ESAB AristoMig 450 User manual

0740 800 160 Valid for serial no. 310--xxx--xxxx to 620--xxx--xxxx060814

Mig U4500i

Mig 4500i

AristoMig 320

Aristo

t

AristoMig 450

Service manual

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Rights reserved to alter specifications without notice.

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

INTRODUCTION 4...................................................................

TECHNICAL DATA 5.................................................................

WIRING DIAGRAM 7.................................................................

Component description 7..........................................................

AristoMig 320/450, Mig 4500i 10.....................................................

DESCRIPTION OF OPERATION 12.....................................................

AP1 Power board 12...............................................................

AP1:1 The mains power unit 12....................................................

AP1:2 Capacitive potential divider 12...............................................

AP1:3 Main transformer 12.......................................................

AP1:4 IGBT 14..................................................................

AP1:5 T ransient protection 14.....................................................

AP1:6 The gate circuit 14.........................................................

AP1 Component positions 16....................................................

AP2 Control board 17..............................................................

AP2:1 Power supply 17...........................................................

AP2:2 Current sensor 18.........................................................

AP2:3 Arc voltage input 19........................................................

AP2:4 Overcurrent protection 20...................................................

AP2:5 Overvoltage and Undervoltage protection 21..................................

AP2:6 Gate pulses to AP1 22.....................................................

AP2:7 CAN bus 22...............................................................

AP2:8 Thyristor control 24........................................................

AP2:9 Thermal overload switch 24.................................................

AP2:10 Fan control 25.............................................................

AP2:11 Input for a flow monitor switch 25............................................

AP2:12 External shutdown 26......................................................

AP2 Component positions 26....................................................

LED indications on AP2 26..................................................

AP5 Interference suppressor board 28...............................................

AP6 TIG board 28..................................................................

AP6:1 Power supply / the CAN bus 28..............................................

AP6:2 Welding gun switch 29.....................................................

AP6:3 HF generator 29...........................................................

AP6:4 Gas valve 30..............................................................

AP6:5 Gas flow monitors 31.......................................................

AP6:6 Extra outputs 31...........................................................

AP6 Component positions 32....................................................

REMOTE CONTROLS 32..............................................................

F AULT CODES 33....................................................................

Fault log 33........................................................................

Summary of fault codes 33.........................................................

Fault code description, power source 34............................................

SERVICE INSTRUCTIONS 37..........................................................

What is ESD? 37...................................................................

Service aid 38......................................................................

Service traps 39....................................................................

Checking the IGBT transistors 39...................................................

Mounting components on the heat sink 40...........................................

Checking the gate pulses 41........................................................

Pulses from circuit board AP1 to the IGBT transistors 42.................................

Pulses from circuit board AP2 to circuit board AP1 43....................................

Soft starting 44....................................................................

Calibration of the current sensor signal 46...........................................

Calibration of the arc voltage input 48...............................................

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INSTRUCTIONS 50...................................................................

SAFETY 50........................................................................

INSTALLATION 51..................................................................

Mains power supply 51.............................................................

Terminating resistor 52.............................................................

OPERATION 52....................................................................

Settings 52........................................................................

Connections and control devices 53.................................................

Pulse welding 53...................................................................

Remote control unit 54.............................................................

MAINTENANCE 54.................................................................

Filling the coolant 54...............................................................

Inspection and cleaning 54.........................................................

SPARE PARTS 54....................................................................

NOTES 55...........................................................................

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READ THIS FIRST

Maintenance and repair work should 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

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

the description of operation. All component names in the wiring diagram are listed in the

component description.

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

including July 2006.

The manual is valid for:

AristoMig 320 and AristoMig 450 with serial no. 304--xxx--xxxx, 445--xxx--xxxx.

Mig U4500i and Mig 4500i with serial no. 620--xxx--xxxx.

The AristoMig 450 is renamed, new name: Mig U4500i and Mig 4500i

The AristoMig 320, AristoMig 450, Mig U4500i and Mig 4500i are designed and tested in

accordance with international and European standard IEC/EN 60974.

On completion of service or repair work, it is the responsibility of the person(s) etc.

performing the work to ensure that the product does not depart from the requirements

of the above standard.

INTRODUCTION

The power sources are intended for MMA, MIG/MAG, TIG welding and CAG (Carbon Arc

Gouging). They are designed to operate with CAN bus controlled wire feed units.

Man --machine communication through the control panels M2, MA4, MA6, U6 and U8.

The wire feed units and the control panels have their own service manuals.

WARNING

Many parts of the power source are at mains voltage.

