ESAB Aristo Arc 4000i User manual

0740 800 191 Valid for serial no. 803--xxx--xxxx080229
AristotOrigot
Arc 4000i, Mig U4000i,
Mig 4000i, Tig 4000i
Service manual

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Rights reserved to alter specifications without notice.
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...............................................
1 MMC module 22..................................................................
2AP1 Interference suppressor board (EMC board) 23.................................
5 Cooling unit 24...................................................................
15 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.........................................................

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Rights reserved to alter specifications without notice.
REMOTE CONTROLS 50..............................................................
FAULT CODES 50....................................................................
Fault log 50........................................................................
Summary of 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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READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault--tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit
boards are divided into numbered blocks, which are described individually in more detail in
the description of operation. Component names in the wiring diagram are listed in the
component description.
Use the spare parts list as a guide to where the components are located in the equipment.
The spare parts list is published as a separate document, see page 77.
This manual contains details of design changes that have been made up to and including
February 2008.
The manual is valid for:
Mig U4000i, Mig 4000i, Tig 4000i and Arc 4000i with serial no. 803--xxx--xxxx.
Note! Mig U4000i, Mig 4000i, Tig 4000i and Arc 4000i with serial number 105--xxx--xxxx to
802--xxx--xxxx differ from the description in this manual. For those machines there is
another service manual with file name 0740 800 166
The Mig U4000i, Mig 4000i, Tig 4000i and Arc 4000i are designed and tested in
accordance with international and European standards IEC/EN 60974.
On completion of service or repair work, it is the responsibility of the person(s)
performing the work to ensure that the product still complies with the requirements of
the above standard.
CAUTION!
Read and understand the instruction manual before
installing or operating.
WARNING!
Many parts of the power source are at mains voltage.

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INTRODUCTION
The power source is transistor--controlled, operating on the inverter principle. It consists of a
number of function modules, as shown in the schematic diagram below. Each module has a
module number, which is always included as the first part of the name/identification of
components in the module.
Block diagram of the power source
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, control power transformer, contactor.
15 Power module
This module is a forward converter inverter, operating at a switching frequency of 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.

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TECHNICAL DATA
Mig U4000i
Mains voltage 400V ±10%, 3∼50 Hz
Mains supply Ssc min 2.0 MVA
Primary current
Imax MIG/MAG
Imax MMA
Imax TIG
25 A
27 A
20 A
No--load power demand when in the energy--saving mode,
6.5 min. after welding 60 W
Voltage/current range
MIG/MAG
MMA
TIG
8--60V/16--400A
16 -- 400 A
4 -- 400 A
Permissible load at MIG/MAG
35 % duty cycle
60 % duty cycle
100 % duty cycle
400 A / 34 V
320 A / 30 V
250 A / 27 V
Permissible load at MMA
35 % duty cycle
60 % duty cycle
100 % duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
Permissible load at TIG
35 % duty cycle
60 % duty cycle
100 % duty cycle
400 A / 26 V
320 A / 23 V
250 A / 20 V
Power factor at maximum current 0.90
Efficiency at maximum current 86 %
Open--circuit voltage
MIG/MAG
MMA
TIG
55 -- 70 V
78 -- 90 V
78 -- 90 V
Operating temperature -- 1 0 t o + 4 0 ˚C
Transportation temperature -- 2 0 t o + 5 5 ˚C
Continual sound pressure at no--load <70db(A)
Dimensions, lxbxh
with cooling unit
625 x 394 x 496 mm
625 x 394 x 776 mm
Weight
with cooling unit
63.5 kg
83.5 kg
Insulation class H
Enclosure class IP 23
Application class

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Mig 4000i
Mains voltage 400V ±10%, 3∼50 Hz
Mains supply Ssc min 2.0 MVA
Primary current
Imax (MIG/MAG)
Imax (MMA)
25 A
27 A
No--load power demand when in the energy--saving mode,
6.5 min. after welding 60 W
Voltage/current range
(MIG/MAG)
(MMA)
8--60V/16--400A
16 -- 400 A
Permissible load at (MIG/MAG)
35 % duty cycle
60 % duty cycle
100 % duty cycle
400 A / 34 V
320 A / 30 V
250 A / 27 V
Permissible load at (MMA)
35 % duty cycle
60 % duty cycle
100 % duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
Power factor at maximum current 0.90
Efficiency at maximum current 86 %
Open--circuit voltage
(MIG/MAG)
(MMA)
55 -- 70 V
78 -- 90 V
Operating temperature -- 1 0 t o + 4 0 ˚C
Transportation temperature -- 2 0 t o + 5 5 ˚C
Dimensions, lxbxh
with cooling unit
625 x 394 x 496 mm
625 x 394 x 776 mm
Continual sound pressure at no--load <70 db (A)
Weight
with cooling unit
59.5 kg
79.5 kg
Insulation class H
Enclosure class IP 23
Application class

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Tig 4000i
Mains voltage 400V ±10%, 3∼50 Hz
Mains supply Ssc min 2.0 MVA
Primary current
Imax (TIG)
Imax (MMA)
20 A
27 A
No--load power in the energy--saving mode, 6.5 min. after
welding 60 W
Voltage/current range
(TIG)
(MMA)
8 -- 60 V / 4 -- 400 A
16 -- 400 A
Permissible load at TIG
35 % duty cycle
60 % duty cycle
100 % duty cycle
400 A / 26 V
320 A / 23 V
250 A / 20 V
Permissible load at MMA
35 % duty cycle
60 % duty cycle
100 % duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
Power factor at maximum current 0.90
Efficiency at maximum current 86 %
Open--circuit voltage 78 -- 90 V
Operating temperature range -- 1 0 t o + 4 0 ˚C
Transportation temperature -- 2 0 t o + 5 5 ˚C
Dimensions, lxbxh
with cooling unit
625 x 394 x 496
625 x 394 x 776
Continual sound pressure at no--load <70 db (A)
Weight
with cooling unit
61.5 kg
81.5 kg
Insulation class H
Enclosure class IP 23
Application class
Cooling unit
Cooling power 2.0 kW at 40˚C temperature difference and flow1.5 l/min
Coolant 50 % water / 50% mono--ethylen glycol
Coolant quantity 5.5 l
Maximum water flow 2.0 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

