ESAB Mig U4500i User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
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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Rights reserved to alter specifications without notice.
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 ÎĽH at high currents and
about 60 ÎĽH 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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ESAB Mig U4500i User manual
- Category
- Welding System
- Type
- User manual
- This manual is also suitable for
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