14 Measurements (DC-bus, output voltage and diodes) ......................... 74

TABLE OF CONTENTS

0740 800 217 © ESAB AB 2018

8.15 Checking temperature monitoring........................................................ 76

8.16 Checking the overvoltage and undervoltage threshold values ......... 79

8.17 Calibrating the current sensor signal................................................... 80

8.18 MIG power source, calibration of the arc voltage feedback............... 81

8.19 MMA power sources, calibration of the arc voltage feedback ........... 83

8.20 Connection of terminating resistors..................................................... 84

9

IN-SERVICE INSPECTION AND TESTING.............................................. 86

9.1 General requirements ............................................................................ 86

9.2 After repair, inspection and test ........................................................... 86

9.3 Visual inspection .................................................................................... 86

9.4 Electrical test .......................................................................................... 87

9.5 Functional test ........................................................................................ 90

9.6 Test report ............................................................................................... 91

10

SPARE PARTS ......................................................................................... 92

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 design changes that have been made up to and including

January 2018.

The manual is valid for:

• Mig 4004i with serial no. 145-xxx-xxxx and 806-xxx-xxxx

• Mig 5004i with serial no. 145-xxx-xxxx and 806-xxx-xxxx

• Mig 4004i Pulse with serial no. 240-xxx-xxxx

• Mig 4004i A44 with serial no. 145-xxx-xxxx

• Mig 4004i Pulse WeldCloud™ with serial no. 550-xxx-xxxx

Mig 4004i, Mig 5004i, Mig 4004i Pulse, Mig 4004i A44 and Mig 4004i Pulse WeldCloud™

are designed and tested in accordance with international and European standards IEC/EN

60974-1 and IEC/EN 60974-10. 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

This power source series is intended for MIG/MAG welding, as well as for welding with

powder filled cored wire (FCAW-S), live TIG welding (power source with panel A44) and for

welding with coated electrodes (MMA).

There are different variants of the power source:

Mig 4004i max current 400A, without cooling unit, no MMC panel

Mig 5004i max current 500A, without cooling unit, no MMC panel

Mig 4004i Pulse max current 400A, without cooling unit, no MMC panel

Mig 4004i A44 max current 400A, without cooling unit, with A44 panel

Mig 4004i Pulse

WeldCloud™

max current 400A, without cooling unit, no MMC panel, with

WeldCloud™

For WeldCloud™ information, see

• Service manual W8

2

, Retrofit Mig 4004i WeldCloud™, WeldCloud™ Mobile,

(0740800203)

• Instruction manual WeldCloud™ (0463 450 *)

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 on the next page. 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, control power transformer.

5 Cooling unit module

Block diagram of the cooling unit.

15 Power module

This module is a full-bridge converter inverter, operating at a switching frequency of 27kHz.

IGBT transistors are used as the switching elements.

20 Processor board module (controller module)

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

voltage and current.

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

2 INTRODUCTION

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Block diagram

The block diagram below shows the function blocks of the power source and also the MMC

and cooling options.

Block diagram of the power source

3 TECHNICAL DATA

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3 TECHNICAL DATA

Mig4004i A44 Mig 4004i Mig 5004i

Mains voltage 380-440 V ±10%,

3~50/60 Hz

380-440 V ±10%,

3~50/60 Hz

380-440 V ±10%,

3~50/60 Hz

Mains supply S

scmin

1.8 MVA

1.8MVA

2)

, 6.1MVA

3)

2.2 MVA

2)

, 8.5MVA

3)

Mains supply Z

max

- -

0.022 Ω

2)

Primary current I

max

28 A

26A(MMA)

25A(MIG)

3)

36A(MMA)

35A(MIG)

3)

No-load power

40 W 40W

2)

, 91W

3)

40W

2)

, 91W

3)

Setting range

MIG/MAG

16A/15V-

400A/34.0V

16A/15V- 400A/34.0V

2)

16A/14.8V-

400A/36.0V

3)

16A/14.8V-

500A/39.0V

MMA

16A/21V-

400A/36.0V

16A/21V- 400A/36.0V

2)

16A/20.8V-

400A/34.0V

3)

16A/20.8V-

500A/40.0V

TIG

4A/10V-

400A/34.0V

- -

Permissible load at MIG/MAG

40% duty cycle

- -

500 A/39.0 V

3)

60% duty cycle 400 A/34.0 V 400 A/34.0 V

500A/40.0V

2)

,

420A/35.0V

3)

80% duty cycle

- -

400 A/34.0 V

2)

100% duty cycle 300 A/29.0 V 350 A/31.5 V 350 A/31.5 V

Permissible load at MMA

40% duty cycle

- -

500 A/40.0 V

3)

