ESAB Mig 4004i Pulse WeldCloud™ - 380-460 V version User manual

Category
Measuring, testing & control
Type
User manual

This manual is also suitable for

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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
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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© ESAB AB 2018
Mig 4004i Pulse
Mig 4004i Pulse
WIRING DIAGRAM
0463 395 001
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© ESAB AB 2018
WIRING DIAGRAM
0463 395 001
- 15 -
© ESAB AB 2018
WIRING DIAGRAM
0463 395 001
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© ESAB AB 2018
Mig 4004i Pulse WeldCloud™, Valid from serial no. 834-xxx-xxxx
WIRING DIAGRAM
0463 395 001
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© ESAB AB 2018
Position of the components
WIRING DIAGRAM
0463 395 001
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© ESAB AB 2018
DESCRIPTION OF OPERATION
0463 395 001
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© ESAB AB 2018
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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© ESAB AB 2018
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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ESAB Mig 4004i Pulse WeldCloud™ - 380-460 V version User manual

Category
Measuring, testing & control
Type
User manual
This manual is also suitable for

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