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ESAB Arc 4000i User Manual

ESAB Arc 4000i
78 pages
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0740 800 191 Valid for serial no. 803--xxx--xxxx080229
Aristot Origot
Arc 4000i, Mig U4000i,
Mig 4000i, Tig 4000i
Service manual

Table of Contents

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ESAB Arc 4000i Specifications

General IconGeneral
Input Frequency50/60 Hz
Output Current Range10-400 A
Duty Cycle60% at 400 A
Protection ClassIP 23
Efficiency85%
Power Factor0.93

Summary

READ THIS FIRST

Safety Standards Compliance

Equipment meets IEC/EN 60974. Ensure compliance post-service.

TECHNICAL DATA

Mig U4000i Specifications

Detailed specifications for the Mig U4000i model.

Mig 4000i Specifications

Detailed specifications for the Mig 4000i model.

Tig 4000i Specifications

Detailed specifications for the Tig 4000i model.

Cooling Unit Specifications

Technical data for the water cooling unit.

Arc 4000i Specifications

Detailed specifications for the Arc 4000i model.

DETAILED WIRING DIAGRAMS

Mig U4000i Wiring Diagram

Detailed wiring for Mig U4000i (Ser. No. 803-xxx-xxxx).

Mig 4000i Wiring Diagram

Detailed wiring for Mig 4000i (Ser. No. 803-xxx-xxxx).

Tig 4000i Wiring Diagram

Detailed wiring for Tig 4000i (Ser. No. 803-xxx-xxxx).

Arc 4000i Wiring Diagram

Detailed wiring for Arc 4000i (Ser. No. 803-xxx-XXXX).

COOLING UNIT OPERATION

Cooling Unit Components and Wiring

Lists components and shows the wiring diagram for the cooling unit.

THE POWER MODULE

Power Module Block Diagram and Warnings

Block diagram and safety warnings for the power module.

15AP1 POWER BOARD DETAILS

Mains Rectifier and Charging Circuit

Describes the 15AP1:1 circuit for mains rectification and charging.

Switching Circuit Description

Details the 15AP1:2 switching circuit with IGBTs.

Voltage Protection Circuits

Explains 15AP1:3 over/undervoltage protection.

15AP2 GATE DRIVER BOARD DETAILS

Gate Driver Stages and Protection

Describes 15AP2:1 gate driver stages and fuses.

20AP1 CONTROL BOARD FUNCTIONS

Control Board Power Supply

Details the various power supply outputs on 20AP1.

CONTROL BOARD MONITORING SYSTEMS

Overvoltage and Undervoltage Protection

Refers to 15AP2:2 for voltage protection details.

ARC VOLTAGE FEEDBACK AND CONTROL

RELAY BOARD FUNCTIONS AND DIAGRAMS

FAULT CODES AND TROUBLESHOOTING

Fault Log and Summary Table

Recording and summary of fault codes.

Power Source Fault Code Descriptions

Detailed descriptions and actions for power source fault codes.

IGBT TRANSISTOR CHECKS

SOFT STARTING AND GATE PULSE TESTING

Gate Pulse Verification from 15AP2

How to check gate pulses from the 15AP2 gate driver board.

Gate Pulse Verification from 20AP1

How to check gate pulses from the 20AP1 control board.

OVERVOLTAGE AND UNDERVOLTAGE THRESHOLD CHECK

CURRENT SENSOR CALIBRATION

Current Calibration Procedure

Step-by-step guide for calibrating the current sensor signal.

ARC VOLTAGE FEEDBACK CALIBRATION

MIG Machine Arc Voltage Calibration

Procedure for calibrating arc voltage feedback in MIG machines.

DC TIG/MMA Arc Voltage Calibration

Steps for calibrating arc voltage feedback in TIG and MMA machines.

MAINTENANCE PROCEDURES

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