Schematic diagram of the power source

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TECHNICAL DATA

AristoMig 320 Mig 4500i/U4500i,

AristoMig 450

Mains voltage,

not reconnectable

400V 3~ 50/60Hz 400V 3~ 50/60Hz

Mains voltage,

reconnectable *

208/230/400/460/475/500/575V

3~ 50/60Hz

208/230/400/460/475/500/575V

3~ 50/60Hz

Permissible load at

100% duty cycle

270A / 30.8V 360 / 34.4V

60% duty cycle 320A / 32.8V 425A / 37V

45% duty cycle 320A / 32.8V 450A / 38V

Setting range

MIG/MAG

15A/15V(8V) -- 320A/30V 15A/15V(8V) -- 450A/36.5V

MMA 16A/20V -- 320A/32.8V 16A/20V -- 450A/38V

TIG 4A/10V -- 320A/22.7V 4A/10V -- 450A/28V

Open -- circuit voltage

MIG/MAG, TIG

65 -- 80 V 65 -- 80 V

MMA 50 -- 60 V 50 -- 60 V

Open--circuit power 520 W 520 W

Efficiency

at max current

MIG/MAG 82%

MMA 84%

TIG 84%

MIG/MAG 82%

MMA 83%

TIG 83%

Power factor

at max current

MIG/MAG 0.85

MMA 0.85

TIG 0.80

MIG/MAG 0.92

MMA 0.92

TIG 0.90

Enclosure class IP 23 IP 23

Weight, not reconnectable

mains voltage

AristoMig 320: 96kg

AristoMig 320w: 110kg

Mig 4500i: 96kg

Mig 4500iw: 110kg

Weight,

reconnectable mains voltage

AristoMig 320: 143kg

AristoMig 320w: 157kg

Mig 4500i: 143kg

Mig 4500iw: 157kg

Dimensions lxbxh 910 x 642 x 835 mm 910 x 642 x 835 mm

Application classification

* Mains power supply module 0456 271 001 max 500V input voltage

* Mains power supply module 0456 271 002 max 575V input voltage

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain load without overloading.

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 designed for indoor and outdoor use.

Application class

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

electrical hazard.

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WIRING DIAGRAM

Component description

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

S Observe precautions for handling electrostatic--

sensitive devices.

S Use proper static--proof bags and boxes.

ESD

This component description refers to the diagram on page 10.

AP1 Power board; see the function description on page 12.

AP2 Control circuit board; see the function description on page 17.

AP3 Connection board, for communication with the setting unit, wire feed unit and

remote control device.

AP4 Hall effect sensor, 1 V / 100 A

AP5 Circuit board, suppression (EMC). See circuit diagram on page 28.

AP6 Circuit board for TIG welding; see the function description on page 28.

AP7 HF device, output voltage: 500V peak. Only on machines with TIG welding

capability.

C1 -- C2 Capacitor, decoupling.

C3 Start and run capacitor for pump motor M1.

C4 Start and run capacitor for fan EV2.

C5 Capacitor, decoupling.

C6 Capacitor, for speed reduction of cooling fan EV2.

C7 Capacitor, C7 and R3 smooth the no-- load voltage for MMA welding.

C8 Capacitor, decoupling.

EV1 Fan, 24 V DC. Cools circuit board AP1.

EV2 Fan, 230 V AC.

FU1 MCB, 10 A, protects the 42 V supply to the wire feed unit.

FU2 Fuse, 2A, slow -- blow. Protects fan EV2, pump motor M1 and HF generator

AP7.

HL1 Indicating lamp on the front of the machine. Lights when the main On/Off

switch QF1 is on.

L1 Primary inductor. Filters the mains voltage and improves the power factor.

L2 Secondary inductor. Its inductance exceeds 10 μH at high currents and

about 60 μH at low currents.

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L3 2+4+4 ferrite rings. Reduce transients to/from transformer TM1. See also V1

below and AP1:3 on page 12.

L4 Ferrite ring. Suppresses interference in the signal from Hall effect sensor

AP4. The wires from AP4 must be wound four turns around the ring.

M1 Pump motor. Only machines with water cooling.

Q1 -- Q2 IGBT modules. See AP1:4 on page 14 and the instructions on page 40.

QF1 Main power supply switch.

QF2 Cooling water pump switch. Only machines with water cooling.

R2 Resistor. Discharges capacitor C7 when the no-- load voltage is turned off.

R3 Resistor. With C7, it smooths the no-- load voltage for MMA welding.

SL1 Flow switch for cooling water (accessory). See AP2:11 on page 25.

ST1 Thermal switch: see AP2:9 on page 24, and the fitting instructions

on page 40.

ST2 Thermal switch: controls the fan speed. See AP2:10 on page 25.

ST3 Thermal switch; see AP2:9 on page 24.

TA1 Current transforme r, 400:1. Note that it must never

be run with open--

circuited secondary. See also AP2:4 on page 20.

TC1 Auxiliary transformer. If the mains voltage exceeds 427 V, the link on terminal

2XT2 must be moved from the 400 V terminal to the 428 V terminal.

