ESAB Warrior™ 400i cc/cv Warrior™ 500i cc/cv User manual

Service manual

0740 800 221 GB 20150602 Valid for: Serial no. 339-xxx-xxxx, 405-xxx-xxxx

Warrior™400iCC/CV

Warrior™500iCC/CV

TABLE OF CONTENTS

0740 800 221 © ESAB AB 2015

READ THIS FIRST................................................................................................ 4

INTRODUCTION................................................................................................... 5

Design structure of the power source ...............................................................5

Working principle................................................................................................. 5

TECHNICAL DATA ............................................................................................... 7

WIRING DIAGRAM ............................................................................................... 9

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

Warrior 400i/500i CC/CV ....................................................................................12

Warrior component positions ...........................................................................14

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

Warrior internal voltage map.............................................................................17

1AP1 MMC board................................................................................................18

1AP1:1 Power supply....................................................................................... 18

1AP1:2 Display and LEDs................................................................................ 19

1AP1:3 Encoder ............................................................................................... 19

1AP1:4 Selectors ............................................................................................. 20

1AP1 Component positions..............................................................................21

2AP1 Mains filter board .....................................................................................22

2AP1 Component positions..............................................................................23

15AP1 Power board ...........................................................................................23

15AP1:1 Power supply..................................................................................... 24

15AP1:2 DC bus and precharge circuit............................................................ 26

15AP1:3 IGBT drives ....................................................................................... 27

15AP1:4 Primary current.................................................................................. 28

15AP1:5 DC bus voltage monitoring ................................................................ 29

15AP1:6Temperature monitoring ....................................................................30

15AP1:7 Torch.................................................................................................. 30

15AP1:8 Fan and cooler .................................................................................. 31

15AP1 Component positions............................................................................32

15AP2 Capacitor board......................................................................................33

15AP2 Component positions............................................................................33

20AP1 Control board .........................................................................................34

20AP1:1 Power supply..................................................................................... 34

20AP1:2 DC bus monitoring.............................................................................37

20AP1:3 Primary current.................................................................................. 37

20AP1:4 Secondary current ............................................................................. 38

20AP1:5 Arc voltage ........................................................................................ 39

20AP1:6 Current regulator ............................................................................... 40

20AP1:7 PWM circuit ....................................................................................... 41

20AP1:8 Gate drives ........................................................................................ 42

20AP1:9 Digital inputs/outputs ......................................................................... 43

20AP1:10 Remote interface ............................................................................. 43

TABLE OF CONTENTS

0740 800 221 © ESAB AB 2015

20AP1:11 Wire feeder interface .......................................................................44

20AP1:12 MMC interface ................................................................................. 45

20AP1:13 Processor and miscellaneous circuits ............................................. 46

20AP1 Component positions............................................................................47

FAULT INDICATIONS ......................................................................................... 48

Fault descriptions .............................................................................................. 48

SERVICE INSTRUCTIONS................................................................................. 50

What is ESD?...................................................................................................... 50

Service aid .......................................................................................................... 50

Special tools ....................................................................................................... 51

Mounting components on the heat sink ..........................................................51

Tightening torque for screw joints on power components............................52

Power On/Off sequence.....................................................................................54

Checking the IGBT transistor modules............................................................55

Measurement with the IGBT modules connected to the power

board ............................................................................................................56

Measurement with the IGBT modules disconnected from the power

board ............................................................................................................57

Checking the precharge power resistors R4, R5 ............................................57

Checking the primary rectifier bridge ..............................................................58

Checking the secondary rectifier diodes.........................................................59

Soft start .............................................................................................................60

AC power supply – preparations before soft starting ....................................... 60

DC power supply – preparations before soft starting ....................................... 61

Checking the IGBT gate pulses ....................................................................... 63

Checking the main transformer primary voltage .............................................. 64

Checking the welding outlet voltage.................................................................64

Restoring the power source after soft starting ................................................. 64

Calibrating the arc voltage ................................................................................65

Calibrating the welding current ........................................................................66

IN-SERVICE INSPECTION AND TESTING........................................................ 67

General requirements ........................................................................................ 67

Periodic inspection and test ............................................................................. 67

Cleaning instruction ..........................................................................................67

After repair, inspection and test .......................................................................68

Visual inspection................................................................................................ 69

Electrical test...................................................................................................... 70

Functional test.................................................................................................... 73

Test report........................................................................................................... 74

SPARE PARTS AND ACCESSORIES ...............................................................75

Rights reserved to alter specifications without notice.

READ THIS FIRST

0740 800 221

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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 AND

ACCESSORIES" chapter in this manual.

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

December 2012.