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Arc 4000i
Mains voltage 400 V ±10%, 3∼50 Hz
Mains supply Ssc min 2.0 MVA
Primary current Imax 27 A
No--load power in energy--saving mode 6.5 min. after
welding 50 W
Setting range 16 A -- 400 A
Maximum permissible load at
35 % duty cycle
60 % duty cycle
100 % duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
Power factor at maximum current 0.90
Efficiency at maximum current 86%
Open--circuit voltage 78 -- 90 V
Temperature range --10 till + 40˚C
Transportation temperature -- 2 0 t o + 5 5 ˚C
Dimensions, l x b x h 625 x 294 x 492 mm
Continual sound pressure at no--load <70 db (A)
Weight 47.5 kg
Insulation class H
Enclosure class IP 23
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading. The duty cycle is valid for 40˚C.
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.
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000--3--12

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WIRING DIAGRAM
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,
connection (plug/socket) XS1 -- XS99 (S = sleeve), XP1 -- XP99 (P = pin) 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 = module association, 1--69
Q = transistor
1 = individual identification number, 0--99
CAUTION !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
SObserve precautions for handling electrostatic--
sensitive devices.
SUse proper static--proof bags and boxes.
ESD
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 22.
AP3 CAN bus distribution board. Accessory, included in the MMC kit for the
MIG machines, see page 13.
C3 Capacitor, 100 nF 250 V.
C4 Capacitor, 100 nF 250 V.
D1 LED, orange, for overtemperature indication.
D2 LED, white. Indicates Power On.
XP.. Plug connectors.
XS.. Socket connectors.

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Component Description
XT.. Terminal blocks.
1 MMC module. Wire numbers 100--199. See description on page 22.
2 Mains module. Wire numbers 200--299.
2AP1 EMC suppressor board. See diagram on page 23.
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, slow blow (anti--surge), different rating depending on machine type.
Mig U4000i and Mig 4000i: 8 A.
Tig 4000i: 0.5 A
2FU5 Fuse, 2 A, slow blow (anti--surge).
2KM1 Main contactor. See 20AP2:3 on page 43.
2QF1 Mains switch. See 20AP2:3 on page 43.
2TC1 Auxiliary transformer.
2TC2 Auxiliary transformer. If the mains voltage exceeds 427 V, the link on
terminal 2XT2 must be moved from the 400 V terminal to the 428 V
terminal.
3 Primary inductor module. Wire numbers 300--399.
3L1 Primary inductor.
5 Water cooling module. Wire numbers 500--599.
The wiring diagram for the cooling module is on page 24.
The power supply to the cooling water pump and fan is controlled by the
machine software. See the description of the 20AP2:5 on page 44.
10 TIG module. Wire numbers 1000--1199.
10AP1 HF starting device. See the description of 20AP2:7 on page 47.
10C1 Interference suppression capacitor, 47 nF 250V.
10TV1 HF transformer.
10YV1 Gas valve. See the description of 20AP2:6 on page 47.
15 Power module. Wire numbers 1500--1699. See the schematic diagram
and description on page 25.
15AP1 Power board.
15AP2 Driver board.
15AP3 Current sensor. See the description of 20AP1:8 on page 37.

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Component Description
15BR1 Rectifier bridge. See the description of 15AP1:1 on page 26 and the
assembly instructions on page 59.
15D1, 15D2 Rectifier and freewheel diode modules. Each module consists of two
diodes.
15D1 rectifies the welding current. During the time interval between two
voltage pulses from transformer 15TM1, the freewheel diodes 15D2
maintain the welding current from inductor 15L3.
See page 59 for assembly instructions for the diode modules.
15EV1, 15EV2 Fans, 24 V DC. See the description of 20AP1:2 on page 33.
15L1, 15L2 2 + 2 ferrite rings. Reduce transient voltages produced when the diode
modules 15D1 and 15D2 turn off.
15L3 Inductor.
15Q1, 15Q2 IGBT transistors. See the description of 15AP1:2 on page 27 and the
installation instructions on page 59.
15ST1 Thermal overload cutout, in the winding of main transformer TM1. See the
description of 20AP1:4 on page 36.
15ST2 Thermal overload cutout, mounted on the heat sink for the IGBT modules.
See the description of 20AP1:4 on page 36 and the installation
instructions on page 59.
15TM1 Main transformer.
20AP1 Controller circuit board.
20AP2 Relay board.

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MMC option for MIG machines
CAN bus distribution board AP3 connected to Mig 4000i
The MIG machines are normally delivered without MMC module. If the accessory ’MMC kit’
is used, the MMC module can be moved from the wire feed unit to the power source.

S0740 800 191/E080229/P78
Mig U4000i valid for serial number 803--xxx--xxxx
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Mig 4000i valid for serial number 803--xxx--xxxx
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Tig 4000i valid for serial number 803--xxx--xxxx
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Arc 4000i valid for serial number 803--xxx--xxxx
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