ESAB | Arc 5000i - AristoMig 500 | Service manual | ESAB Arc 5000i - AristoMig 500 User manual

ESAB Arc 5000i - AristoMig 500 User manual
Aristot
Mig U5000i, Mig 5000i
AristoMig U500, AristoMig 500
460 V version
Aristot
Origot
Arc 5000i
AristoArc 500
460 V version
Service manual
0740 800 159
080418
Valid for serial no. 304--xxx--xxxx to 620--xxx--xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mig U5000i / 5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc 5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MMC option for MIG machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mig U5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mig 5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc 5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2 Interference suppressor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 MMC module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 The power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1 Power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:1 Mains rectifier bridge and charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:2 Switching circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:3 Overvoltage and undervoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1
Connections to the circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2 Gate driver board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2:1 Gate driver stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2:2 Overvoltage and undervoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP4 Filter board with main rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:2 Fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:3 The CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminating resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:4 Temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:5 Overvoltage and undervoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:6 Communication with relay board 20AP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:7 Gate pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:8 Current sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:9 Arc voltage input, Arc 5000i & AristoArc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:9 Arc voltage input, MIG machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2 Relay board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:2 External shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:3 Starting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:4 Power supply to the cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:5 Cooling water monitoring in MIG welding mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:5 Cooling water monitoring in TIG welding mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:6 TIG Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:7 TIG HF starting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:8 TIG Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:9 TIG, Gas flow monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
6
6
7
8
8
11
12
14
16
18
18
18
19
21
22
22
23
24
24
25
26
26
27
28
29
30
30
30
31
32
33
33
33
33
34
35
36
38
39
39
39
40
41
41
43
44
44
44
45
45
46
47
Rights reserved to alter specifications without notice.
TOCe
-- 2 --
S0740 800 159/E080418/P80
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault code description, power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking power board 15AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting components on the heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the gate pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulses from circuit board 15AP2 to the IGBT transistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulses from circuit board 20AP1 to circuit board 15AP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soft starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the overvoltage and undervoltage threshold values . . . . . . . . . . . . . . . . . . . . . .
Calibrating the current sensor signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration of the arc voltage input, Arc 5000i & AristoArc 500 . . . . . . . . . . . . . . . . . . . . .
Calibration of the arc voltage input, MIG machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing TR1 on 15AP1 with new version of 2TC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTION MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminating resistor, MIG machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices, Mig U5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices, Mig 5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices, Arc 5000i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning on the power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan control timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
47
47
48
51
51
52
53
53
54
56
57
58
60
62
64
66
67
68
70
71
71
71
71
72
72
73
73
74
74
75
75
75
75
76
76
76
76
77
78
78
Rights reserved to alter specifications without notice.
TOCe
-- 3 --
S0740 800 159/E080418/P80
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.
The circuit boards are 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 March 2008.
The manual is valid for:
AristoMig U500, AristoMig 500 and AristoArc 500 with serial no. 310--xxx--xxxx, 445--xxx--xxxx
and 524--xxx--xxxx.
Mig U5000i, Mig 5000i, and Arc 5000i with serial no. 620--xxx--xxxx.
Note! Mig U5000i and Mig 5000i with serial number 803--xxx--xxxx differ from the
description in this manual. For those machines there is another service manual available,
file name: 0740 800 193.
The power sources are renamed:
New name Old name
Mig U5000i
AristoMig U500
Mig 5000i
AristoMig 500
Arc 5000i
AristoArc 500
WARNING!
Many parts of the power source are at mains voltage.
INTRODUCTION
The Mig U5000i is a MIG/MAG welding power source, which can also be used for MMA and
TIG welding.
The Mig 5000i can be used for MIG/MAG and MMA welding.
There are two variants of the Mig U5000i: with cooling unit or without cooling unit.
This service manual describe a Mig U5000i with a cooling unit.
The power sources are intended for use with the Feed 3004 (AristoFeed 30--4) or Feed
4804 (AristoFeed 48--4) wire feed units. All the settings are made from the wire feed unit or
control box U8.
The Arc 5000i is a welding current power source intended for use with coated electrodes
(MMA welding).
It is available in two variants: Arc 5000i with the A2 control panel and Arc 5000i with the A4
control panel.
Design structure of the power source
The power source is transistor--controlled, operating on the inverter principle. It consists of a
number of function modules, as shown in the block diagram on next page. Each module
cu15de1
-- 4 --
S0740 800 159/E080418/P80
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 control panel and welding data unit, which control the machine functions.
2 Mains module
Mains interference suppressor, mains switch, auxiliary transformer, contactor.
15 Power module
This module is a dual forward converter inverter, operating at a switching frequency of
2 x 27 kHz. IGBT transistors are used as the switching elements. All power semiconductors
are built into modules in order to ensure a robust design suitable for use in the demanding
welding environment.
20 Processor board module (controller module)
This is the controller board, 20AP1, with a microprocessor, that monitors and controls the
voltage and current. It is served by relay board 20AP2, which handles input and output
signals to/from the controller board.
Further information on the modules can be found in the component and function
descriptions.
3 x 460 V
Block diagram of the power source
cu15de1
-- 5 --
S0740 800 159/E080418/P80
TECHNICAL DATA
Mig U5000i / 5000i
Mig U5000i
Mig 5000i
Mains voltage
460V, ±10%, 3∼ 60 Hz
460V, ±10%, 3∼ 60 Hz
Primary current
Imax MIG/MAG
Imax MMA
Imax TIG
35 A
36 A
29 A
35 A
36 A
--
No--load power demand when in the
energy--saving mode, 6.5 min. after welding
70 W
70 W
Voltage/current range
MIG/MAG
MIG/MAG, with Control Panel M2
MMA
TIG
8 -- 60 V / 16 -- 500 A
8 -- 42 V
16 -- 500 A
4 -- 500 A
8 -- 60 V / 16 -- 500 A
-16 -- 500 A
--
Permissible load at MIG/MAG
60 % duty cycle
100% duty cycle
500 A / 39 V
400 A / 34 V
500 A / 39 V
400 A / 34 V
Permissible load at MMA
60 % duty cycle
100% duty cycle
500 A / 40 V
400 A / 36 V
500 A / 40 V
400 A / 36 V
Permissible load at TIG
60 % duty cycle
100% duty cycle
500 A / 30 V
400 A / 26 V
---
Power factor at maximum current
0.83
0.83
Efficiency at maximum current
87 %
87 %
Open--circuit voltage
MIG/MAG
MMA
TIG
72 -- 88 V
68 -- 80 V
72 -- 88 V
72 -- 88 V
68 -- 80 V
--
Operating temperature
--10 to +40˚C
--10 to +40˚C
Transportation temperature
--20 to +55˚C
--20 to +55˚C
Dimensions, l x w x h
with cooling unit
625 x 394 x 496 mm
625 x 394 x 776 mm
625 x 394 x 496 mm
--
Continual sound pressure at no--load
<70 db
<70 db
Weight
with cooling unit
70 kg
90 kg
68 kg
--
Insulation class transformer
H
H
Enclosure class
IP 23
IP 23
Application class
Cooling unit
Cooling power
2500 W at 40˚C temperature difference and flow1.5 l/min
Coolant
50 % water / 50% mono--ethylen glycol
Coolant quantity
5.5 l
cu15de1
-- 6 --
S0740 800 159/E080418/P80
Cooling unit
Maximum water flow
2 l/min
Maximum number of water--cooled welding guns/torches that may be connected:
Two MIG welding guns or one TIG torch and one MIG welding gun
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a certain 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.
Arc 5000i
Arc 5000i
Mains voltage
Primary current Imax
No--load power in energy--saving mode
6.5 min. after welding
Setting range
Maximum permissible load at
60 % duty cycle
100 % duty cycle
Power factor at maximum current
Efficiency at maximum current
Open--circuit voltage
Temperature range
Dimensions, l x w x h
Continual A--weighted sound pressure
Weight
Insulation class transformer
Enclosure class
Application class
cu15de1
460 V, ±10%, 3∼ 60 Hz
36 A
70 W
16 A -- 500 A
500 A / 40 V
400 A / 36 V
0.83
87%
68 -- 80 V
--10 to + 40˚C
625 x 294 x 492 mm
<70 db
57 kg
H
IP 23
-- 7 --
S0740 800 159/E080418/P80
WIRING DIAGRAMS
CAUTION !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostatic-sensitive devices.
S
Use proper static--proof bags and boxes.
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) etc.
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
Q
1
= module association, 1--69
= transistor
= individual identification number, 0--99
Component description
Component
Description
AP1
Connection board for communication with the wire feed unit and remote
control device.
AP2
Interference suppressor board. See diagram on Page 18.
AP3
CAN bus distribution board. Accessory, included in the MMC kit for the
MIG machines, see page 11.
C3
Capacitor, 100 nF 250 V.
C4
Capacitor, 100 nF 250 V.
D1
LED, orange, for overtemperature indication.
cu15de1
-- 8 --
S0740 800 159/E080418/P80
Component
Description
HL1
Indicating lamp, white. Indicates Power On.
The lamp is replaced by a LED. Spare part with LED replaces the lamp.
XP..
Plug connectors.
XS..
Socket connectors.
XT..
Terminal blocks.
1
MMC module. Wire numbers 100--199. This module is described in a
separate service manual for the control panels. See page 18.
2
Mains module. Wire numbers 200--299.
2FU1
Fuse, 4 A, slow blow (anti--surge).
