ESAB Aristo Arc 4000i Service Manual Download Page 71

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S0740 800 191/E080229/P78

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cu20i1

When welding with water--cooled MIG/--guns on all wire feed units, it is recommended to

connect a separate cooling unit for the 2 extra guns.

We recommend connecting the guns in parallel.

Two wire feed units

A connection kit is required when connecting two wire feed units, see accessory part of the

spare parts list.

Four wire feed units

Two connection kits and an extra cooling unit are required when connecting four wire feed

units, see accessory part of the spare parts list.

Summary of Contents for Aristo Arc 4000i

Page 1: ...0740 800 191 Valid for serial no 803 xxx xxxx 080229 Aristot Origot Arc 4000i Mig U4000i Mig 4000i Tig 4000i Service manual...

Page 2: ...er board 29 15AP2 1 Gate driver stages 29 15AP2 2 Overvoltage and undervoltage protection 30 15AP2 Component positions 31 20AP1 Control board 32 20AP1 1 Power supply 32 20AP1 2 Fan control 33 20AP1 3...

Page 3: ...e threshold values 64 Calibrating the current sensor signal 65 MIG machines calibration of the arc voltage feedback 66 DC TIG machines calibration of the arc voltage feedback 68 INSTRUCTIONS 69 SAFETY...

Page 4: ...ts list is published as a separate document see page 77 This manual contains details of design changes that have been made up to and including February 2008 The manual is valid for Mig U4000i Mig 4000...

Page 5: ...ule Mains interference suppressor mains switch control power transformer contactor 15 Power module This module is a forward converter inverter operating at a switching frequency of 27 kHz IGBT transis...

Page 6: ...0 A 27 V Permissible load at MMA 35 duty cycle 60 duty cycle 100 duty cycle 400 A 36 V 320 A 33 V 250 A 30 V Permissible load at TIG 35 duty cycle 60 duty cycle 100 duty cycle 400 A 26 V 320 A 23 V 25...

Page 7: ...duty cycle 400 A 34 V 320 A 30 V 250 A 27 V Permissible load at MMA 35 duty cycle 60 duty cycle 100 duty cycle 400 A 36 V 320 A 33 V 250 A 30 V Power factor at maximum current 0 90 Efficiency at maxim...

Page 8: ...t maximum current 0 90 Efficiency at maximum current 86 Open circuit voltage 78 90 V Operating temperature range 10 to 40 C Transportation temperature 20 to 55 C Dimensions lxbxh with cooling unit 625...

Page 9: ...294 x 492 mm Continual sound pressure at no load 70 db A Weight 47 5 kg Insulation class H Enclosure class IP 23 Application class Duty cycle The duty cycle refers to the time as a percentage of a ten...

Page 10: ...tification 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 CAUTION STAT...

Page 11: ...voltage exceeds 427 V the link on terminal 2XT2 must be moved from the 400 V terminal to the 428 V terminal 3 Primary inductor module Wire numbers 300 399 3L1 Primary inductor 5 Water cooling module...

Page 12: ...or the diode modules 15EV1 15EV2 Fans 24 V DC See the description of 20AP1 2 on page 33 15L1 15L2 2 2 ferrite rings Reduce transient voltages produced when the diode modules 15D1 and 15D2 turn off 15L...

Page 13: ...option for MIG machines CAN bus distribution board AP3 connected to Mig 4000i The MIG machines are normally delivered without MMC module If the accessory MMC kit is used the MMC module can be moved fr...

Page 14: ...S0740 800 191 E080229 P78 Mig U4000i valid for serial number 803 xxx xxxx 14 cu19_00...

Page 15: ...S0740 800 191 E080229 P78 15 cu19_00...

Page 16: ...S0740 800 191 E080229 P78 Mig 4000i valid for serial number 803 xxx xxxx 16 cu19_00...

Page 17: ...S0740 800 191 E080229 P78 17 cu19_00...

Page 18: ...S0740 800 191 E080229 P78 Tig 4000i valid for serial number 803 xxx xxxx 18 cu19_00...

Page 19: ...S0740 800 191 E080229 P78 19 cu19_00...

Page 20: ...S0740 800 191 E080229 P78 Arc 4000i valid for serial number 803 xxx xxxx 20 cu19_00...

Page 21: ...S0740 800 191 E080229 P78 21 cu19_00...

Page 22: ...elding data it also exercises overall control of the system as a whole Setting the welding data Man machine communication MMC is assisted by the modular architecture of the equipment It is possible to...

Page 23: ...S0740 800 191 E080229 P78 23 ct32_02 2AP1 Interference suppressor board EMC board Circuit diagram and component positions 2AP1...

Page 24: ...h for the water lock connection 5SL1 Water flow guard The contact closes for flow rates of 0 7 l min and over Note This is an accessory 5ST1 Temperature sensor switch Closes at 45 C opens at 35 C Wiri...

