ESAB Mig 4004i Pulse User manual

Aristo®

Service manual

0463 395 001 GB 20181123

Valid for: serial no. 419-, 528-, 551-, 627-, 704-, 834-xxx-xxxx

Mig 4004i Pulse,

Mig4004iPulseWeldCloud™

TABLE OF CONTENTS

0463 395 001 © ESAB AB 2018

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

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

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

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

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

Mig 4004i Pulse....................................................................................... 13

Mig 4004i Pulse WeldCloud™, Valid from serial no. 834-xxx-xxxx.... 16

Position of the components .................................................................. 17

DESCRIPTION OF OPERATION.............................................................. 19

2 Mains module....................................................................................... 19

2AP1 Interference suppressor board (EMC-board).............................. 19

2AP2 Rectifier board ............................................................................ 20

2AP2 Block diagram.......................................................................... 20

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

2AP2:2 Pulse generator .................................................................... 21

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

2AP2:4 Charging circuit..................................................................... 22

2AP2:5 Mains supply monitoring....................................................... 23

2AP2 Component positions............................................................... 24

2AP3 Power supply board.................................................................... 25

2AP3 Block diagram.......................................................................... 25

2AP3:1 Power supply ........................................................................ 25

2AP3:2 +25V PWM driver ................................................................. 26

2AP3:3 +25V power supply ............................................................... 26

2AP3:4 +12V power supply ............................................................... 27

2AP3 Component positions............................................................... 28

2AP4 Filter board ................................................................................. 29

2AP4 Block diagram.......................................................................... 30

2AP4 Component position................................................................. 31

5 Cooling unit.......................................................................................... 31

5AP1 Block diagram............................................................................. 31

15 The power module............................................................................. 32

15AP1 Power board ............................................................................. 32

15AP1 Block diagram........................................................................ 32

15AP1:1 Gate drivers ........................................................................ 34

15AP1:2 Switching circuit.................................................................. 35

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

15AP1:4 Temperature protection....................................................... 37

15AP1:5 Fan control.......................................................................... 38

15AP1:6 Voltage regulator ................................................................ 38

15AP1:7 Supply circuit ...................................................................... 38

TABLE OF CONTENTS

0463 395 001 © ESAB AB 2018

15AP1 Component positions............................................................. 39

20 Control module .................................................................................. 40

20AP1 Control board............................................................................ 40

20AP1 Block diagram........................................................................ 41

20AP1:1 Power supply ...................................................................... 42

20AP1:2 Fan control.......................................................................... 42

20AP1:3 CAN bus ............................................................................. 43

20AP1:4 Temperature monitoring...................................................... 45

20AP1:5 Overvoltage and undervoltage protection........................... 45

20AP1:6 Rectifier board interface ..................................................... 45

20AP1:7 Gate pulses ........................................................................ 45

20AP1:8 Output current sensors ....................................................... 46

20AP1:9 Arc voltage feedback .......................................................... 47

20AP1:10 Primary current sensor ..................................................... 49

20AP1:11 LED board interface.......................................................... 49

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

20AP1:10 External shutdown ............................................................ 50

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

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

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

FAULT CODES ......................................................................................... 54

SERVICE INSTRUCTIONS....................................................................... 58

What is ESD? .......................................................................................... 58

Service aid .............................................................................................. 58

Service traps........................................................................................... 59

Disassembling and reassembling the power source.......................... 61

Checking the input rectifier ................................................................... 61

Checking the rectifier module ............................................................... 62

Checking the IGBT transistors.............................................................. 64

Checking the transistor module............................................................ 66

Checking the output diodes .................................................................. 67

Mounting components on the heat sinks............................................. 70

Soft starting ............................................................................................ 71

Checking the gate pulses from circuit board 20AP1 .......................... 72

Checking the gate pulses from circuit board 15AP1 .......................... 75

Measurements (DC-bus, output voltage and diodes) ......................... 77

Checking temperature monitoring........................................................ 78

Checking the overvoltage and undervoltage threshold values ......... 81

Calibrating the current sensor signal................................................... 82

MIG power source, calibration of the arc voltage feedback............... 83

MMA power sources, calibration of the arc voltage feedback ........... 85

TABLE OF CONTENTS

0463 395 001 © ESAB AB 2018

Connection of terminating resistors..................................................... 86

IN-SERVICE INSPECTION AND TESTING.............................................. 88

General requirements ............................................................................ 88

After repair, inspection and test ........................................................... 88

Visual inspection .................................................................................... 88

Electrical test .......................................................................................... 89

Functional test ........................................................................................ 91

Test report ............................................................................................... 92

SPARE PARTS ......................................................................................... 93

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 395 001

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READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

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

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

description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

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

August 2018.

The manual is valid for:

• Aristo® Mig 4004i Pulse, CE-version with serial no. 551-xxx-xxxx

• Aristo® Mig 4004i Pulse, CE- and AU-version with serial no. 704-xxx-xxxx

• Aristo® Mig 4004i Pulse, CSA-version with serial no. 419-xxx-xxxx, 528-xxx-xxxx

• Aristo® Mig 4004i Pulse WeldCloud™ with serial no. 627-xxx-xxxx, 834-xxx-xxxx

Mig 4004i Pulse is designed and tested in accordance with international standards IEC/EN

60974-1 and US standards ANSI/IEC 60974:1:2008. 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 mentioned standards.

Aristo® Mig 4004i Pulse with serial no. 551-, 704-xxx-xxxx:

Mig 4004i Pulse is designed and tested in accordance with the 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 mentioned standards.

For WeldCloud™ information, see

• Service manual W8

2

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

(0740800203)

• Instruction manual WeldCloud™ (0463 450 *)

CAUTION!