2FU2
Fuse, 6.3 A, slow blow (anti--surge).
2FU3
Fuse, 3.15 A, slow blow (anti--surge).
2FU4
Fuse, 8 A, slow blow (anti--surge).
2FU5
Fuse, 2 A, slow blow (anti--surge).
2KM1
Main contactor. See 20AP2:3 on Page 40.
2QF1
Mains switch. See 20AP2:3 on Page 40.
2TC1
Auxiliary transformer. New winding added from serial no. 524--xxx--xxxx,
see page 70.
2TC2
Auxiliary transformer.
2TC3
Auxiliary transformer.
3
Primary inductor module. Wire numbers 300--399.
3L1
Primary inductor.
4
Autotransformer module. Wire numbers 400--499.
4TM1
Autotransformer, option.
Connection instruction and wiring diagram are in the instruction manual
for the autotransformers TUA 1 and TUA 2.
5
Water cooling module. Wire numbers 500--599.
The connection diagram for the cooling module is on Page 19.
The power supply to the cooling water pump and fan is controlled by the
machine software. See the description of 20AP2:5 on Page 41.
10
TIG module. Wire numbers 1000--1199.
10AP1
HF starting device. See the description of 20AP2:7 on Page 44.
10C1
Interference suppression capacitor, 47 nF 250V.
10TV1
HF transformer.
cu15de1
-- 9 --
S0740 800 159/E080418/P80
Component
Description
10YV1
Gas valve. See the description of 20AP2:6 on Page 44.
15
Power module. Wire numbers 1500--1699. See the schematic diagram
and description on Page 21.
15AP1
Power board. See the description on Pages 22 -- 25.
15AP2
Driver board. See the description on Pages 26 -- 28.
15AP3
Current sensor. See the description of 20AP1:8 on Page 34.
15AP4
Filter board with rectifier bridge. See the diagrams on Page 29.
15BR1
Rectifier bridge. See the description of 15AP1:1 on Page 22 and the
assembly instructions on Page 56.
15D1, 15D2,
15D3, 15D4
Rectifier and freewheel diode modules. Each module consists of two
diodes.
15D1 and 15D3 rectifies the welding current. During the time interval
between the voltage pulses from transformers 15TM1 and 15TM2, the
freewheel diodes 15D2 and 15D4 maintain the welding current from
inductor 15L3.
See Page 56 for assembly instructions for the diode modules.
15EV1,
15EV2
Fans, 24 V DC. See the description of 20AP1:2 on Page 30.
15L1, 15L2
2 + 2 ferrite rings. Reduce transient voltages produced when the diode
modules 15D1 and 15D2 turn off.
15L4, 15L5
2 + 2 ferrite rings. Reduce transient voltages produced when the diode
modules 15D3 and 15D4 turn off.
15L3
Inductor.
15Q1, 15Q2,
15Q3, 15Q4
IGBT transistors. See the description of 15AP1:2 on Page 23 and the
installation instructions on Page 56.
15ST1
Thermal overload cutout, in the winding of main transformer 15TM1. See
the description of 20AP1:4 on Page 33.
15ST2
Thermal overload cutout, mounted on the heat sink of the diode modules.
See the description of 20AP1:4 on Page 33 and the installation
instructions on Page 56.
15ST3
Thermal overload cutout, in the winding of main transformer 15TM2. See
the description of 20AP1:4 on Page 33.
15TM1,
15TM2
Main transformers.
20AP1
Controller circuit board. See the description on Pages 30 -- 38.
20AP2
Relay board. See the description on Pages 39 -- 46.
cu15de1
-- 10 --
S0740 800 159/E080418/P80
MMC option for MIG machines
The CAN bus distribution board connected to a Mig 5000i
The MIG machines are normally delivered without MMC module. If the accessory ’MMC kit’
is used, the MMC module can be moved from the wire feed unit to the power source.
cu15de1
-- 11 --
S0740 800 159/E080418/P80
Mig U5000i
460 V version
cu15de1
-- 12 --
S0740 800 159/E080418/P80
cu15de1
-- 13 --
S0740 800 159/E080418/P80
Mig 5000i
460 V version
cu15de1
-- 14 --
S0740 800 159/E080418/P80
cu15de1
-- 15 --
S0740 800 159/E080418/P80
Arc 5000i
460 V version
cu15de1
-- 16 --
S0740 800 159/E080418/P80
cu15de1
-- 17 --
S0740 800 159/E080418/P80
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.
AP2 Interference suppressor board
Component positions and circuit diagram of the AP2 circuit board
The circuit board removes interference signals.
The connections A1, A2 and B1, B2 are not used in the MIG machines.
1 MMC module
The MMC module consists of an operator’s control panel and a welding data board.
The power source, the wire feed unit and the control panel each have their own
microprocessor for control, with the control panel being the central unit in the system. In
addition to storing and issuing welding 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 choose systems with the emphasis on the simplest possible
operation, or those that can provide more optimised settings for the best welding
performance.
The MMC modules are described in separate service manuals
MMC modules for the Mig U5000i and AristoMig 5000i
The MMC module can either be a control panel fitted to the wire feed unit or a control
pendant connected to the remote connection of the power source or the feed unit.
Mig U5000i: control panel U6 and pendant U8.
Mig 5000i: control panel M2, control panel MA4, control panel MA6 and pendant U8.
MMC modules for the Arc 5000i
The power source is supplied with control panel A2 or control panel A4.
cu15de1
-- 18 --
S0740 800 159/E080418/P80
5 Cooling unit
Component description, water cooling unit
5C1
5C2
5EV1
5M1
5S1
5SL1
5ST1
Start and run capacitor for the fan motor, 5 mF 450 V AC.
Start and run capacitor for the pump motor, 3 mF 400 V.
Fan motor, 230 V AC.
Pump motor, 230 V AC.
Microswitch for the water lock connection.
Water flow guard. The contact closes for flow rates of 0.7 l/min and over.
Note: this is an accessory.
Temperature sensor switch. Closes at 45 °C, opens at 35 °C.
Wiring diagram for the cooling unit
The power supply to cooling water pump 5M1 and fan 5EV1 is controlled by the machine
software in the welding data unit. See the description of the 20AP2:5 on Page 41. The fan
is energised in parallel with the pump, and is controlled by temperature sensor switch 5ST1.
cu15de2
-- 19 --
S0740 800 159/E080418/P80
cu15de2
-- 20 --
S0740 800 159/E080418/P80
15 The power module
The power module converts 3--phase 460 V to the welding voltage. It consists of a dual
forward converter inverter, operating at a switching frequency of 2 x 27 kHz.
The mains rectifier bridge 15BR1, the IGBT transistors 15Q1 -- 15Q4 and the diode
modules 15D1 -- 15D4 are all mounted on a heat sink. Circuit board 15AP1 links them
together. Circuit board 15AP2 provides the functions for the gate drivers and overvoltage
and undervoltage protection.
3 x 460 V
Block diagram of the power module
If the IGBT transistors 15Q1 -- 15Q4, or circuit boards 15AP1, 15AP2 or 20AP1, are
replaced, the gate pulse waveforms must be checked afterwards and the machine must be
soft--started. See Pages 57 and 62.
See the instructions on Page 56 concerning mounting of the components on the heat sink
(15Q1, 15Q2, 15Q3, 15Q4,15BR1, 15D1, 15D2, 15D3 and 15D4).
WARNING
The power module is at mains voltage.
0 V in the power module is connected to mains voltage.
cu15de3pwr
-- 21 --
S0740 800 159/E080418/P80
15AP1 Power board
The power board carries the charging circuit, the switching circuit and a transformer for
voltage supply to the overvoltage and undervoltage protection.
Circuit board connectors marked NC are not connected.
If this circuit board is to be replaced in machines with serial number prior to 524--xxx--xxx:
See page 70 for instructions.
15AP1:1
Mains rectifier bridge and charging circuit
When the mains power supply is turned on, smoothing capacitors C1--C4
charge up via rectifier bridge BR1. Contactor 2KM1 closes after about twelve
seconds and connects the mains supply to rectifier bridge 15BR1. See
Page 40 for a more detailed description of the starting sequence.
Component description:
15AP1
Power board
BR1
Rectifier for charging current.
C1 -- C4
Smoothing capacitors, with a total capacitance of 1000 mF.
C17, C18
Capacitors, restricting the inrush charging current to rectifier
bridge BR1. The current while capacitors C1 -- C4 are charging
is about 0.7 A.
R1, R2
Potential divider and discharge resistors for C1 -- C4.
R3, R4
Discharge resistors for C17 and C18.
R5, R7
Series resistors for the charging current to C1 -- C4.
15AP4
Filter board
R11 -- R13 Varistors. Clip the voltage peaks exceeding about 1100 V.
The varistors do not conduct when the voltage is below 575 V
AC RMS, this corresponds to a peak voltage of 810 V.
15BR1
cu15de3pwr
Main rectifier for mains voltage. See connection instruction on
page 29.
-- 22 --
S0740 800 159/E080418/P80
15AP1:2
Switching circuit
The power module switching components consist of IGBT transistors 15Q1 -15Q4, operating at a switching frequency of 2 x 27 kHz. The transistors must
never be energised when the gate connections are removed.
The gate pulse waveforms and duration are vital for correct operation. See
also Page 26.