60% duty cycle 400 A/36.0 V 400 A/36.0 V

500A/40.0V

2)

,

420A/36.8V

3)

80% duty cycle

- -

400 A/36.0 V

2)

100% duty cycle 300 A/32.0 V 350 A/34.0 V 350 A/34.0 V

Permissible load at TIG

60% duty cycle 400 A/26.0 V - -

80% duty cycle - - -

100% duty cycle 300 A/22.0 V - -

Power factor at

maximum current

0.94 0.93

0.95

2)

, 0.94

3)

Efficiency at

maximum current

88%

90%(MMA)

3)

, 89%(MIG) 89%

2)

, 90%

3)

No-load voltage

VRD function inactive

1)

55 V 55 V 55 V

VRD function active

1)

<35 V

<35V

2)

, 25V

3)

<35V

2)

, 25V

3)

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

3 TECHNICAL DATA

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Mig4004i A44 Mig 4004i Mig 5004i

Transportation

temperature

-20 to +55°C -20 to +55°C -20 to +55°C

Continual sound

pressure at no-load

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

Dimensions

l × w × h

610 × 250

×445mm

610 × 250 ×445mm 610 × 250 ×445mm

Weight 46 kg 46 kg 46 kg

Insulation class H H H

Enclosure class IP23 IP23 IP23

Application class

Mig 4004i Pulse / Mig 4004i Pulse WeldCloud™

Mains voltage 380-440 V, +/- 10%, 3~ 50/60 Hz

Mains supply S

scmin

1.8 MVA

Primary current I

max

28 A

No-load power Mig 4004i Pulse: 40 W

Mig 4004i Pulse WeldCloud™: 42 W

Setting range (DC)

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

MMA 16 A / 21 V - 400 A / 36 V

TIG 4 A / 10 V - 400 A / 34 V

Permissible load at MIG/MAG

60 % duty cycle 400 A / 34.0 V

100% duty cycle 300 A / 29.0 V

Permissible load at MMA

60 % duty cycle 400 A / 36.0 V

100% duty cycle 300 A / 32.0 V

Permissible load at TIG

60 % duty cycle 400 A / 26.0 V

100% duty cycle 300 A / 22.0 V

Power factor at maximum current 0.94

Efficiency at maximum current 88 %

Open circuit voltage

VRD function inactive

1)

55V

VRD function active

1)

<35V

Operating temperature -10 to +40°C

Transport temperature -20 to +55°C

Constant sound pressure when

idling

<70 dB(A)

3 TECHNICAL DATA

0740 800 217

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Mig 4004i Pulse / Mig 4004i Pulse WeldCloud™

Dimensions l×w×h Mig 4004i Pulse: 610×250×445 mm

(24.0x9.8x17.5in.)

Mig 4004i Pulse WeldCloud™: 610×250×515mm

(24.0x9.8x20.3in.)

Weight Mig 4004i Pulse: 44.5kg (98lb)

Mig 4004i Pulse WeldCloud™: 47.9kg (105lb)

Insulation class H

Enclosure class IP23

Application classification

1)

The VRD function is explained in the instruction manual for the control panel.

2)

Valid for serial no. 145-xxx-xxxx

3)

Valid from serial no. 806-xxx-xxxx

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, 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 WIRING DIAGRAM

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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 chapter "Description

of operation".

1AP1 MMC Control board (welding data unit).

1AP2 MMC Panel.

2 Mains module. Wire numbers 200-299.

2AP1 EMC suppressor board. See chapter "Description of operation".

2AP2 Rectifier board.

2AP3 Power supply board.

2AP4 Filter board.

2L1, 2L2 Ferrite rings.

2TC1 Auxiliary transformer.

2QF1 Mains switch.

3 Primary inductor module. Wire numbers 300−399.

3L1 Primary inductor.

5 Water cooling module. Wire numbers 500−599. The power supply to the

cooling water pump and fan is controlled by the power source software.

See the description in section "Cooling unit".

5EV1 Fan, 24 V DC.

5M1 Pump, 24 V DC.

5XP1 Cooling unit plug connector (pin).

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

and description in section "Power board".

15AP1 Power board.

15AP2 Current sensor. See the description of 20AP1:8.

15D1, 15D2, 15D3,

15D4

Rectifier diode modules. Each module consists of two diodes.

See chapter "Service Instructions" for assembly instructions for the

diode modules.

15EV1, 15EV2 Fans, 24 V DC. See the description of 20AP1:2.

15L1 Inductor.