TM1 Main transformer. See AP1:3 on page 12.

TM2 Autotransformer. There are two versions: 575 V max input voltage for the US

and Canadian market, 500 V max input voltage for other markets.

TV1 HF transformer. The primary winding has one turn, and the secondary

winding has 26 turns. The unloaded secondary winding is about 13 kV peak.

When fitting the transformer it is important that the air gaps in the transformer

cores are correct. See item 621 in the spare parts list.

Fitted only to machines with TIG welding capability.

V1 Diode modules with secondary diodes. There are five diode modules in the

AristoMig 450, Mig 4500i and four in the AristoMig 320.

Each module consists of two diodes. The transient voltages produced when

the d iodes turn off are suppressed by eight ferrite rings, i.e. four in each

diode leg.

If one diode module is faulty, replace all diode modules.

See page 40 for fitting instructions for V1.

V2 (TY1) Thyristor module. See AP2:8 on page 24 and the instructions on page 40.

V3 LED, yellow. Indicates overtemperature. See AP2:9 on page 24.

VC1 (BR1) Rectifier bridge. See fitting instructions on page 40.

XP.. Plug connectors (male).

XS.. Socket connectors (female).

XS29 Central connector for TIG welding.

XS30 Connector, OKC 50 HF, for TIG welding.

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XT.. Terminal blocks.

YV1 Solenoid valve. Only on machines with TIG welding capability.

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AristoMig 320/450, Mig 4500i

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DESCRIPTION OF OPERATION

This description of operation describes the function of circuit boards and other components

in the power source. It is divided into sections, numbered to correspond to the circuit board

numbers and divisions into function blocks.

AP1 Power board

Circuit board AP1 is the mother board in the power section of the power source. The

components of the power section are mounted on a cast heat sink.

If the IGBT modules, circuit board AP1 and/or circuit board AP2 are replaced, the gate

pulses must be checked and the machine must be soft-- started: see pages 22 and 45.

AP1:1 The mains power unit

The mains voltage is rectified by rectifier VC1. Primary inductor L1 improves

the power factor and increases resistance to mains-- borne transients.

Smoothing capacitors C12 -- C15 charge up through resistors R3 and R4 when

the power is turned on. The two resistors are short--circuited by thyristor TY1

(V2) about 1.2 seconds after starting. If the thyristor fails to do this, the two

resistors could be burnt out when load was applied to the machine. Their

ratings are 12Ω 10 W each and their ordering number is: 0193 775 114.

Resistors R5 and R9 form a potential divider / discharge resistor for capacitors

C12 -- C15.

See page 40 for instructions on fitting VC1 and TY1 (V2).

AP1:2 Capacitive poten tial divider

Capacitors C1 and C2 form a capacitive potential divider for the centre point to

which the main transformer is connected. Resistors R1 and R2 are discharge /

potential divider resistors.

AP1:3 Main transformer

The transformer is strip -- wound, with four primary turns and 1 + 1 secondary

turns.

Its core has an air gap of about 0.13 mm, which is of key importance for

operation of the entire inverter. It must not be reduced or eliminated.

Two ferrite rings, L3, are fitted to the conductors connected to the primary

winding. Their purpose is to attenuate current transients arising from operation

of the IGBT transistors.

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Circuit diagram, Power board AP1

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AP1:4 IGBT

The switching components in the power section consist of two IGBT modules,

Q1 and Q2, operating at a fixed switching frequency of 2 0 kHz.

The IGBT modules must never be energised when the gate conductors are

disconnected.

Fitting instructions are given on page 40.

If the IGBT modules have failed, we recommend that the mains rectifier, VC1,

should also be replaced.

AP1:5 Transient protection

An RCD filter protects against transients produced by turn--off of the IGBT

modules. It consists of components R18, R19, C10, C11, D1 and D2.

AP1:6 The gate circuit

The IGBT transistors are each driven by their own gate circuits. These circuits

are galvanically isolated from control circuit board AP2 by transformers TR1

and TR2.

Fuses F1 and F2 protect the gate drive circuits if the power source should fail.

Instructions for checking the gate pulses can be found on page 22.

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Circuit diagram, Power board AP1

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AP1 Component positions

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AP2 Control board

Sections AP2:1 -- AP2:11 refer to the wiring diagram on page 10 and the components

position diagram on page 27.

If circuit boards AP1 and/or AP2 are replaced, the gate pulses must be checked and the

machine must be soft-- started: see pages 22 and 45.

If circuit board AP2 is replaced, the input for the current sensor must be adjusted:

see page 18.

Circuit board identity

The AP2 circuit board has a software identity, machine ID. To read or change the machine

ID you need the Esat service kit, see page 38. The spare part boards are delivered with

machine ID.

