ESAB Warrior™ 400i MV CC/CV User manual

Service manual

0463 402 001 GB 20190814

Valid for: Warrior™ 350i MV CC/CVserialno.635-xxx-xxxx

Warrior™ 400i MV CC/CVserial no.505-xxx-xxxx

Warrior™350iMVCC/CV,

Warrior™400iMVCC/CV

TABLE OF CONTENTS

0463 402 001 © ESAB AB 2019

READ THIS FIRST

....................................................................................

4

INTRODUCTION

.......................................................................................

5

Design structure of the power source

..................................................

5

Working principle

...................................................................................

5

TECHNICAL DATA

...................................................................................

8

WIRING DIAGRAM

...................................................................................

11

Component description

.........................................................................

11

Warrior™ 350i MV CC/CV and Warrior™ 400i MV CC/CV

...................

14

Components positions

...........................................................................

17

DESCRIPTION OF OPERATION

..............................................................

20

Warrior™350iMVCC/CV and Warrior™400iMVCC/CV internal

voltage map

............................................................................................

20

1AP1 MMC board

....................................................................................

20

2AP1 Mains filter board

.........................................................................

24

2AP2 Auxiliary supply board

.................................................................

25

15AP1 Power board

................................................................................

31

15AP2 Capacitor board

..........................................................................

39

15AP3 Filter board

..................................................................................

39

17AP1 Boost power board

.....................................................................

40

17AP2 Boost control board

...................................................................

42

20AP1 Control board

..............................................................................

47

FAULT INDICATION

.................................................................................

58

Fault descriptions

...................................................................................

58

SERVICE INSTRUCTIONS

.......................................................................

60

What is ESD?

..........................................................................................

60

Service aid

..............................................................................................

60

Special tools

...........................................................................................

61

Mounting components on the heat sink

...............................................

61

Tightening torque for screw joints on power components

................

61

Power On/Off sequence

.........................................................................

64

Checking the IGBT transistor and diode modules

..............................

65

Measurement with the IGBT and diode modules connected to the

power board .........................................................................................

66

Measurement with the IGBT and diode modules disconnected from

the boost power board..........................................................................

67

Checking the IGBT transistor modules

................................................

67

Checking the precharge power resistors R7 and R8

..........................

70

Checking the MOSFET

...........................................................................

70

Checking the primary rectifier bridge

..................................................

73

Checking the secondary rectifier diodes

.............................................

74

Soft start

..................................................................................................

74

AC power supply – preparations before soft starting ........................... 76

TABLE OF CONTENTS

0463 402 001 © ESAB AB 2019

DC power supply – preparations before soft starting ........................... 76

Checking the IGBT gate pulses of the inverter section ........................ 81

Checking the main transformer primary voltage................................... 82

Checking the welding outlet voltage..................................................... 82

Checking boost converter output voltage ............................................. 82

Restoring the power source after soft starting...................................... 83

Calibrating the arc voltage

....................................................................

83

Calibrating the welding current

.............................................................

84

IN-SERVICE INSPECTION AND TESTING

..............................................

85

General requirements

............................................................................

85

Periodic inspection and test

..................................................................

85

Cleaning instruction

...............................................................................

85

After repair, inspection and test

...........................................................

86

Visual inspection

....................................................................................

87

Electrical test

..........................................................................................

87

Functional test

........................................................................................

90

Test report

...............................................................................................

90

SPARE PARTS AND ACCESSORIES

.....................................................

92

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 402 001

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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 chapter

"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

August 2016.

The manual is valid for: Warrior™ 350i MV CC/CV 0465 885 881

Warrior™ 400i MV CC/CV 0465 885 880

Warrior™ 350i MV CC/CV and Warrior™ 400i MV CC/CV fulfill the Australian standard AS

1674.2 - 2003 regarding the output no load voltage for category C environment when VRD

35 V is activated. Filter board 15AP3 and resistor 15R1 are needed for this and have been

added.

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.

Warrior™ 350i MV CC/CV and Warrior™ 400i MV CC/CV are designed and tested in

accordance with international standards IEC 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 above standard.