The manual is valid for: Warrior 500i CC/CV, 380 - 460 V 0465 350 880

Warrior 500i CC/CV, 460 V 0465 350 881

Warrior 400i CC/CV, 380 - 460 V 0465 350 882

Warrior 500i CC/CV, 575 V 0465 350 887

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

The Warrior 400i CC/CV and Warrior 500i CC/CV (460VAC versions) are designed and

tested in accordance with international standard IEC 60974-1. 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.

The Warrior 500i CC/CV (575VAC version) is designed and tested in accordance with

international standard IEC 60974-1, Canadian standards CAN/CSA-E60974-1:11 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 above standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

INTRODUCTION

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INTRODUCTION

Design structure of the power source

The Warrior power source is transistor-controlled, operating on the inverter principle. It

consists of a number of function modules. 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 MMC board including two three-digit displays, and two LEDs. Attached to the MMC

board are two selector switches, one potentiometer and one encoder.

2 Mains module

Mains filter board, mains switch, auxiliary transformer

15 Power module

Power board including primary rectifier and IGBT transistor modules. Capacitor board, main

transformer, secondary inductor, secondary diode modules.

20 Control module

The control board, with a microprocessor, that monitors and controls the welding process.

Working principle

The mains input voltage range is three-phase 380±10% VAC to 460±10% VAC at rated load

(for 460VAC version).

The mains input voltage range is three-phase 380±10% VAC to 575±10% VAC at rated load

(for 575VAC version).

The auxiliary transformer 2T1 has multiple primary connections and has to be correctly

connected depending on the mains voltage.

The primary rectifier creates the DC bus voltage by rectifying the input AC voltage.

The primary inverter of the Warrior power source is a 4-transistor IGBT fullbridge, operating

at a switching frequency of 22 kHz. All power semiconductors are built into modules.

The primary inverter output is connected to a main transformer with a 7:1 turns ratio (for

460VAC version) or a 9:1 turns ratio (for 575VAC version).

The main transformer output is connected to a secondary rectifier which contains four diode

modules.

The Warrior power source is rated 400A/36VDC or 500A/40VDC at 60% duty cycle.

INTRODUCTION

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Block diagram of the Warrior 400i/500i CC/CV power sources

TECHNICAL DATA

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TECHNICAL DATA

Warrior 400i CC/CV

460VACversion

Warrior 500i CC/CV

460VACversion

Warrior 500i CC/CV

575VACversion

Mains voltage 380–460VAC±10%

3~50/60Hz

380–460VAC±10%

3~50/60Hz

380–575VAC±10%

3~50/60Hz

Primary current

I

max

MIG/MAG 27 A 37 A 38 A

I

max

TIG 23 A 30 A 31 A

I

max

MMA 29 A 38 A 38 A

No-load power in

energy-saving mode,

6.5min. after welding

30 W 30 W 40 W

Setting range

MIG/MAG 16A/15V - 400A/34V 16A/15V - 500A/39V 16A/15V - 500A/39V

TIG 5A/10V - 400A/26V 5A/10V - 500A/30V 5A/10V - 500A/30V

MMA 16A/20V - 400A/36V 16A/20V - 500A/40V 16A/20V - 500A/40V

Permissible load at MIG/MAG

60 % duty cycle 400 A / 34 V 500 A / 39 V 500 A / 39 V

100 % duty cycle 300 A / 39 V 400 A / 34 V 400 A / 34 V

Permissible load at TIG

60 % duty cycle 400 A / 26 V 500 A / 30 V 500 A / 30 V

100 % duty cycle 300 A / 22 V 400 A / 26 V 400 A / 26 V

Permissible load at MMA

60 % duty cycle 400 A / 36 V 500 A / 40 V 500 A / 40 V

100 % duty cycle 300 A / 32 V 400 A / 36 V 400 A / 36 V

Power factor at maximum current

MIG/MAG 0.84 0.88 0.87

TIG 0.75 0.85 0.83

MMA 0.82 0.88 0.87

Efficiency at maximum current

MIG/MAG 91 % 90 % 90 %

TIG 88 % 87 % 88 %

MMA 91 % 91 % 90 %

Electrode types Basic Basic Basic

Rutile Rutile Rutile

Cellulosic Cellulosic Cellulosic

Open-circuit voltage

without VRD function 71 VDC 71 VDC 84 VDC

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

Transportation

temperature

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

TECHNICAL DATA

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Warrior 400i CC/CV

460VACversion

Warrior 500i CC/CV

460VACversion

Warrior 500i CC/CV

575VACversion

Constant sound

pressure when idling

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

Dimensions l×w×h 712×325×470 mm 712×325×470 mm 712×325×470 mm

Weight 52.5 kg 52.5 kg 52.5 kg

Insulation class H H H

Enclosure class IP 23 IP 23 IP 23

Application class

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.