If an IGBT transistor in a pair(15Q1, 15Q2 or 15Q3, 15Q4) has failed, both
transistors in the pair must be replaced. Failure of either transistor pair always
subjects rectifier bridge 15BR1 to a high current surge, which substantially
reduces its life. We therefore recommend that the rectifier bridge should also
be replaced if the transistors have failed. See Page 54 for instructions on
checking the IGBT transistors.
Diode modules 15D1 -- 15D4 each contain two diodes. Both they and the IGBT
transistors must be mounted in accordance with the instructions on Page 56.
If any of the diodes have failed, probably the IGBT transistors have failed too.
cu15de3pwr
-- 23 --
S0740 800 159/E080418/P80
15AP1:3
Overvoltage and undervoltage protection
The voltage protection function monitors the voltage across smoothing
capacitors C1--C4. See Page 27 for a description of operation.
From serial no. 524--xxx--xxx the voltage protection function is powered from
transformer 2TC1.
Before serial no. 524--xxx--xxx the voltage protection function was powered
from transformer TR1 on power board 15AP1. See page 70 for more
information.
15AP1
Connections to the circuit board
Circuit board 15AP1, soldering side
Wires 1595 and 1594 are the negative and positive voltage supply from
rectifier bridge 15BR1. Wires 1531 and 1543 are connected to the over/under
voltage protection.
Twisted red and yellow wires connected to C, E, G and H must be connected
to connectors marked C, E, G and H on circuit board 15AP2. Yellow wires are
connected to connection marked Y above, red wires are connected to R.
cu15de3pwr
-- 24 --
S0740 800 159/E080418/P80
15AP1
cu15de3pwr
Component positions
-- 25 --
S0740 800 159/E080418/P80
15AP2 Gate driver board
The gate driver board carries circuitry for gate driving and overvoltage and undervoltage
protection.
15AP2:1
Gate driver stages
WARNING! Dangerous voltage -- mains voltage. Never measure the gate
signals when the power source is connected to the mains supply.
The gate pulse frequency is 27 kHz, with a maximum pulse width of 39.0 -40.8 % of the cycle width. See Page 57 for screen traces of waveforms and
measurement instructions.
Transformers TR101, TR102, TR201 and TR202 are gate driver transformers
for galvanic isolation of the drive circuits from controller board 20AP1. Fuses
S101, S102, S201 and S202 protect the gate driver circuit if the IGBT
transistors fail.
Transistors 15Q1 and 15Q3 have a diode connected in series with the emitter:
these transistors have the identification ’GAR’ on the case.
Transistors 15Q2 and 15Q4 have a diode in series with the collector, and are
identified by ’GAL’ on the case.
cu15de3pwr
-- 26 --
S0740 800 159/E080418/P80
15AP2:2
Overvoltage and undervoltage protection
650V
WARNING! Dangerous voltage. Mains voltage on circuit boards 15AP1
and 15AP2 when connected to the 460 V supply.
0 V on power board 15AP1 and gate driver board 15AP2 is connected to the
mains supply. 0 V on the power board and gate driver board is galvanically
isolated from 0 V on controller board 20AP1.
The overvoltage and undervoltage protection generates a fault signal if the
voltage across capacitors C1--C4 falls outside the permitted interval of
330 -- 820 V DC, which is equivalent to 235 -- 580 V AC to mains rectifier
15BR1. The lower voltage limit is fixed, while the upper voltage limit can be
adjusted by potentiometer R1.
During normal operating conditions, the voltage between pins A1 and A2 on
circuit board 15AP2 is about 0.1 V. Optocoupler IC2 is used for galvanic
isolation of the voltage monitoring circuit from control board 20AP1.
A break in any of the conductors to/from 15AP2, as shown in the diagram
above will result in a fault state.
In the event of a fault, the charging relay and the contactor open, as described
in the description of the starting sequence on Page 40. Machines with a
display panel will show fault code 5.
See Page 64 for instructions on check measurements of voltage levels.
cu15de3pwr
-- 27 --
S0740 800 159/E080418/P80
15AP2
Component positions
Warning:
0 V on this circuit board is at mains voltage.
cu15de3pwr
-- 28 --
S0740 800 159/E080418/P80
15AP4 Filter board with main rectifier
WARNING
The filter board is at mains voltage.
The function of the circuit board is described on page 22.
Circuit diagram
Component positions
Connections to the soldering side of the 15AP4 circuit board
Note: connect cable 1595 to the negative pole of rectifier 15BR1 and cable 1594 to the
positve pole. The voltage between cables 1595 and 1594 is about 650 V DC.
cu15de3pwr
-- 29 --
S0740 800 159/E080418/P80
20AP1 Control board
The processor on the control board monitors and controls the various functions of the power
source. It obtains information on welding data and welding processes from the welding data
board in the MMC control panel.
CAUTION!
This circuit board looks identical to the control board used in other machines, but there is a
difference 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.
From serial no. 803--xxx--xxxx there is a new version of the control board. The soft starting
and measuring procedure for the new version of the board differs from the earlier version.
The new version is described in another service manual that is valid from serial number
803--xxx--xxxx. The new version may be used in all machines.
Circuit board identity
The control board has a machine ID, a hardware ID and a unit type number. To read this
you need the ESAT service kit, see page 52.
S
S
S
The machine ID defines which type of power source the board is intended for.
The hardware ID shows design and type of circuit board.
The unit type is used for identification on the CAN bus.
The ID numbers of the Mig U5000i (AristoMig U400), Mig 5000i (AristoMig 500) and Arc 5000i
(AristoArc 500) are: Machine ID = 17 Hardware ID = 2 Unit type = 2
20AP1:1
Power supply
+24 V Power supply to relay board 20AP2
+15 V Internal power supply on 20AP1 and power supply to the pulse
transformers on 15AP2.
--15 V Internal power supply on 20AP1.
+5 V Internal power supply on 20AP1.
20AP1:2
Fan control
When the mains power supply is turned on, the fans are off. After about 4
seconds they start and run at full speed, for a short moment, before shutting
down until welding starts.
The fan speed depends on the welding current. For loads up to 182 A, the fans
run at low speed, supplied at about 18 V. At load currents above 182 A, the
fans are supplied at 24 V and run at full speed. On conclusion of welding, the
fans continue to run for 6.5 minutes.
cu15de4ctr
-- 30 --
S0740 800 159/E080418/P80
If the welding current is above 182 A and then is reduced to a lower value, the
fans continue to run at full speed for 6.5 minutes, before dropping to the lower
speed.
Up to serial no. 304--412--xxxx, the supply voltage to the fans at low speed is
about 12 V.
If the power source is controlled by an U8 with software version 1.11, or an
earlier version, the fans run at full speed at load currents above 146 A.
The power supply and control circuits of the fans
20AP1:3
The CAN bus
Bus communication circuits to and from the control board
A standardised communication (CAN -- Controller Area Network) bus is used
for communication between the units of the machine. Communication speed is
400 kbit/s.
cu15de4ctr
-- 31 --
S0740 800 159/E080418/P80
The CAN bus is connected 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--connectors is connected to 0V_Can. GND in the diagram
above is connected to the power source chassis.
The CAN_A connector is connected to remote control unit connector XS3.
Connector CAN_B is used for internal communication, e.g. with the control
panel. See the machine connection diagram.
Voltage regulator VR1 supplies a 5 V power supply to the CAN circuits on
20AP1.
If the CAN bus fails, the control panel will normally generate a fault message.
Check the following points in the event of problems with CAN communications:
S
The terminating resistor. 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
the remote control connector socket XS3.
S
The connection cable between units. Check that the correct type of cable
is being used. Check that each signal is being carried by the correct core.
CAN H and CAN L must be carried by the twinned pair.
S
All screen connections must be sound.
S
Good contact with the chassis connections from/to the control board,
suppressor board and suppressor capacitors. See the main circuit
diagram.
Terminating resistors
In order to avoid communication interference, the ends of the CAN bus must
be terminated by resistive loads.
One end of the CAN bus is at the control panel, which incorporates a
terminating resistor. The other end is in the power source and it must be fitted
with a terminating resistor. If a CAN remote control with terminating resistor is
connected to the power source, the terminating resistor must be removed from
the power source.
The CAN remote controls and CAN adapters have a built--in terminating
resistor. This resistor can be disconnected or connected by moving a jumper:
See the service manual for the CAN based remote controls (file name 0740
800 170).
Principal diagram of the CAN bus and connecting up of the terminating resistors
cu15de4ctr
-- 32 --
S0740 800 159/E080418/P80
20AP1:4
Temperature monitoring
Thermal cutout switch 15ST1 is fitted under the winding of main transformer
15TM1, and opens at a temperature of 130°C.
Thermal cutout switch 15ST3 is fitted under the winding of main transformer
15TM2, it opens at a temperature of 130°C.
Thermal cutout switch 15ST2 is mounted on the heat sink, between the diode
modules, and opens at a temperature of 80°C. See Page 56 for fitting
instructions.
If either of the switches operates, the power source is stopped and LED D1 on
the front panel lights. The power source cannot be restarted until it has cooled
sufficiently for the switch(es) to reclose.
Principal diagram of the temperature monitoring circuits
20AP1:5
Overvoltage and undervoltage protection
See 15AP2:2 on Page 27.
20AP1:6
Communication with relay board 20AP2
20AP1:7
Gate pulses
cu15de4ctr
See Page 39, 20AP2 relay board.
See Page 26, 15AP2:1 gate driver stage.
-- 33 --
S0740 800 159/E080418/P80
20AP1:8
Current sensor
The current signal supplied to contact S3 on circuit board 20AP1 is 250 mA at
500 A, and is linearly proportional to the current. Measuring the voltage
between contacts S3 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 66 for calibration instructions.