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™ 350i MV CC/CV and Warrior™ 400i MV CC/CV power sources are

transistor-controlled, operating on the inverter principle. The power source 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 includes two three-digit displays and two LEDs. Attached to the MMC board

are two selector switches, one potentiometer and one encoder.

2 Mains module

The mains module includes a mains filter board, a mains switch, an auxiliary transformer and

a micro controller based auxiliary supply board.

15 Power module

The power module includes a power board with primary rectifier and IGBT transistor

modules, a capacitor board, a main transformer, a secondary inductor and secondary diode

modules.

17 Boost module

The boost module includes a power board with an IGBT module, a boost convertor control

board and a boost inductor

20 Control module

The control module includes a control board with a microprocessor, that monitors and

controls the welding process.

Working principle

The mains input is a three phase voltage from 208VAC to 460VAC(±10%) for

Warrior™350iMVCC/CV and from 220VAC to 460VAC(±10%) for

Warrior™400iMVCC/CV at rated load. The primary rectifier converts the input AC voltage

to uncontrolled DC bus voltage. The boost converter keeps the DC bus voltage at

750VDC(±5%). The boost converter operates at a switching frequency of 20kHz.

NOTE!

Warrior™ 350i MV CC/CV and Warrior™ 400iMVCC/CV are designed to work on

3-phase input supply only.

Warrior™ 350i MV CC/CV and Warrior™ 400iMVCC/CV are 4-transistor IGBT full bridge

inverters and operate at a switching frequency of 22 kHz. The main inverter output is

connected to a main transformer with a turn's ratio of 9:1. The main transformer output is

connected to a secondary rectifier which contains four diode modules. The

Warrior™350iMVCC/CV power source is rated to 350A/34VDC at 60% duty cycle. The

Warrior™400iMVCC/CV power source is rated to 400A/36VDC at 60% duty cycle.

INTRODUCTION

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NOTE!

The "DC bus" mentioned in this document refers to the voltage after the booster.

The “uncontrolled DC bus” mentioned in this document refers to voltage before the

booster.

INTRODUCTION

0463 402 001

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Block diagram of Warrior™350iMVCC/CV and Warrior™400iMVCC/CV power sources

TECHNICAL DATA

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TECHNICAL DATA

Warrior™ 400i MV CC/CV

Mains voltage 220-460 V ±10%, 3~50/60Hz

Primary current I

max

GMAW (MIG/MAG) 44 A

GTAW (TIG) 34 A

SMAW (MMA) 44 A

No-load power in energy-saving mode

6.5 min. after welding 50 W

Setting range

GMAW (MIG/MAG) 16 A/15 V - 400 A/34 V

GTAW (TIG) 5 A/10 V - 400 A/26 V

SMAW (MMA) 16 A/20 V - 400 A/36 V

Permissible load at GMAW (MIG/MAG)

60 % duty cycle 400 A/34 V

100% duty cycle 300 A/29 V

Permissible load at GTAW (TIG)

60 % duty cycle 400 A/26 V

100% duty cycle 300 A/22 V

Permissible load at SMAW (MMA)

60 % duty cycle at 220 VAC 380 A / 35.2 V

60 % duty cycle 400 A / 36 V

100% duty cycle 300 A / 32 V

Power factor at maximum current 0.95

Efficiency at maximum current 85 %

Electrode types Basic

Rutile

Cellulosic

Open-circuit voltage

VRD 35 V deactivated 56 V DC peak

VRD 35 V activated 28 V DC peak

Apparent power at maximum current 17.8 kVA

Active power at maximum current 16.9 kW

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

Transportation temperature -4-131°F (-20to+55°C)

Constant sound pressure when idling <70 dB(A)

Dimensions l × w × h 28.03×12.80×18.50in. (712×325×470mm)

Weight 134 lbs (60.8 kg)