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

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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

WIRING DIAGRAM

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Component description

Component Description

1 MMC module. Wire numbers 100-199.

1AP1 Display board

1G1 Encoder

1R1 Potentiometer 10kΩ (inductance/arc force selection)

1S1 Switch selector, three positions (electrode type)

1S3 Switch selector, five positions (process type)

2 Mains module. Wire numbers 200-299.

2AP1 Mains filter board

2QF1 Mains switch

2T1 Auxiliary transformer, with multiple input windings

Input voltage windings:

• 380V

• 400V

• 415V

• 440V

• 460V

• 575V (only for 575V version)

Output voltages:

• 20V (primary)

• 40V (secondary)

• 42V (secondary)

15 Power module. Wire numbers 1500-1699.

15AP1 Power board

15AP2 Capacitor board

15BR1 Primary rectifier bridge, 3 phase

15C1 Capacitor 0.1µF

15C2 Capacitor 0.1µF

15C3 Capacitor 0.1µF

15CS1 Secondary current sensor, 1:2000

15EV1 Fan, 24VDC

15FU1 Automatic fuse 10A

15L1 Secondary inductor

15L2-15L9 Ferrite ring cores

15PM1, 15PM2 IGBT power transistor modules. Each module consists of two

transistors and two freewheel diodes.

15PM3, 15PM4, 15PM5,

15PM6

Secondary rectifier diode modules. Each module consists of two

diodes.

WIRING DIAGRAM

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Component Description

15ST2 Temperature switch, on the primary heatsink

15ST3 Temperature switch, on the secondary heatsink

15T1 Main transformer

• 7:1 turns ratio (for 460VAC version)

• 9:1 turns ratio (for 575VAC version)

20 Control module. Wire numbers 2000-2099

20AP1 Control board

20C1 Capacitor 0.1µF

XS.. Socket (sleeve)

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling

electrostaticsensitive devices.

• Use proper static-proof bags and boxes.

WIRING DIAGRAM

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Warrior 400i/500i CC/CV

WIRING DIAGRAM

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WIRING DIAGRAM

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Warrior component positions

Left view

WIRING DIAGRAM

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Right view

WIRING DIAGRAM

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Right view, power modules

DESCRIPTION OF OPERATION

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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.

Warrior internal voltage map

Principle diagram of the Warrior 400i/500i CC/CV internal power supplies

DESCRIPTION OF OPERATION

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1AP1 MMC board

The user interface contains a circuit board with two three-digit LED displays and two LEDs.

Two selector switches, one potentiometer and one encoder are connected to the MMC

board.

1AP1:1 Power supply

The MMC board is supplied at 24VDC and 15VDC from the control board 20AP1. An

illuminated LED D4 indicates that +5V is OK.

+24V (±0.1V ) is converted to +5V by the switching circuit IC5, D5, L1.

+15V (±0.5V) supplies the selector switches 1S1 and 1S3, the potentiometer 1R1 and the

encoder 1G1.

+5V (4.6±0.2V ) supplies the displays, the LEDs and the logic circuitry. The actual voltage is

not really 5V but 4.6V.

DESCRIPTION OF OPERATION

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1AP1:2 Display and LEDs

The displays and LEDs are controlled by the LED drivers IC1-IC3. The data to the LED

drivers is received from the control board 20AP1 over a three-line serial bus through the IC4

buffer circuits. The normal data speed is about 1kHz.

An illuminated LED D8 indicates a thermal error, which means that one or both of the

temperature switches 15ST2-15ST3 have tripped. An illuminated LED D9 indicates that

VRD is active.

The three-digit display DY1-DY3 shows the arc voltage The three-digit display DY4-DY6

shows the welding current.

NOTE!

The decimal points of displays DY3 and DY6 are not connected.

At power on, all the display segments (except for DY3 and DY6 dots) and the LEDs are

illuminated for about one second, to indicate correct function.

1AP1:3 Encoder

The panel encoder 1G1 generates two square wave pulse trains when turned. Square

waveA is90° phase shifted relative to square waveB. This phase shift is necessary for the

processor to determine in which direction the encoder is being turned.

DESCRIPTION OF OPERATION

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1AP1:4 Selectors

Potentiometer 1R1 steplessly sets either the inductance or the arc force, depending on the

chosen welding process.

Selector switch 1S1 chooses the electrode type in three steps through the voltage divider

R39-R42.

Selector switch 1S3 chooses the type of welding process in five steps through the voltage

divider R29-R34.

The values set by 1R1,1S1,1S3 are inputs to the control board 20AP1.

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ESAB Warrior™ 400i cc/cv Warrior™ 500i cc/cv User manual

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