Offset potentiometer R201 is not mounted on circuit board 20AP1. The offset
adjustment is carried out by fixed resistors.
On no load, there must be a voltage of 0 V ±2 mV at input S3 of circuit board
20AP1. If the current sensor gives an incorrect value on no load, it must be
replaced. The sensor must be connected to 20AP1 when making the
measurement.
cu15de4ctr
-- 34 --
S0740 800 159/E080418/P80
20AP1:9
Arc voltage input, Arc 5000i & AristoArc
Circuit diagram of the arc voltage input
The arc voltage input senses the welding voltage at the power source’s
welding current terminals. Contacts Y2 and Y3 must be linked.
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 controller
activates/deactivates the no--load voltage reduction function.
The arc voltage signal provides a voltage signal to the power source’s display
panel.
See Page 67 for instructions for calibrating the arc voltage signal input.
No--load voltage reduction
The no--load voltage controller senses the voltage at the welding current
terminals and limits it to a level between 68 V and 80 V. This function is
inactive during welding, and is activated within 0.5 seconds after conclusion of
welding.
cu15d_20_1
-- 35 --
S0740 800 159/E080418/P80
20AP1:9
Arc voltage input, MIG machines
Circuit diagram of the 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 source’s
terminals is used.
When the machine is in MMA or TIG welding mode contacts Y2 and Y3 must
be linked.
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 controller
activates/deactivates the no--load voltage reduction function.
The arc voltage signal provides a voltage signal to the display panel.
See Page 68 for instructions for calibrating the arc voltage signal input.
No--load voltage reduction
MIG welding mode
The no--load voltage controller senses the voltage at the welding current
terminals and limits it to a level between 72 V and 88 V. This function is
inactive during welding, and is activated within 0.5 seconds after conclusion of
welding.
MMA welding mode
The no--load voltage is 68 -- 80 V. The no--load voltage controller is inactive
during welding, and is activated within 0.5 seconds after conclusion of welding.
TIG welding mode (only, Mig U5000i & AristoMig U500)
For TIG welding with HF starting, the power source produces the unregulated
no--load voltage of about 80 V while the starting function is active, which is
normally a maximum of 0.5 seconds.
cu15d_20_1
-- 36 --
S0740 800 159/E080418/P80
Methods of measuring the arc voltage
Various methods of measurement are available by transferring a link between
contacts Y1, Y2 and Y3. When delivered, the link is fitted between Y2 and Y3.
The link must be connected between Y2 and Y3 for MMA or TIG welding.
S
Welding with the filler wire positive: voltage sensing from the wire.
This is the commonest arrangement for MIG welding.
Y2 -- Y3 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 X1 and W2. Amplifier IC8:14 is active.
S
Welding with the filler wire negative: 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 is active.
S
Welding with the filler wire positive or negative, without external
sensing from the wire or workpiece.
Y2 -- Y3 must be linked. The input signal is measured between inputs W5
and W2 (= the voltage at the power source terminals), as there is no
connection to X1. Amplifier IC8:14 is active.
S
Welding with the filler wire positive: voltage sensing from the wire
and workpiece.
Y1 and Y2 must be linked. This method allows for the voltage drop in both
the supply and return conductors. The input signal is measured between
X1 and X3. Amplifier IC8:14 is active.
Note: If the voltage signal connection to X3 is lost, the power source loses
control of the arc voltage.
cu15d_20_1
-- 37 --
S0740 800 159/E080418/P80
20AP1
cu15d_20_1
Component positions
-- 38 --
S0740 800 159/E080418/P80
20AP2 Relay board
The relay board handles hardware--connected inputs and outputs to/from control board
20AP2. The relays provide the necessary galvanic insulation. In the event of a relay fault,
the entire board must be replaced.
20AP2:1
Power supply
The relay 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
The external shut down function is redesigned. The redesigned boards are
delivered as spare parts and fitted to new machines from the end of 2005.
First version of relay board 20AP2 (0486 855 880
Contacts H1 and H2 must be linked if the power source is to work. All relay
coils are supplied at +24 V. Relay RE1 is supplied directly from 20AP1, while
the other relays are supplied indirectly via the +24VA supply. If there is no
+24VA supply, the processor and PWM circuit on the control board are
disabled.
The H1 -- H2 inputs are used in connection with mechanised welding to
provide On/Off control of the welding power source.
Redesigned version of relay board 20AP2 (0486 855 884)
Contacts H1 and H2 must be linked if the power source is to work. If there is
no link, the processor and PWM circuit on the control board are disabled.
The H1 -- H2 inputs are used in connection with mechanised welding to
provide On/Off control of the welding power source.
See also the circuit diagram on page 46.
cu15d_20_2
-- 39 --
S0740 800 159/E080418/P80
20AP2:3
Starting sequence
Schematic diagram of the power source starting circuits
Starting sequence:
1.
Turning main switch 2QF1 from 0 to 1 closes contacts a--1 and c--3, this
energises the relay contacts on RE1 -- RE3.
2.
Turning 2QF1 to the START position closes contacts 2--b and 4--d.
3.
The controller board is energised from the auxiliary transformer 2TC2.
4.
Relay RE1 is energised by transistor Q29.
5.
The auxiliary transformer is supplied via contacts 1--2 and 3--4 on relay
RE1. The relay is held in via the controller circuit board.
6.
When released from the START position, the main switch returns 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 BR1 on circuit board 15AP1.
10. After about three seconds, the voltage across smoothing capacitors C1 -C4 is about 440 V.
11. The overvoltage and undervoltage protection senses whether the voltage
across capacitors C1 -- C4 is within the tolerance range of 330 -- 820 V.
12. If the voltage is within the tolerance range, relay RE3 is activated by
transistor Q31.
If the voltage is outside the tolerance range, the starting sequence is
interrupted at this point. Contactor 2KM1 does not close, and relay RE2
drops off. Machines having an MMC--panel with dispay show fault code 5.
13. RE3 energises main contactor 2KM1, which closes and connects 3--phase
400 V to main rectifier 15BR1.
cu15d_20_2
-- 40 --
S0740 800 159/E080418/P80
20AP2:4
Power supply to the cooling unit
The cooling water pump is controlled by the software in the welding data unit
via circuit board 20AP1. The wiring diagram for the cooling unit is shown on
Page 19.
20AP2:5
Cooling water monitoring in MIG welding mode
Water lock and flow guard in a MIG machine
Microswitch 5S1 in the water lock connector closes when a
cooling water hose is connected to the blue water connector
on the front of the cooling unit. The pump stops if the switch
opens.
In MIG welding mode, the 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 cooling water
connections on the front of the wire feed unit do have a water
lock, within which microswitch 13S1 senses if a cooling water
hose is connected, see the diagram below.
Water lock
Contact 5SL1 in the flow guard closes when the water flow rate exceeds 0.7
l/minute. The flow guard is an accessory: if no flow guard is fitted,
connections XS18:3 and XS18:4 are linked.
The following description refers to cooling units with a flow guard: machines
without a flow guard behave as if cooling water is always flowing.
Water lock in the wire feed unit
cu15d_20_2
-- 41 --
S0740 800 159/E080418/P80
Starting the welding equipment
1. The MMC panel senses whether microswitch 13S1 in the wire feed unit is
closed.
2. If 13S1 is closed, the panel generates a command to start the pump. If
water flow is not detected within 15 seconds, 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 with a display panel show fault code 29.
The pump is stopped if microswitch 13S1 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 starts.
If water flow is not detected within three seconds, the pump is stopped.
If the water flow stops during welding, welding will be interrupted and the fault
indication lamp on the MMC panel will flash. Machines with a display show
fault code 29.
Stopping welding
1. The welder releases the welding gun trigger switch.
2. Welding stops.
3. The water pump continues to run for a further 6.5 minutes.
If welding is restarted while the pump is still running, the pump will continue to
run as required, i.e. the 6.5 minute shutdown countdown is interrupted.
Water lock and flow guard in a MIG machine
cu15d_20_2
-- 42 --
S0740 800 159/E080418/P80
20AP2:5
Cooling water monitoring in TIG welding mode
Microswitch 5S1 in the water lock connector closes
when a cooling water hose is connected to the blue
water connector on the front of the cooling unit. The
pump stops if the switch opens.
Contact 5SL1 in the flow guard closes when the water
flow rate exceeds 0.7 l/minute. The flow guard is an
accessory: if no flow guard is fitted, connections
XS18:3 and XS18:4 are linked.
The following description refers to cooling units with a
flow guard: machines without a flow guard behave as if
cooling water is always flowing.
Water lock
Starting the welding equipment
1. The MMC panel senses whether microswitch 5S1 is closed.
2. If 5S1 is closed, the panel generates a command to start the pump. If
water flow is not detected within 15 seconds, 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 with a display panel show fault code 29.
The pump is stopped if microswitch 5S1 opens.
Starting to weld
1. The welder presses the trigger switch on the welding gun.
2. The water pump starts if microswitch 5S1 is closed.
3. If water flow is achieved within three seconds, welding starts.
If water flow is not detected within three seconds, the pump is stopped.
If the water flow stops during welding, welding will be interrupted and the fault
indication lamp on the MMC panel will flash. Machines with a display show
fault code 29.
