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ESAB
Welding System
Arc 4000i
ESAB Arc 4000i User Manual
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0740
800
191
V
ali
d
fo
r
serial
no
.
803
-
-
xxx
-
-
xxxx
080229
Aristo
t
Origo
t
Arc
4000i,
Mig
U4000i,
Mig
4000i,
T
ig
4000i
Ser
vice
manual
2
Table of Contents
Table of Contents
2
Read this First
4
Introduction
5
Technical Data
6
Mig U4000I
6
Mig 4000I
7
Tig 4000I
8
Cooling Unit
8
Arc 4000I
9
Wiring Diagram
10
Component Description
10
MMC Option for MIG Machines
13
Mig U4000I Valid for Serial Number 803- -XXX- -XXXX
14
Mig 4000I Valid for Serial Number 803- -XXX- -XXXX
16
Tig 4000I Valid for Serial Number 803- -XXX- -XXXX
18
Arc 4000I Valid for Serial Number 803- -XXX- -XXXX
20
Description of Operation
22
AP2 Interference Suppressor Board
22
2AP1 Interference Suppressor Board (EMC Board)
23
The Power Module
25
15AP1 Power Board
26
15AP1:1 Mains Rectifier Bridge and Charging Circuit
26
15AP1:2 Switching Circuit
27
15AP1:3 Overvoltage and Undervoltage Protection
27
15AP1 Component Positions
28
15AP2 Gate Driver Board
29
15AP2:1 Gate Driver Stages
29
15AP2:2 Overvoltage and Undervoltage Protection
30
15AP2 Component Positions
31
20AP1 Control Board
32
20AP1:1 Power Supply
32
20AP1:2 Fan Control
33
20AP1:3 the CAN Bus
34
Starting Sequence
35
Communication Interruptions
35
Terminating Resistors
35
20AP1:4 Temperature Monitoring
36
20AP1:5 Overvoltage and Undervoltage Protection
36
20AP1:6 Communication with Relay Board 20AP2
37
20AP1:7 Gate Pulses
37
20AP1:8 Current Sensor
37
20AP1:9 Arc Voltage Feedback for Universal and MIG Machines
38
20AP1:9 Arc Voltage Feedback for TIG and MMA Machines
40
20AP1 Component Positions
41
20AP2 Relay Board
42
20AP2:1 Power Supply
42
20AP2:2 External Shutdown
42
20AP2:3 Starting Sequence
43
20AP2:4 Power Supply to the Cooling Unit
44
20AP2:5 Cooling Water Monitoring in MIG Welding Mode
44
20AP2:5 Cooling Water Monitoring in TIG Welding Mode
46
20AP2:6 TIG Gas Valve
47
20AP2:7 TIG HF Starting Device
47
20AP2:8 TIG Starting
47
20AP2:9 Gas Flow Monitor
48
20AP2 Component Positions
48
20AP2 Circuit Diagram
49
Fault Log
50
Remote Controls
50
Fault Codes
50
Fault Code Description, Power Source
51
Service Instructions
55
What Is ESD
55
Service Aid
56
Special Tools
56
Dismantling
57
Service Traps
57
Checking the IGBT Transistors
58
Mounting Components on the Heat Sink
59
Soft Starting
60
Checking the Gate Pulses from Circuit Board 20AP1
60
Checking the Gate Pulses from Circuit Board 15AP2
62
Measurements
63
Checking the Overvoltage and Undervoltage Threshold Values
64
Calibrating the Current Sensor Signal
65
MIG Machines, Calibration of the Arc Voltage Feedback
66
DC TIG Machines, Calibration of the Arc Voltage Feedback
68
Instructions
69
Safety
69
Installation
69
Lifting Instructions
69
Mains Power Supply
70
Terminating Resistor, MIG Machines
70
Connection of Multiple Wire Feed Units, MIG Machines
70
Operation
72
Connections and Control Devices, Mig U4000I
72
Connections and Control Devices, Mig 4000I
73
Connections and Control Devices, Arc 4000I
73
Connections and Control Devices, Tig 4000I
74
Turning on the Power Source
74
Fan Control
75
Overheating Protection
75
Cooling Unit
75
Remote Control Unit
75
Maintenance
76
Cleaning the Air Filter
76
Topping up the Coolant
76
Spare Parts
77
Notes
77
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ESAB Arc 4000i Specifications
General
Input Frequency
50/60 Hz
Output Current Range
10-400 A
Duty Cycle
60% at 400 A
Protection Class
IP 23
Efficiency
85%
Power Factor
0.93
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