15L2, 15L3, 15L4,

15L5

2 + 2 ferrite rings. Reduces transient voltages.

Note that there are only two ferrite rings mounted in Mig 4004i A44 and

Mig 4004i Pulse (15L2, 15L4) placed in the cooling channel.

15C1, 15C2 Smoothing capacitors.

15C3, 15C4, 15C5 Interference capacitors

15Q1, 15Q2 IGBT transistors. See the description of 15AP1:2 and the installation

instructions in section "Mounting components on the heat sinks".

15R1, 15R2 Power resistors.

4 WIRING DIAGRAM

0740 800 217

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15R3, 15R4 Varistors.

Note that it's not the same kind of varistors mounted in all power source

variants.

15ST1 Temperature sensor, mounted on the heat sink for the output diode

modules. See the description of 15AP1:4.

15ST2 Temperature sensor, mounted on the heat sink for the IGBT modules.

See the description of 15AP1:4.

15ST3 Temperature sensor, mounted on the main transformer. See the

description of 15AP1:4.

15TM1 Main transformer.

Note that it's not the same kind of transformer mounted in all power

source variants.

20 Control module. Wire numbers 2000−2099. See description in section

"Control module".

20AP1 Control circuit board.

20AP2 LED board.

FU01 Automatic fuse 10 A.

L1 Ferrite ring.

XS1, XS2 Output outlets terminals.

XS3 Control socket connector (sleeve).

XS4 Cooling unit socket connector (sleeve).

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 Diagram

Mig 4004i, Mig 5004i, Mig 4004i Pulse and Mig 4004i A44

4 WIRING DIAGRAM

0740 800 217

- 15 -

4 WIRING DIAGRAM

0740 800 217

- 16 -

4.3 Placement of the components

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 equipment.

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. The welding data unit is 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.

5.1.1 1AP1 MMC control board

The welding data board has a machine ID, a hardware ID, a unit type and a unit number. To

read them you need the ESAT service kit, see chapter "Service instructions".

• The machine ID determines which type of control panel the board is intended for.

• The hardware ID shows the design and type of circuit board.

• The unit type and unit number are used for identification on the CAN bus.

The identification numbers of this board are:

Machine ID 31

Hardware ID 4

Unit type 0

Unit number 1

If power source with control panel A44 (unit number = 1) is connected to a wire feeder with

control panel MA44 (unit number = 0). The MA44 welding data board will then control the

system.

NOTE!

The welding data board in the A44 control panel does not have a terminating

resistor.

Read more about the CAN bus in section "Control module".

5 DESCRIPTION OF OPERATION

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- 18 -

5.1.1.1 1AP2 MMC panel

A44 is a MMC unit with welding data board.

MMC unit A44

The MMC unit is described in separate instruction and service manuals.

5.2 2 Mains module

The mains module filter the input mains power (2AP1), convert 3−phase 400 V AC to DC

voltage (2AP2) and deliver +25VDC to the control electronic.

5.2.1 2AP1 Interference suppressor board (EMC-board)

This circuit board reduces mains interference to/from the power source.

Circuit diagram, 2AP1

5 DESCRIPTION OF OPERATION

0740 800 217

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Components position, 2AP1

R4, R5 and R6 are varistors that cut the voltage peaks exceeding about 1100Vpk. The

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

peak voltage of 810 V. Varistors are assembled on separated PCB (Varistor Board).

5.2.2 2AP2 Rectifier board

The rectifier board carries the mains rectifier and input power three phase monitoring circuit.

Also it ensures soft start for the DC-link (15AP1) and provides rectified voltage for the Power

supply board (2AP3).

5.2.2.1 2AP2 Block diagram

Input rectifier board 2AP2 contains a number of functional systems such as:

• Thyristor power rectifier system - Provides voltage to power the DC-link.

• Mains supply monitoring - Controls the presence of three phases on the power input.

• Charging circuit - Slow charging of the capacitors on the DC-link.

• The voltage regulator - provides power to the pulse generator module.

5 DESCRIPTION OF OPERATION

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5.2.2.2 2AP2:1 Voltage regulator

The voltage regulator stabilize +15V that is used for the internal supply circuit IC1 in 2AP2:2

Pulse generator.

5.2.2.3 2AP2:2 Pulse generator

In the pulse generator block, IC1 generates a square wave formed in pulse bursts with

constant amplitude and frequency. This signal controls the transistor Q2. The transistor

switches the current flowing through the impulse transformer T1. The signal from the impulse

transformer T1 provides impulses to the control thyristor driver.

The function of the pulse generator (work / stop) is controlled by the external signal from the

control board connected to transistor Q1.

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