Stopping welding
1. The welder releases the welding gun trigger switch.
2. Welding stops.
3. The water pump continues to run for a further 6.5 minutes.
If welding is restarted while the pump is still running, the pump will continue to
run as required, i.e. the 6.5 minute shutdown countdown is interrupted.
cu15d_20_2
-- 43 --
S0740 800 159/E080418/P80
20AP2:6
TIG Gas valve
Gas valve 10YV1 is controlled by the processor on circuit board 20AP1. It can
be activated via service function no. 10.
20AP2:7
TIG HF starting device
The 10AP1 HF starting device is controlled by the processor on circuit board
20AP1. It is activated during the starting sequence until the arc strikes, or for a
maximum of 0.7 seconds. 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
spark is about 8 kV.
Due to electromagnetic interference regulations the energy in the HF ignition
spark is limited. The HF spark weakens with increasing length of the torch. The
HF ignition is satisfactory for welding torches up to 16 metres.
20AP2:8
TIG Starting
The welding torch trigger switch is supplied at 42 V AC. Closing the contact
activates IC1 and supplies a Low signal to 20AP1.
cu15d_20_2
-- 44 --
S0740 800 159/E080418/P80
20AP2:9
TIG, Gas flow monitor
Input G4 is intended for use with a gas flow monitor. The processor reacts to
voltage flanks from the input.
Mig U5000i & AristoMig U500 units are not normally fitted with gas flow
monitors, which means that this input must be short--circuited by a link. If the
link is open the control panel shows fault code 32.
Arc 5000i & AristoArc 500
Terminals G4, G5 and resistors R8 -- R10 are not mounted on the board that is
delivered with the machine.
Spare part circuit boards are delivered with all components fitted. When a
spare part circuit board is fitted to the machine, terminals G4 -- G5 must be
short--circuited by a link. If the link is open the control panel shows fault code
32.
20AP2
Component positions
The component positions and circuit diagram show all the components with
which the board may be fitted: the exact choice of components varies,
depending on in which machine the board is used.
Spare part circuit boards are delivered with all components fitted.
cu15d_20_2
-- 45 --
S0740 800 159/E080418/P80
20AP2
cu15d_20_2
Circuit diagram
-- 46 --
S0740 800 159/E080418/P80
REMOTE CONTROLS
A number of remote control units can be connected to the power sources, these are
described in a separate service manual with filename / ordering no. 0740 800 170.
FAULT CODES
Fault codes are used in order to indicate and identify a fault in the equipment.
Fault log
All faults that occur when using the welding equipment are documented as error messages
in the fault log. When the fault log is full, the oldest message will automatically erase when
the next fault occurs.
Only the most recent fault message is displayed on the control panel. To read the entire
fault log, the machine must be connected to the ESAT: see service tools on page 52.
Faults 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 unit has generated the fault. The
following unit numbers are used:
U0 = control panel
U2 = power source
U3 = wire feed unit
U4 = remote control unit
Summary of fault codes
Fault
code
Description
Control
panel
Power
source
Wire feed
unit
Remote
control
unit
x
1
Memory error, EPROM
x
x
x
2
Memory error, RAM
x
x
x
3
Memory error, external RAM
x
x
4
+5 V power supply
x
x
5
Intermediate DC voltage outside limits
x
6
High temperature
x
8
Power supply 1
9
x
x
x
Power supply 2
x
x
x
10
Power supply 3
x
11
Wire feed speed servo
12
Communication error (warning)
x
14
Communication error (bus off)
x
15
Lost messages
x
17
Lost contact with the wire feed unit
x
18
Lost contact with the power source
x
19
Memory error in data memory
x
cu15fe1com
x
x
-- 47 --
x
x
x
x
x
S0740 800 159/E080418/P80
Description
Fault
code
Control
panel
Power
source
Wire feed
unit
20
Memory allocation error
x
22
Transmitter buffer overflow
x
x
x
23
Receiver buffer overflow
x
x
x
26
Program operating fault
x
x
27
Out of wire
28
Stack overflow
29
No cooling water flow
31
No reply from the display unit
32
No gas flow
40
Incompatible units
Remote
control
unit
x
x
x
x
x
x
x
x
x
Fault code description, power source
This manual describes the fault codes for the power source. The fault codes for other units
are described in the manuals for these units.
Code Description
1
EPROM check sum error -- program memory error
Check sum test of the program memory, which is run only when initiating the power source
after 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 machine. If the fault persists, load new software via ESAT. If the fault still
persists, replace circuit board 20AP1, which carries the memory chip.
2
Microprocessor RAM error
The microprocessor is unable to read/write from/to a particular memory address in its
internal memory. This test is preformed only on initiation after power--up. This fault does not
disable any functions.
Action: Restart the machine. If the fault persists, replace circuit board 20AP1, which carries
the microprocessor chip.
3
Memory error, external RAM
The microprocessor is unable to read/write from/to a particular memory address in its
external memory. This test is preformed only on initiation after power--up. This fault does not
disable any functions.
Action: Restart the machine. If the fault persists, replace circuit board 20AP1, which carries
the microprocessor chip.
4
5 V power supply too low
The unregulated power supply voltage is too low: the smoothing capacitors cannot keep the
voltage up enough for the processor to continue to operate. The processor stops all normal
activities, expecting to be shut down.
Action: Turn off the mains power supply to reset the unit. If the fault persists, check the
power supply to circuit board 20AP1.
cu15fe1com
-- 48 --
S0740 800 159/E080418/P80
Code Description
5
Intermediate DC voltage outside limits
The DC voltage from the main rectifier, 15BR1, is too high or too low.
Too high a voltage can be due to severe transients on the mains power supply or to a weak
power supply (high inductance of the supply).
The power source is stopped immediately, and cannot be restarted until the voltage has
returned to within the limit values.
Action:
Turn off the mains power supply to reset the unit. See also section 15AP1:3 on page 24 and
section 15AP2:2 on page 27.
6
High temperature
Thermal overload cutout 15ST1 or 15ST2 has operated. The power source is stopped, and
cannot be restarted until the cutout has reset.
Possible causes: Overloading, fan not working properly, cooling air inlets or outlets blocked
or obstructed 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 -- 15.9 V. This fault does
not disable any functions.
9
--15 V power supply on circuit board 20AP1
The voltage is too high or too low: it must be within the range 14.2 -- 16.4 V. This fault does
not disable any functions.
10
+24 V power supply on circuit board 20AP1
The voltage is too high or too low: it must be within the range 22.1 -- 26.0 V. For sofware
version 2.46Q and 2.46R the upper limit is 24.8 V, for later versions the limit is 26.0 V.
12
Communication error (warning)
The load on the system CAN bus is temporarily too high, or there is electric noise on the
bus.
Action: Check the equipment to ensure that only one wire feed unit and/or remote control
unit are connected. See also section 20AP1:3 ’The CAN bus’ on pages 31 to 33.
15
Lost messages
The bus CAN controller indicates that a message has been lost. No functions are disabled
by this fault.
Action: Check that all units are correct connected to the CAN bus. See also section
20AP1:3 ’The CAN bus’ on pages 31 to 33.
22
Transmitter buffer overflow
The control board is unable to transmit information to the other units at a sufficiently high
speed.
Action: A break in the bus line can cause this fault. Check the CAN cabling. Turn off the
mains power supply to reset the unit.
23
Receiver buffer overflow
The control board is unable to process information from the other units at a sufficiently high
speed. This fault is caused by abnormal loading of the microprocessor.
Action: Turn off the mains power supply to reset the unit.
cu15fe1com
-- 49 --
S0740 800 159/E080418/P80
Code Description
26
Program operating fault
Something has prevented 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 should never occur in reality. Contact ESAB if the fault does occur.
28
Stack overflow
The stack memory is full.
This fault should never occur in reality: the fault code is intended as an aid during
development work. Contact ESAB if the fault does occur.
29
No cooling water flow
The flow monitor switch has operated. The current welding process will be stopped, and
cannot be restarted.
Action: Check the cooling water circuit and pump.
Water flow monitoring is an option.
32
No gas flow
Gas flow is too low.
Action: Check the gas valve, hoses and connectors.
Gas monitoring is fitted only to special versions of the MIG machines.
cu15fe1com
-- 50 --
S0740 800 159/E080418/P80
SERVICE INSTRUCTIONS
CAUTION !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostatic-sensitive devices.
S
Use proper static--proof bags and boxes.
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD stands for
Electrostatic Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components, but is not dangerous to people.
ESD damage occurs when an ungrounded person or object with a static charge comes into
contact with a component or assembly that is grounded. A rapid discharge can occur,
causing damage. This damage can take the form of immediate failure, but it is more likely
that system performance will be affected and the component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static 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 and hold static
charge, so you should not bring unnecessary nonconductive items into the work area.
It is obviously difficult to avoid all such items, so various means are used to drain off any
static discharge from persons to prevent the risk of ESD damage. This is done by simple
devices: wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only antistatic
packaging materials. Overall, handling of ESD--sensitive devices should be minimized to
prevent damage.
cu15fe1com
-- 51 --
S0740 800 159/E080418/P80
Service aid
We can offer a number of service tools that will simplify the service.
Antistatic service kit
Ordering no. 0740 511 001
The kit makes it easier to protect sensitve
components from electrostatic discharge.
Contents:
S
A conductive mat (size 610 x 610 mm)
S
A 1.5 metre long ground cable with a
crocodile clip
S
An adjustable wrist strap and cable with
an inbuilt protective resistor
Antistatic service kit
ESAT service kit
Ordering no. 0458 847 880
The software update is made from a PC, it has to be managed by a trained serviceman. For
this a computer program called ESAT, ESAB software administration tool, is needed. The
PC is connected to the welding equipment by a cable connector and a CAN reader. From
the ESAT it is 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 equipment.