Page 25: ...also carries a smaller circuit board 15AP2 which provides the functions for the gate drivers and overvoltage and undervoltage protection Block diagram of the power module If the IGBT transistors 15Q1...

Page 26: ...detailed description of the starting sequence Component description BR2 Rectifier for charging current C1 C2 Capacitors restricting the inrush charging current to rectifier bridge BR2 The current whi...

Page 27: ...ansistors have failed See page 58 for instructions on checking the IGBT transistors Diode modules 15D1 and 15D2 each contain two diodes Both they and the IGBT transistors must be mounted in accordance...

Page 28: ...S0740 800 191 E080229 P78 28 ct32_15 15AP1 Component positions...

Page 29: ...a maximum pulse width of 39 0 40 8 of the cycle width See page 60 for screen traces of waveforms and measurement instructions Transformers TR1 and TR2 are gate driver transformers for galvanic isolati...

Page 30: ...tage limit is fixed while the upper voltage limit can be adjusted by potentiometer R1 The neutrals 0V on the power board and the gate driver board are connected to each other by a metal spacer screw D...

Page 31: ...S0740 800 191 E080229 P78 31 ct32_15 15AP2 Component positions WARNING 0 V on this circuit board is at mains voltage 0V...

Page 32: ...fferences in both hardware and software If wrong board is used it might cause serious damage to the machine Make sure that the replacement board has correct article number see the spare parts list Cir...

Page 33: ...ed depends on the welding current For loads up to 146 A the fans run at low speed supplied at about 18 V At load currents above 146 A the fans are supplied at 24 V and run at full speed On conclusion...

Page 34: ...onnected in parallel to the connectors CAN_A and CAN_B The 12V_Can and 0V_Can power supply is unregulated and is galvanically isolated from other parts of the control board The shell of the CAN connec...

Page 35: ...sistor The CAN bus resistance must lie in the range 50 130 ohm the optimum value is 60 ohm To check the resistance turn off the power source and measure the resistance between pins L and K in connecto...

Page 36: ...can be disconnected or connected by moving a jumper See the service manual for the CAN based remote controls filename 0740 800 170 20AP1 4 Temperature monitoring Principal diagram of the temperature...

Page 37: ...and S4 on circuit board 20AP1 must show 0 195 V at 100 A welding current U R x I 3 91 x 0 05 0 195 If circuit boards 20AP1 or 15AP3 are replaced the machine must be recalibrated See page 65 for calibr...

Page 38: ...load voltage controller senses the voltage at the welding current terminals and limits it to a level between 55 V and 70 V This function is inactive during welding and is activated within 0 5 seconds...

Page 39: ...voltage sensing from the wire Y2 Y3 must be linked This method of measurement allows for the voltage drop in the supply conductor The input signal is measured between inputs X1 and W5 Amplifier IC8 8...

Page 40: ...rating instructions No load voltage reduction MMA The no load voltage controller senses the voltage at the welding current terminals and limits it to a level between 78 V and 90 V This function is ina...

Page 41: ...S0740 800 191 E080229 P78 20AP1 Component positions 41 cu19_20_1...

Page 42: ...ay board is supplied at 24 V from controller circuit board 20AP1 Link BY3 tells the processor on the controller board what version of the relay board is in use 20AP2 2 External shutdown Contacts H1 an...

Page 43: ...to Position 1 7 The software in the MMC module is initiated for about nine seconds 8 Relay RE2 is activated by transistor Q32 9 RE2 connects 400 V AC to rectifier bridge BR2 on circuit board 15AP1 10...

Page 44: ...e cooling water connection on the front of the cooler is not used instead the water connections on the back of the unit which have no water locks must be connected to the wire feed unit However the co...

Page 45: ...1 opens Starting to weld 1 The welder presses the trigger switch on the welding gun 2 The water pump starts if microswitch 13S1 is closed 3 If water flow is achieved within three seconds welding start...

Page 46: ...conds the pump is stopped 3 If welding does not start within 6 5 minutes the pump is stopped If the water flow stops when the pump is started the fault indication lamp on the MMC will flash Machines w...

Page 47: ...onds The voltage on the primary side of transformer 10TV1 is about 500 V producing a secondary voltage of 10 12 kV if a 4 metre long welding torch is connected If the welding torch is 16 metre the HF...

Page 48: ...are not mounted on the board that is delivered with the machine Spare part circuit boards are delivered with all components fitted Terminals G4 and G5 are intended for use with a gas flow monitor MMA...

Page 49: ...S0740 800 191 E080229 P78 49 cu19_20_2 20AP2 Circuit diagram...

Page 50: ...ults are monitored detected in two ways by test routines that are run on initiation and by functions that can detect a fault when it occurs The control panel displays a unit number to indicate which u...

Page 51: ...power up This fault does not disable any functions The program memory is damaged This is a serious fault that can have unforeseen effects Action Restart the power source If the fault persists load ne...