Insulation class H

TECHNICAL DATA

0463 402 001

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Warrior™ 400i MV CC/CV

Enclosure class IP 23

Application class

Warrior™ 350i MV CC/CV

Mains voltage 208-460 V ±10%, 3~50/60Hz

Primary current I

max

MIG/MAG (GMAW) 39 A

TIG (GTAW) 30 A

MMA (SMAW) 41 A

No-load power in energy-saving mode

6.5 min. after welding 50 W

Setting range

MIG/MAG (GMAW) 16 A/15 V - 350 A/32 V

TIG (GTAW) 5 A/10 V - 350 A/24 V

MMA (SMAW) 16 A/20 V - 350 A/34 V

Permissible load at MIG/MAG (GMAW)

60 % duty cycle 350 A / 32 V

100% duty cycle 300 A / 29 V

Permissible load at TIG (GTAW)

60 % duty cycle 350 A / 24 V

100% duty cycle 300 A / 22 V

Permissible load at MMA (SMAW)

60 % duty cycle 350 A / 34 V

100% duty cycle 300 A / 32 V

Power factor at maximum current 0.95

Efficiency at maximum current 85 %

Electrode types Basic

Rutile

Cellulosic

Open-circuit voltage

VRD 35 V deactivated 56 V DC peak

VRD 35 V activated 28 V DC peak

Apparent power at maximum current 14.7 kVA

Active power at maximum current 14.0 kW

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

Transportation temperature -20 to +55°C (-4-131°F)

Constant sound pressure when idling <70 dB(A)

Dimensions l × w × h 712 × 325 × 470 mm (28.03 x 12.80 x 18.50 in.)

Weight 60.8 kg (134lb.)

Insulation class H

TECHNICAL DATA

0463 402 001

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Warrior™ 350i MV CC/CV

Enclosure class IP23

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, 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.

WIRING DIAGRAM

0463 402 001

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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

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

2AP2 Auxiliary supply board

2QF1 Mains switch

2T1 Auxiliary transformer, with multiple input windings

Input voltage windings:

• 220 V (not used in this version)

• 380 V

• 400 V (not used in this version)

• 415 V (not used in this version)

• 440 V (not used in this version)

• 460 V (not used in this version)

• 575 V (not used in this version)

Output voltages:

WIRING DIAGRAM

0463 402 001

- 12 -

• 20 V (primary)

• 40 V (secondary)

• 42 V (secondary)

15 Power module. Wire numbers 1500-1699.

15AP1 Power board

15AP2 Capacitor board

15AP3 Filter board

Added from serial no. 339-xxx-xxxx

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.

15R1 Resistor 150 ohm, 50 W (added from serial no. 339-XXX-XXXX)

15ST2 Temperature switch, on the primary heatsink

15ST3 Temperature switch, on the secondary heatsink

15ST4 Temperature switch, on the boost heatsink

15T1 Main transformer, 9:1 turns ratio

17 Boost module. Wire numbers 1700-1799.

17AP1 Boost power board

17AP2 Boost control board

17L1 Boost inductor

17PM1 Power module with an IGBT and a diode.

20 Control module. Wire numbers 2000-2099.

20AP1 Control board

20C1 Capacitor 0.1µF

XS.. Socket (sleeve)

WIRING DIAGRAM

0463 402 001

- 13 -

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 402 001

- 14 -

Warrior™ 350i MV CC/CV and Warrior™ 400i MV CC/CV

WIRING DIAGRAM

0463 402 001

- 15 -

WIRING DIAGRAM

0463 402 001

- 16 -

NOTE!

Make sure that wire number 7101 is connected to connector CNB1 and wire number

1701 is connected to CNB3 on 17AP2 circuit board before switching ON the power

source.

Make sure that wire number 1582 is connected to connector CNC5 and wire number

1702 is connected to CNC2 on 17AP2 circuit board before switching ON the power

source.

WIRING DIAGRAM

0463 402 001

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Components positions

Left view

WIRING DIAGRAM

0463 402 001

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Right view

WIRING DIAGRAM

0463 402 001

- 19 -

Right view, power modules

DESCRIPTION OF OPERATION

0463 402 001

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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.

Warrior™350iMVCC/CV and Warrior™400iMVCC/CV internal

voltage map

Principle diagram of the Warrior™350iMVCC/CV and Warrior™400iMVCC/CV internal

power supplies

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

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