For the installation and use of ESAT program you need a computer with operating system
Windows 9x, NT4, 2000 or XP.
The ESAT service kit contents:
S
CAN adapter PPCAN
S
Connection Cable between CAN reader and power source
S
CAN adapter software and ESAT software on CD
S
Instruction manual for ESAT
cu15fe1com
-- 52 --
S0740 800 159/E080418/P80
Dismantling
When dismantling the power source, start as follows:
1.
Remove the screws securing the cover and the rear handle.
2.
Pull the cover backwards and lift it off.
3.
Remove the side panels.
Service traps
The following are a number of points where it is easy to make a mistake and damage the
equipment.
Main On/Off switch, 2QF1
Don’t get the cable cores mixed up. Connect all the cores to the switch in accordance with
their numbers and the terminal numbers on the switch, all as shown in the circuit diagram of
the power source. If the cores are mixed up and connected to the wrong terminals, there is
a risk of short--circuiting and burning up relay board 20AP2.
Terminal block, 2XT2
Don’t mix up the wires connected to terminal block 2XT2:
take care to connect them as shown in the circuit
diagram. If the wires are mixed up and connected to the
wrong terminals, there is a risk of short--circuiting and
burning up relay board 20AP2.
The gate contacts
Make sure that the gate contacts 15XS6, 15XS8, 15XS10
and 15XS11 are connected to terminal strips C, E, H and
G on circuit board 15AP2 before the power source is
energised.
If the contacts are not connected, the IGBT transistors will
fail.
Don’t mix up the gate contacts.
Gate connections on circuit board 15AP2
The current sensor
Check that current sensor 15AP3 is connected to control circuit board 20AP1. If it is not,
then there will be no current limit protection, and the power source can fail.
Power components
Follow the instructions for fitting components to the heat sink. Use thermal contact paste,
and tighten all bolts to the correct torque. Incorrectly mounted components can cause
breakdowns. See the instructions on Page 56.
cu15fe1com
-- 53 --
S0740 800 159/E080418/P80
Checking power board 15AP1
IGBT transistors Q1, Q2, Q3 and Q4
Carry out this check when the power board is mounted in the
machine.
1.
Short--circuit the pins on each one of terminals TC, TD, TE
and TF of circuit board 15AP2. This short--circuits the gate
connections of the IGBT transistors. Without the
short--circuiting link, the measurements will be incorrect.
2.
Use a multimeter in diode test mode to check the IGBT
transistors.
3.
Measure all transistors the same way as indicated for
transistor Q3 on next page. The forward voltage drop
must be 0.1 to 0.5 V. In the reverse direction, the meter
must indicate open circuit.
4.
Remove the short--circuiting links after the measurement.
Terminals TC to TF on 15AP2
Rectifier bridge BR1
Measure the forward voltage drop of the diodes of the rectifier bridge, see next page. The
voltage drop must be 0.1 to 0.5 V. In the reverse direction, the meter must indicate open
circuit.
Transformer TR1
Measure the resistance of the primary winding of transformer TR1, it must be between 7
and 9 kohm. If the primary winding is open, the MMC unit shows fault code 5.
Checking the IGBT transistors separately
WARNING: these components are very sensitive to static electricity (ESD).
Use protective equipment to protect against ESD.
1.
Place the transistors on a
conducting and grounded surface.
Never touch the gate connections.
2.
Short--circuit the gate and emitter
connections (terminals 4 -- 5 and 6 -7 respectively) before making the
measurements. Make sure that you
and the short--circuiting link are not
statically charged relative to the
IGBT transistor.
Touch your 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.
3.
Use a multimeter in diode test mode
to measure the forward and reverse
voltage drop of the transistors, as
Points of measuring of the IGBT transistors
shown in the diagram.
cu15fe1com
-- 54 --
S0740 800 159/E080418/P80
4.
If an IGBT transistor in a pair(15Q1, 15Q2 or 15Q3, 15Q4) has failed, both transistors
in the pair must be replaced. See also the description on page 23.
Power board 15AP1, as fitted in the machine, points of measuring of Q1, Q2, Q3, Q4, BR1 and TR1.
cu15fe1com
-- 55 --
S0740 800 159/E080418/P80
Mounting components on the heat sink
Thermal paste
Apply thermal conducting paste to the following components before fitting them.
Start by cleaning the heat sink, and then apply a very thin, even layer of thermal paste to
the contact surfaces of the components. The purpose of the paste is to fill out any hollows
in the surfaces of the components and the heat sink. Those parts of the component and the
heat sink that are in true metallic contact may have such contact.
Mount the components as described below.
See the spare parts list for the order number for thermal paste. Use only the paste
recommended by us.
Fitting instructions
15Q1, 15Q2,
15Q3, 15Q4
IGBT transistors
Clean the heat sink and apply thermal conducting paste as described
above. Fit the transistor and tighten 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 board
15AP1 to a torque of 4.5 Nm.
Warning: Incorrectly fitted IGBT transistors can cause failure. Do not
tighten the screws to more than 4.5 Nm.
15D1, 15D2,
15D3, 15D4
Diode modules
Clean the heat sink and apply thermal conducting paste as described
above. Fit the module and tighten the screws to a torque of 1 Nm, and
then further tighten them to 2.5 Nm.
Tighten the connections to the busbars to 4.5 Nm.
15BR1
Rectifier bridge
Clean the heat sink and apply thermal conducting paste as described
above. Fit the bridge and tighten the screws to a torque of 1 Nm, and then
further tighten them to 4.5 Nm.
Tighten the screws that connect the bridge to circuit board 15AP4 to
4.5 Nm.
15ST2
Thermal overload cutout
Clean the heat sink and apply thermal conducting paste as described
above. Fit the thermal overload cutout.
cu15fe1com
-- 56 --
S0740 800 159/E080418/P80
Checking the gate pulses
Never measure the gate pulses when the power source is connected to the mains. The
gate circuits are at mains voltage.
Disconnect the machine from the mains, and follow the instructions below.
Disconnection from the mains supply
1.
Disconnect wires 1594 (+) and 1595
(--) from circuit board 15AP1.
2.
Unplug connector 2XS2 from terminal
C on 15AP1.
3.
Insulate the wires that have been
removed from each other and from
all other parts.
Disconnection of the 650V DC and 460V AC supply from 15AP1
Disconnection of the overvoltage and undervoltage protection
In order to be able to start the power source, the overvoltage and undervoltage protection
must be disabled before connecting the power source to the mains. Short--circuit pins 1 and
3 on connector SB on circuit board 20AP1.
Circuit board 20AP1, connector SB
Mig U5000i & AristoMig U500:
Disconnect the HF starting unit by removing fuse 2FU5 from transformer 2TC2: see the
wiring diagram.
MIG machines:
A wire feed unit with control panel or pendant U8 must be connected in order to be able to
operate the power source.
cu15fe1com
-- 57 --
S0740 800 159/E080418/P80
Pulses from circuit board 15AP2 to the IGBT transistors
Warning: The IGBT transistors are sensitive to ESD. Read and follow the instructions on
page 57, before you check the pulses.
1.
Remove the gate connections from terminals C, E, G and H on circuit board 15AP2.
2.
Connect a 100 nF capacitor (dummy gate load) across the gate output when
measuring, see the right part of the circuit diagram below.
Test points for the gate pulses
Pulses from 20AP1
Pulses from 15AP2
3.
Connect the dummy gate load and an oscilloscope with the probe to H1 and the screen
to H2.
4.
Start the power source and set it to the MMA mode.
5.
Compare the waveform of the gate pulses with the diagram below.
The waveform shape must be as in the diagram.
Gate pulses from 15AP2 to 15Q1, 15Q2, 15Q3 and 15Q4 respectively
cu15fe1com
-- 58 --
S0740 800 159/E080418/P80
6.
Measure the pulse frequency, it must be 27 kHz ±0.5 kHz.
7.
Measure the pulse duration, it must be 40.5 --43 % of the cycle time, measured at a
voltage level of +5 V.
8.
Measure the maximum pulse voltage, it must be in the range 14 -- 17 V. The minimum
voltage must be in the range from --9 to --12.5 V.
9.
Repeat the measurements, in items 5 to 8 above, on the remaining gate outputs:
S the probe to G1 and the screen to G2
S the probe to E1 and the screen to E2
S the probe to C1 and the screen to C2
The pulses on outputs C1--C2 and E1--E2 are in phase with each other, they operate in
anti--phase with the pulses on outputs G1--G2 and H1--H2.
Pulse frequency and duration are controlled by circuit board 20AP2: rise and fall times are
controlled by gate driver board 15AP2.
If the waveform shape, pulse duration and frequency are as described above, the results
are satisfactory and the measurements can be concluded here.
cu15fe1com
-- 59 --
S0740 800 159/E080418/P80
Pulses from circuit board 20AP1 to circuit board 15AP2
Read and follow the instructions on page 57, before you check the pulses. Measure the
pulses when loaded by the pulse transformers on 15AP2.
1.
Connect an oscilloscope with the screen to SB2 and the probe to SB4, see the left part
of the circuit diagram below.
Test points for the gate pulses
Pulses from 15AP2
Pulses from 20AP1
2.
Start the power source and set it to MMA mode.
3.
Compare the waveform of the gate pulses with the diagram below.