Page 52: ...or dirt on the heat exchanger 8 15 V power supply on circuit board 20AP1 The voltage is too high or too low it must be within the range 14 1 to 15 9 V This fault does not disable any functions 9 15 V...

Page 53: ...evented the processor from performing its normal program duties The program restarts automatically The current welding process will be stopped This fault does not disable any functions This fault shou...

Page 54: ...S0740 800 191 E080229 P78 54 emptypage...

Page 55: ...electricity is prevented from building up on you or on anything at your work station then there cannot be any static discharges Nonconductive materials e g fabrics or insulators e g plastics generate...

Page 56: ...possible to update the software in power source wire feeder and control panel ESAT contains also service functions by which it is possible to control change or read the different functions in the equi...

Page 57: ...hort circuiting and burning up relay board 20AP2 Overvoltage and undervoltage protection Don t mix up contacts 15XS7 and 15XS5 if you do you write off circuit board 15AP2 Contact 15XS5 is marked B and...

Page 58: ...hand and the short circuiting link to terminals 1 2 and 3 on the transistor before fitting the link Without the short circuiting link the measurements will be incorrect Measure the transistor voltage...

Page 59: ...hten the screws alternately to a torque of 2 5 Nm and then further tighten them to 4 5 Nm NB The screws must be tightened diagonally Tighten the screws that connect the IGBT transistors to circuit boa...

Page 60: ...ing 1 Disconnect wires 261 262 and 263 from terminal block A on circuit board 15AP1 2 Unplug contact 2XS2 from 15AP1 3 Insulate the wires that have been removed from each other and from all other part...

Page 61: ...it must be 41 43 of the cycle time measured at 10 V on the negative pulse as shown in the diagram above 6 Measure the maximum pulse voltage it must be in the range 30 38 V The minimum voltage must be...

Page 62: ...lses with the diagram below The waveform shape must be as in the diagram 4 Measure the pulse frequency it must be 27 kHz 0 5 kHz 5 Measure the pulse duration it must be 39 0 40 8 of the cycle time mea...

Page 63: ...oltage across capacitors C16 and C14 respectively It should be about 6 9 V DC 5 Use ESAT to set a current reference 6 Using an oscilloscope examine the waveforms on the secondary side of TM1 at the in...

Page 64: ...y 1 Remove wires 261 262 and 263 from terminal block A on circuit board 15AP1 2 Unplug contact 2XS2 from 15AP1 3 Insulate the wires that have been removed from each other and from all other parts 4 En...

Page 65: ...de or use ESAT to set a current reference 5 Set a welding current of 400 A 6 Load the power source so that the voltage across the load is 35 37 V Circuit diagram for current calibration 7 Measure the...

Page 66: ...it to the power source Connect long welding current cables to give an appreciable voltage drop in the cables Connect a wire to the feed rollers and connect an external voltmeter as shown in the diagra...

Page 67: ...control panel must show the same voltage value as shown on the external voltmeter 0 6 V Adjust the display value by means of potentiometer R103 3 Welding with the filler wire positive or negative no e...

Page 68: ...oving fuse 2FU5 from transformer 2TC2 see the circuit diagram on Page 18 Set the power source to the MMA welding mode TIG and MMA machines 1 Set a welding current of about 100 A supplying it to a resi...

Page 69: ...anuals for the Mig U4000i Mig 4000i Arc 4000i and Tig 4000i SAFETY CAUTION Read and understand the instruction manual before installing or operating INSTALLATION The installation must be executed by a...

Page 70: ...not be applicable in other countries make sure that the cable area and fuse sizes comply with the relevant national regulations Terminating resistor MIG machines In order to avoid communication inter...

Page 71: ...or the 2 extra guns We recommend connecting the guns in parallel Two wire feed units A connection kit is required when connecting two wire feed units see accessory part of the spare parts list Four wi...

Page 72: ...Connection for welding current cable at MMA welding or for return cable at TIG welding 12 Connection for control cable to the wire feed unit or to the terminating resistor 5 Connection for remote con...

Page 73: ...tor 5 Connection for remote control adapter 11 Connection for welding current to the wire feed unit 6 Connection for return cable 12 Connection for cooling water to the wire feed unit BLUE 7 Main powe...

Page 74: ...rch 14 Connection for cooling water Not used on this model 8 Connection for gas to the TIG torch 15 Connection for cooling water Not used on this model Turning on the power source Turn on the mains po...

Page 75: ...s to run for 6 5 minutes and then switches to the energy saving mode Function when welding To start welding the welder presses the welding gun trigger switch The power source turns on and starts the w...

Page 76: ...n the product during the guarantee period in order to rectify any faults Cleaning the air filter S Release the cover plate with the dust filter 1 S Swing out the cover plate 2 S Remove the dust filter...

Page 77: ...otes SPARE PARTS The spare parts list is published in a separate document that can be downloaded from the internet www esab com Product filename Mig U4000i Mig 4000i 0459 839 019 Tig 4000i 0459 839 02...

Page 78: ...92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires...

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