Read and understand the instruction manual before

installing or operating.

WARNING!

Many parts of the power source are at mains voltage.

INTRODUCTION

0463 395 001

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INTRODUCTION

The Mig 4004i Pulse is intended for MIG/MAG welding, as well as for welding with powder

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

The power source has no MMC panel, it is designed to be combined with U6 or U8

2

.

The power source is intended for use with the wire feed unit Feed 3004 or YardFeed 2000

and the cooling unit COOL 1. Feed 3004 is available with two operational solutions, the U6

panel and the U8

2

pendant. YardFeed 2000 is available with the U6 panel.

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:

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 Control module

This is the control 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.

INTRODUCTION

0463 395 001

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Block diagram

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

options.

Block diagram of the power source

TECHNICAL DATA

0463 395 001

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TECHNICAL DATA

Mig 4004i Pulse / Mig 4004i Pulse WeldCloud™

Mains voltage 380-460V, ±10%, 3~ 50/60 Hz

Mains supply S

scmin

5.8 MVA

Primary current I

max

28 A

No-load power 57 W

Setting range (DC)

MIG/MAG 16 A / 14.8 V - 400 A / 34 V

MMA 16 A / 20.6 V - 400 A / 36 V

TIG 4 A / 10.2 V - 400 A / 26 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 0.95

Efficiency at maximum current 89.5 %

Open circuit voltage 55 V

Operating temperature -10 to 40°C (14 to 104°F)

Transport temperature -20 to 55°C (-4 to 131°F)

Constant sound pressure when

idling

<70 dB (A)

Dimensions l×w×h Mig 4004i Pulse:

613 × 257 × 445 mm (24.0 × 10.1 × 17.5 in.)

Mig 4004i Pulse WeldCloud™:

613 × 257 × 517 mm (24.0 × 10.1 × 20.3 in.)

Weight Mig 4004i Pulse: 48 kg (106 lb)

Mig 4004i Pulse WeldCloud™: 54kg (119lb)

Insulation class H

Enclosure class IP23

Application classification

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.

TECHNICAL DATA

0463 395 001

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Enclosure class

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

by solid objects or water.

Equipment marked IP23 is intended for indoor and outdoor use.

Application class

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

electrical hazard.

WIRING DIAGRAM

0463 395 001

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WIRING DIAGRAM

The power source consists of a number of function modules, which are described in the

component descriptions on the following pages. Wire numbers and component names in the

wiring diagrams show to which module each component belongs.

Wires/cables within modules are marked 100 - 6999.

Wires/cables between modules are marked 7000 - 7999.

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

XS1 - XS99 (S = socket), XP1 - XP99 (P = plug), XT1 - XT99 (T = terminal).

Circuit boards within each module have names such as 20AP1 - 20AP99.

20 = module association, 1-69

AP = circuit board

1 = individual identification number, 0-99

Transistors within particular modules have identification numbers such as 15Q1 - 15Q99.

15 = module association, 1-69

Q = transistor

1 = individual identification number, 0-99

Component description

Component Description

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, 2L3 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 Cooling unit Fan, 24 V DC.

5M1 Cooling unit 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.

WIRING DIAGRAM

0463 395 001

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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,

15L6, 15L7, 15L8, 15L9

4 + 4 ferrite rings. Reduces transient voltages. Four ferrites are put

inside the cooling channel and four are put outside.

15L9 Ferrrite ring core

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, 15R5, 15R6 Power resistors.

15R3, 15R4 Varistors.

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

24 I/O module (in Mig 4004i Pulse WeldCloud™)

24AP1 Welding data board (W8

2

board) (in Mig 4004i Pulse WeldCloud™)

24AP4 Communication board Profibus (in Mig 4004i Pulse WeldCloud™)

24AP5 Communication board CANopen (in Mig 4004i Pulse WeldCloud™)

24AP6 Communication board DeviceNet (in Mig 4004i Pulse

WeldCloud™)

24AP7 Communication board EtherNet/IP (in Mig 4004i Pulse

WeldCloud™)

24AP8 Communication board EtherCAT (in Mig 4004i Pulse WeldCloud™)

25 Gateway module (in Mig 4004i Pulse WeldCloud™)

25AP1 SBC board (in Mig 4004i Pulse WeldCloud™)

25AP2 IPS board (Internal Power Supply) (in Mig 4004i Pulse

WeldCloud™)

WIRING DIAGRAM

0463 395 001

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25AP3 Wi-Fi + Bluetooth module board (in Mig 4004i Pulse WeldCloud™)

25AP4 GPS + 3G module board (in Mig 4004i Pulse WeldCloud™)

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.

WIRING DIAGRAM

0463 395 001

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Mig 4004i Pulse

WIRING DIAGRAM

0463 395 001

- 14 -

WIRING DIAGRAM

0463 395 001

- 15 -

WIRING DIAGRAM

0463 395 001

- 16 -

Mig 4004i Pulse WeldCloud™, Valid from serial no. 834-xxx-xxxx

WIRING DIAGRAM

0463 395 001

- 17 -

Position of the components

WIRING DIAGRAM

0463 395 001

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DESCRIPTION OF OPERATION

0463 395 001

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DESCRIPTION OF OPERATION

This section describes the function of circuit boards and other components in the equipment.

It is divided into sections, numbered to correspond to the circuit board numbers and divisions

into function blocks.

2 Mains module

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

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

2AP1 Interference suppressor board (EMC-board)

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

Circuit diagram, 2AP1

Components position, 2AP1

15R3 and 15R4 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).

DESCRIPTION OF OPERATION

0463 395 001

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2AP2 Rectifier board

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

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

supply board (2AP3).

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.

2AP2:1 Voltage regulator

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

Pulse generator.

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