The waveform shape must be as in the diagram.
Pulses from 20AP1 to 15AP2 when the output of 20AP1 is connected to 15AP2.
4.
Measure the pulse frequency, it must be 27 kHz ±0.5 kHz.
5.
Measure the pulse duration, it must be 43.5 -- 46 % of the cycle time, measured at
--10 V of the negative pulse, as shown in the diagram above.
cu15fe1com
-- 60 --
S0740 800 159/E080418/P80
6.
Measure the maximum pulse voltage, it must be 30 -- 38 V. The minimum voltage must
be in the range from --14 V to --16 V.
7.
Connect the probe to SB5 and the screen to SB2.
8.
Repeat the measurements in items 3 to 6 above.
The pulses on outputs G3--G4 and G5--G6 are in anti--phase with each other.
If the pulse transformer on circuit board 15AP2 is not connected, or if there is a break in the
transformer primary, the pulses will look as shown in the figure below.
Pulses from 20AP1 when the output from 20AP1 is not connected to 15AP2.
cu15fe1com
-- 61 --
S0740 800 159/E080418/P80
Soft starting
We recommend soft staring of the machine after replacing control circuit board 20AP1, relay
board 20AP2 or circuit boards or components in the power module. This supplies the power
module with a low AC voltage in order to avoid injury to persons or damage to components.
It is also a good idea to use soft starting when fault tracing in the power module. In addition,
certain measurements in the machine should be made only during soft starting.
The following description refers to the use of 24 V AC from auxiliary transformer 2TCI.
However, an external 24 V source may also be used.
Changing wire connections prior to soft starting
1.
Disconnect wires 1594 (+) and 1595
(--) from circuit board 15AP1. Refit
the screws that were securing the
wires above.
2.
Unplug connector 2XS2 from terminal
C on 15AP1.
3.
Insulate the wires that have been
removed from each other and from
all other parts.
Disconnection of the 650V DC and 460V AC supply from 15AP1
4.
Connect 24 V AC from contact SH on circuit board 20AP1 to terminal C1 and C3 on
circuit board 15AP1.
Connect a fast--acting 1 A fuse in series with the power supply.
This protects the foil on circuit board 20AP1 in the event of any short circuit.
5.
In order to be able to start the power
source, the undervoltage protection
must be disabled before connecting
the machine to the mains.
Short--circuit pins 1 and 3 in
connector SB on circuit board 20AP1.
Power supply for soft starting
Mig U5000i & AristoMig U500:
Disconnect the HF starting unit by removing fuse 2FU5 from transformer 2TC2: see the
wiring diagram.
cu15fe1com
-- 62 --
S0740 800 159/E080418/P80
Circuit connections for soft starting
Measurements
1.
Start the machine.
2.
Measure the voltage across terminals C1
and C3. It should be about 24 V AC. See
the circuit diagram above.
3.
Measure the voltage across the negative
and positive terminals of circuit board
15AP1. It should be about 32 V DC.
Measure the voltage across capacitors C2
and C4 respectively. It should be about
16 V DC.
4.
Set the machine to the MMA mode
5.
Measure the voltage across the negative and positive terminals of circuit board 15AP1.
It should be about 15 V DC. Measure the voltage across capacitors C2 and C4
respectively. It should be about 7.5 V DC. The difference compared to the previous
measurements depends on the voltage drop over the charge capacitors C17 and C18.
6.
Using an oscilloscope, examine the
waveforms on the secondary side of
15TM1. Connect the screen to the
busbar that connects 15TM1 to 15TM2.
Make the corresponding measurement
on 15TM2.
Measure the voltage across the smoothing capacitors
The pulses must look as in the graph to
the rigth.
Output voltage waveform from 15TM1 for soft starting
7.
Using a multimeter, check that the DC voltage at the welding terminals is about 2 V DC.
8.
Switch off the machine. Check the main rectifier bridge 15BR1 with a diode tester. The
forward voltage drop between L1, L2, L3 and + and -- respectively must be about 0.5 V.
The forward voltage drop between + and -- must be about 0.8 V. See the connection
diagram on page 29.
9.
If all the measurements are as described above, reconnect the wires to restore the
power source to normal operation mode and make a test weld.
cu15fe1com
-- 63 --
S0740 800 159/E080418/P80
Checking the overvoltage and undervoltage threshold values
WARNING -- Dangerous voltages. Mains voltage on circuit board 15AP1 and 15AP2
when the power source is connected to the 400 V supply.
Disconnect the machine from the mains, and follow the instructions below.
1.
Disconnect wires 1594 (+) and 1595
(--) from circuit board 15AP1.
2.
Unplug connector 2XS2 from terminal
C on 15AP1.
3.
Insulate the wires that have been
removed from each other and from
all other parts.
Disconnection of the650V DC and 460V AC supply from 15AP1
4.
Disconnect the power supply to the overvoltage and undervoltage protection function:
pull off the plug from terminal D on circuit board 15AP2.
5.
Connect 24 V AC from circuit board 20AP1, terminal SH, to terminals D1 and D2 on
15AP2. Protect the connection by a 1 A fuse: see the connection diagram below and
the circuit diagram on next page.
Temporary power supply connection to the voltage protection function
6.
Energise the power source and measure the voltage between test point T3 (0 V) and:
S
Test point T4, threshold value for undervoltage. Must be about 1.5 V.
S Test point T5, threshold value for overvoltage. Must be 3.2 to 3.4 V.
The circuit board and the test points are varnished. Before measuring, remove the varnish
from the test points.
Disconnect the 24 V supply and restore the connections.
cu15fe1com
-- 64 --
S0740 800 159/E080418/P80
3.30 V
Disconnect wires
1594 and 1595
from 15AP1
Unplug connector
2XS2 from terminal
C on 15AP1
Test connection for checking the threshold values of the overvoltage and undervoltage protection
cu15fe1com
-- 65 --
S0740 800 159/E080418/P80
Calibrating the current sensor signal
1.
If the power source has a TIG function, remove fuse 2FU5 from transformer 2TC2.
This disconnects the supply to the HF ignition unit (see the connection diagram).
2.
Connect the power source to a resistive load.
3.
Connect a calibrated shunt in series with the load.
4.
Set a welding current of 400 A.
5.
Load the power source so that the voltage across the load is 35 -- 37 V.
Circuit diagram for the current calibration
6.
Measure the shunt voltage using a calibrated multimeter.
7.
Using potentiometer R21 on circuit board 20AP1, adjust the shunt voltage to
correspond to 400 A ±4 A.
Position of potentiometer R21 on circuit board 20AP1.
8.
Check the current at low values as well: 16 A at 19 -- 22 V, for which the tolerance is
±1 A. If the current is outside the tolerance, replace current sensor 15AP3.
cu15fe1com
-- 66 --
S0740 800 159/E080418/P80
Calibration of the arc voltage input, Arc 5000i & AristoArc 500
The arc voltage input can be calibrated using trimming potentiometer R87 on circuit board
20AP1. The board has been calibrated in the factory: further adjustment should not
normally be necessary.
Position of potentiometer R87 on circuit board 20AP1
Use an accurately calibrated external voltmeter to measure the voltage at the welding
current terminals.
1.
Set a welding current of about 100 A, supplying it to a resistive load so that the voltage
is 25 -- 30 V. Using an external voltmeter, measure the voltage across the welding
current terminals.
2.
Using the potentiometer, adjust the value shown on the display so that the voltage
shown is about 0.2 -- 1.6 V lower than the voltage at the welding current terminals. This
difference between the measured and the displayed voltages compensates for the
voltage drop in the welding current cables.
cu15f2
-- 67 --
S0740 800 159/E080418/P80
Calibration of the arc voltage input, MIG machines
The arc voltage input can be calibrated using trimming potentiometers R87 and R103 on
circuit board 20AP1. The board has been calibrated in the factory: further adjustment
should not normally be necessary.
Circuit diagram of the arc voltage input
Check that there is a short--circuiting link across connectors Y2 -- Y3: see the circuit
diagram above. Connect a wire feed unit 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 diagrams on next page. Set the power
source to MIG short arc welding mode, and apply a resistive load to give a current of 100 A
at 25 -- 30 V.
Start the power source from the welding gun trigger contact and adjust the current by
changing the wire feed speed setting. Adjust the voltage by varying the load resistor.
Use an accurately calibrated external voltmeter to measure the output voltage of the
machine.
Positions of potentiometers R87 and R103 on circuit board 20AP1
cu15f2
-- 68 --
S0740 800 159/E080418/P80
1.
Welding with the filler wire positive: voltage sensing from the wire
This is the commonest arrangement of arc voltage sensing.
V = external voltmeter. R = load resistor.
The 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 R87.
2.
Welding with the filler wire negative: voltage sensing from the wire
V = external voltmeter. R = load resistor.
The 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 external sensing from the wire
or workpiece
V = external voltmeter. R = load resistor.
The external voltmeter shows a value 0.2 -- 1.6 V higher than the value shown on the
control panel. Do not adjust the value shown on the control panel: this is already
adjusted from 1) above.
4.
Check measurement of the connection for voltage sensing from the workpiece
Measure the resistance between connector pin G on AP1 and input X3 on the circuit
board. See the circuit diagram on Page 68.
cu15f2
-- 69 --
S0740 800 159/E080418/P80
Replacing TR1 on 15AP1 with new version of 2TC1
This instruction is valid for machines with serial no. prior to 524--xxx--xxxx.