The ID numbers of the machines are: AristoMig 320 ID = 7 AristoMig U320 ID = 8

AristoMig 450, Mig 4500i ID = 9 AristoMig U450, Mig U4500i ID = 10

AP2:1 Power supply

+5 V

The +5V supply is regulated by voltage regulator VR5/VR6. IC16 forms a reset

circuit that monitors both the regulated 5V supply after the regulator and the

unregulated.

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When the voltage rises through 4.65V on starting, IC16 maintains the reset

signal for 200 ms to ensure that the machine program starts correctly.

If the voltage after the regulator drops below 4.65V, IC16 generates a reset

signal to the processor and the PWM circuit.

IC16 monitors the voltage to the regulator input in order to make a controlled

shutdown in the event of low mains voltage, loss of power supply or turning off

the machine.

If the voltage across C110 drops below 6V, the gate pulses to the IGBT

transistors are cut off immediately and the processor receives an ’early

warning’ signal that enables it to shut down the process in a controlled manner.

+15 V

There are four different 15V supplies on the board: 15V, 15VB, 15VC and

15VD. The processor monitors all these voltages except 15VD.

15VB

Supplies the pulse transformers that drive the IGBT transistors.

The voltage must be between 13.9V and 15.6V. If it is not, the gate pulses to

the IGBT transistors are interrupted, and the setting unit displays error code

10.

15VC

If the 15VC supply is outside its tolerance of 13.9 -- 15.6V, the setting unit

displays error code 8.

15VD

See OVERVOLTAGE AND UNDER VOLTAGE PROTECTION on page 21.

-- 1 5 V

If this voltage varies outside its tolerance of 14.0 -- 16.1V, the setting unit will

display error code 9.

POWER SUPPLY TO THE CAN BUS

See CAN bus on page 23.

AP2:2 Current sen so r

Input S4 is intended for use with a current sensor that produces a signal of

1V/100A, linearly proportional to the current.

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At no--load, current sensor AP4 must produce an output signal of 0V ±20mV at

input S4. It must be replaced if it produces the wrong value signal at no--load.

If AP2 or AP4 are replaced, the machine must be recalibrated to ensure that it

delivers the correct current. See Page 46 for calibration instructions.

AP2:3 Arc voltage input

The arc voltage input senses the welding voltage regardless of the welding

polarity or welding method. If sensing via the welding filler wire is connected, it

is this voltage that will be used: if not, the voltage at the power sources

terminals is used.

The signal from the arc voltage input is used as an input signal to the welding

process controller: from it, the controller calculates in real time how much

current must flow in the circuit in the next instant.

The arc voltage signal provides a voltage signal to the power source’s display

panel.

See Page 48 for instructions for calibrating the arc voltage signal input.

Methods of measuring the arc voltage

Various methods of measurement are available by transferring a link between

contacts W1, W2 and W3. When delivered, the link is fitted between W2 and

W3. The link must be connected between W2 and W3 for MMA or TIG

welding.

S We lding with the filler wire positive: voltage sensing from the wire.

This is the commonest arrangement for MIG welding.

W2 -- W3 must be linked. This method of measurement allows for the

voltage drop in the supply conductor (= to the welding gun). The input

signal is measured between inputs W5 and W6. Amplifier IC8:1 is active.

S We lding with the filler wire negative: voltage sensing from the wire

W2 -- W3 must be linked. This method of measurement allows for the

voltage drop in the supply conductor. The input signal is measured

between inputs W5 and W7. Amplifier IC8:7 is active.

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S Welding with the filler wire positive or negative, without external

sensing from the wire or workpiece.

W2 -- W3 must be linked. The input signal is measured between inputs W7

and W6 (= the voltage at the power source terminals), as there is no

connection to W1. Amplifier IC8:1 is active.

S We lding with the filler wire positive: voltage sensing from the wire

and workpiece.

W1 and W2 must be linked. This method allows for the voltage drop in

both the supply and return conductors. The input signal is measured

between W5 and W4. Amplifier IC8:1 is active.

Note: If the voltage signal connection to W4 is lost, the power source

loses control of the arc voltage.

AP2:4 Overcurrent protection

The overcurrent protection senses the primary current via current transformer

TA1, the ratio of which is 400:1. It is fitted in the primary supply to the main

transformer.

NOTE! TA1 must never be operated with an open--c ircuit secondary

(= output). This could destroy it by flashover between the windings.

The current from TA1 is rectified and smoothed, before being converted to a

voltage that is proportional to the current.

Operation of the overcurrent protection turns off the gate pulses to the IGBT

transistors immediately and thus stops the machine..

The setting unit displays fault code 7. The fault detection circuits can be reset

only by turning off the power supply.

The current limit is 250A on the primary side, which is equivalent to 1000A on

the secondary.

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