Transformer TR1 is not anymore fitted to circuit board 15AP1, see the diagram on page 24
and the main wiring diagram.
If transformer TR1 is defective, it must be replaced by a new version of transformer 2TC1.
S
Disassemble circuit board 15AP1.
S
If transformer TR1 is the only defective component on the board, unsolder and
remove TR1. If there are additional faults on the board, replace the board.
S
Assemble circuit board 15AP1 to the machine.
S
Tighten the screws that connect the IGBT transistors to the circuit board to a torque of
4.5 Nm.
S
Replace transformer 2TC1 with the new version of the same transformer.
S
Replace the cable set: see the picture below.
Location of new cable set and transformer 2TC1
Ordering numbers:
0486 983 880 Circuit board 15AP1
0459 838 880 Transformer 2TC1 and cable set 2TC1 ------> 15AP2
cu15f3
-- 70 --
S0740 800 159/E080418/P80
INSTRUCTION MANUAL
This chapter is an extract from the instruction manuals for the Mig U5000i,
Mig 5000i and Arc 5000i.
SAFETY
Before the power source is put into operation, the safety precautions in the instruction manual should
be read completely. This will help avoid possible injury due to misuse or improper installation.
CAUTION!
Read and understand the instruction manual before
installing or operating.
INSTALLATION
The installation must be executed by a professional.
Lifting instructions
Power source
cu15i1
Trolley and power source
-- 71 --
Trolley2 and power source
S0740 800 159/E080418/P80
Mains power supply
Check that the unit is connected to the correct mains power supply
voltage, and that it is protected by the correct fuse sizes. A
protective earth connection must be made, in accordance with
regulations.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable area
Mig 5000i / U5000i, Arc 5000i
Mains voltage
460 V 3μ 60 Hz
Mains cable area, CU/AWG (mm2) 10(6)
Phase current, I RMS
28 A
Fuse Time delay
50 A
NB: Sizes per National Electric Code for 90˚C rated copper conductors @30˚C ambient. Not more
than three conductors in raceway or cable. Local codes should be followed if they specify larger sizes
other than those listed above.
Terminating resistor, MIG machines
In order to avoid communication interference, the ends of
the CAN bus must be fitted with terminating resistors.
One end of the CAN bus is at the control panel, which has an
integral terminating resistor. The other end at the power
source must be fitted with the terminating resistor, as
shown on the right.
cu15i1
-- 72 --
S0740 800 159/E080418/P80
OPERATION
General safety regulations for the handling of the equipment can be found in the instruction
manual. Read through before you start using the equipment!
Connections and control devices, Mig U5000i
1
Connection for cooling water from the TIG
torch -- RED
10
White indicating lamp -- Power supply ON
2
Connection with ELP* for cooling water to
the the TIG torch -- BLUE
11
Orange indicating lamp -- Overheating
3
Cooling water filler
4
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 for the terminating resistor
5
Connection for remote control adapter
13
Connection for gas hose
6
Connection for return cable (--) or for welding current cable at TIG welding
14
Connection for welding current to the wire
feed unit
7
Connection for start signal from the torch.
15
Connection for cooling water to the wire
feed unit -- BLUE
8
Connection for gas to the TIG torch
16
Connection for cooling water from the wire
feed unit -- RED
9
Main power supply switch, 0 / 1 / START
* ELP = ESAB Logic Pump, see Cooling unit below
cu15i1
-- 73 --
S0740 800 159/E080418/P80
Connections and control devices, Mig 5000i
1
Connection for welding current cable (+)
(SMAW welding)
5
White indicating lamp -- Power supply ON
2
Connection for remote control adapter
6
Orange indicating lamp -- Overheating
3
Connection for return cable (--)
4
Main power supply switch, 0 / 1 / START
Connections and control devices, Arc 5000i
1
Welding current cable connector (+)
5
White indicating lamp, mains power supply
ON
2
Connector for remote control adapter
6
Orange indicating lamp, overheating
3
Return welding current cable connector (--)
7
Control panel
(see respective instruction manual)
4
Main power supply switch, 0 / 1 / START
cu15i1
-- 74 --
S0740 800 159/E080418/P80
Turning on the power source
Turn on the mains power by turning the main power supply switch to the ”START” position.
Release the switch, and it will return to the ”1” position.
If the mains power supply should be interrupted while welding is in progress, and then be
restored, the power source will remain de--energised until the switch is again turned
manually to the ”START” position.
Turn the unit off by turning the switch to the ”0” position.
Whether in the event of a loss of power supply or of turning the power source off in the
normal manner, welding data will be stored so that it is available next time the unit is
started.
Fan control timer
The power source fans continue to run for 6.5 minutes after welding has stopped, and the
unit switches to energy--saving mode. They start again when welding restarts.
The fans run at reduced speed for welding currents up to 180 A, and at full speed for higher
currents.
Thermal overload protection
The power source has three thermal overload trips which operate if the internal temperature
becomes too high, interrupting the welding current and lighting the orange indicating lamp
on the front of the unit. The trips reset automatically when the temperature has fallen.
Cooling unit
Water connection (TIG welding)
The cooling unit is equipped with a detection system ELP (ESAB Logic Pump) which
checks that the water hoses are connected.
The power source On/Off switch must be in the “0” position (Off) when connecting a
water--cooled TIG torch.
If a water--cooled TIG torch is connected, the water pump starts automatically when the
main On/Off switch is turned to ”START” and/or when welding starts. After welding, the
pump continues 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 wire feed and the cooling water pump.
To stop welding, the welder releases the welding gun trigger switch. Welding ceases, but
the cooling water pump continues to run for 6.5 minutes, after which the unit switches to
energy--saving mode.
Water flow guard
The water flow guard interrupts the welding current in the event of loss of coolant, and
displays an error message on the control panel. The water flow guard is an accessory.
cu15i1
-- 75 --
S0740 800 159/E080418/P80
Remote control unit
The remote control unit must be a CAN based remote control or it must be connected via a
remote control adapter.
The power source and wire feed unit are set to remote control mode and buttons and dials
are blocked when the remote control is connected. Functions can only be adjusted via the
remote unit.
If the remote control unit is not to be used, the remote control unit must be disconnected
from the power source / wire feed unit, as otherwise it will remain in remote control mode.
For more information about the operation of the remote control unit, see the operating
instructions for the control panel.
MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Maintenance must be executed by a professional. Only those persons who have
appropriate electrical knowledge (authorised personnel) may remove the safety plates.
Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in 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 (3).
S
Blow it clean with compressed air at
reduced pressure.
S
Replace the filter with the finer mesh on
the side against the cover plate (2).
S
Replace the cover plate with the filter.
Topping up the coolant
We recommend a 50/50 % mixture of water and ethylene glycol.
Top up with coolant until it is up to the level of the filling hole.
cu15i1
-- 76 --
S0740 800 159/E080418/P80
ORDERING SPARE PARTS
To assure proper operation, it is recommended that only genuine ESAB parts and products b
used with this equipment.
Replacement parts may be ordered from your ESAB distibutor or from:
ESAB Welding & Cuttin Products
Attn: Customer Service Dept.
P.O. Box 100545, 411 S. Ebenezer Road
Florence, SC 29501--0545
To order parts by phone, contact ESAB at 1--843--664--5540. Orders may also be faxed to
1--800--634--7548. Be sure to indicate any special shipping instructions when ordering
replacement parts.
Refer to the Communication Guide below for a list of customer service phone numbers.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A
B
C
CUSTOMER SERVICE QUESTIONS:
Telephone: (800) 362-- 7080 / Fax: (800) 634-- 7548
Order Entry Product Availability
Pricing
Order Information
ENGINEERING SERVICE:
Telephone: (834) 664-- 4416 / Fax: (800) 446-- 5693
Warranty Returns
Authorized Repair Stations
Hours: 7.30 AM to 5:00 PM EST
Welding Equipment Troubleshooting
TECHNICAL SERVICE:
Telephone: (800) ESAB-- 123 / Fax: (843) 664-- 4452
Part Numbers
Technical Applications
Specifications
Hours: 8.00 AM to 7:00 PM EST
Returns
Hours: 8.00 AM to 5:00 PM EST
Equipment Recommendations
D
LITERATURE REQUESTS:
Telephone: (843) 664-- 5562 / Fax: (843) 664-- 5548
E
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-- 4487 / Fax: (843) 664-- 5557
Repair Estimates
Repair Status
Hours: 7.30 AM to 3:30 PM EST
WELDING EQUIPMENT TRAINING:
Telephone: (843) 664-- 4428 / Fax: (843) 679-- 5864
Training School Information and Registrations
Hours: 7.30 AM to 4:00 PM EST
F
Hours: 7.30 AM to 4:00 PM EST
G
WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-- 123
Hours: 7.30 AM to 4:00 PM EST
H
TECHNICAL ASST. CONSUMABLES:
Telephone: (800) 933-- 7070
Hours: 7.30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB--123
Fax: (843) 664--4452
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers:
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
cu15i1
-- 77 --
S0740 800 159/E080418/P80
SPARE PARTS
The spare parts lists are published in separate documents that can be downloaded from the
Internet: www.esab.com
Product
filename
Mig U5000i & AristoMig U500
0459 087 990
Mig 5000i & AristoMig 500
Arc 5000i & AristoArc 500
0458 293 990
0458 085 990
NOTES
notes
-- 78 --
S0740 800 159/E080418/P80
notes
-- 79 --
S0740 800 159/E080418/P80
S0740 800 159/E080418/P80
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising