ESAB Aristo Mig 3001i User manual

0740 800 196 Valid for serial no. 833-xxx-xxxx to 039-xxx-xxxx101019
Aristo Origo
Mig 3001i
Tig 3001i
Service manual

S0740 800 196/E101019/P76
- 2 -TOCe
Rights reserved to alter specifications without notice.
READ THIS FIRST 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mig 3001i 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tig 3001i 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 MMC unit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1 Interference suppressor board and main rectifier 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1 Tig board 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:1 Power supply 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:2 Communication with the control board 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:3 Gas valve 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:4 HF generator 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:5 TIG torch switch 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1:6 Signal transfer 20AP1 - 20AP2 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10AP1 Component positions 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 The power module 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1 Power board 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:1 Internal power supply 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:2 Temperature monitoring 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:3 Overvoltage and undervoltage protection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:4 Charging circuit 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:5 Gate driver stages and switching circuits 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1:6 Fan control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1 Component positions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2 Secondary board 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2:1 Diode modules 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2:2 Temperature monitoring 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2 Component positions 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Control board 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:1 Power supply 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:2 Fan control 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:3 The CAN bus 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication interruptions 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminating resistors 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:4 Temperature monitoring 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:5 Overvoltage and undervoltage protection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:6 Relay driver stages 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:7 Gate pulses 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:8 Current sensor 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:9 Arc voltage feedback 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open-circuit voltage control 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:10 Control panel interface circuits 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Circuit board versions 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Component positions, version 1 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Component positions, version 2 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2 Relay board 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:1 Power supply 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:2 Power supply to the cooling unit 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:3 Cooling water monitoring 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2:4 Gas pressure monitoring 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP2 Component positions 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rights reserved to alter specifications without notice.
20AP2 Circuit diagram 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE CONTROLS 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT CODES 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault log 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of fault codes 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault code description 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service aid 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking power board 15AP1 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking secondary board 15AP2 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soft starting 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting components on the heat sink 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal paste 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier bridge 2BR1 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power board 15AP1 with semicunductor modules 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diode modules 15D1, 15D2 and secondary board 15AP2 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibrating the current sensor signal 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MIG power sources, calibration of the arc voltage feedback 58. . . . . . . . . . . . . . . . . . . . . . . .
TIG power sources, calibration of the arc voltage feedback 60. . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION OF TERMINATING RESISTORS 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mig 3001i 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source without MMC 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source without MMC and with remote control 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source with MMC 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source with MMC and remote control 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source with MMC and wire feeder with MMC 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source with MMC, wire feeder with MMC and remote control 63. . . . . . . . . . . . . . . . . . . . .
Tig 3001i 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source with MMC 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power source with MMC and remote control 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IN-SERVICE INSPECTION AND TESTING 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General requirements 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Periodic inspection and test 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After repair, inspection and test 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual inspection 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical test 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional test 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test report 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting instructions 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices Mig 3001i 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices Tig 3001i 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan control 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIG welding with Mig 3001i 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT-TRACING 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 74.
This manual contains details of design changes that have been made up to and including
September 2010.
The manual is valid for:
Mig 3001i with serial number 833-xxx-xxxx, 950-xxx-xxxx, 039-xxx-xxxx
Tig 3001i with serial number 840-xxx-xxxx, 950-xxx-xxxx, 039-xxx-xxxx
The Mig 3001i and Tig 3001i 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.
INTRODUCTION
Mig 3001i is a welding power source intended for MIG/MAG welding, as well as for welding
with powder filled cored wire (FCAW-S), TIG welding and for welding with coated electrodes
(MMA).
Tig 3001i is a TIG welding power source, which can also be used for MMA welding.
Cooling unit. Mig 3001i and Tig 3001i can be supplied with or without cooling unit. The
cooling unit can be retro fitted. Installation kit for the cooling unit is available as an
accessory, see the spare parts list.
Control panels, welding process parameters are controlled via the control panel. See the
separate instruction and service manuals for a detailed description of the panels.

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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 below. Each module 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 display.
2 Mains module
Mains interference suppressor, mains switch, auxiliary transformer.
10 TIG module
Comprises all TIG functions.
15 Power module
This module is a dual forward inverter, operating at a switching frequency of 2 x 40 kHz.
IGBT transistors are used as the switching elements. All power semiconductors are built
into modules.
20 Processor board module (controller module)
This is the controller board, 20AP1, with a microprocessor, that monitors and controls the
voltage and current.
Block diagram of the Mig 3001i.

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TECHNICAL DATA
Mig 3001i Tig 3001i
Mains voltage 400 V 10%, 3 ∼50/60 Hz 400 V 10%, 3 ∼50/60 Hz
Mains supply Ssc min 1.4 MVA Ssc min 1.4 MVA
Primary current
Imax MIG/MAG
Imax TIG
Imax MMA
16 A
13 A
19 A
13 A
19 A
No-load power demand when in the
energy-saving mode, 6.5 min. after
welding
30 W 30 W
Setting range
MIG/MAG
TIG
MMA
16 A / 8 V - 300 A / 48 V
4 - 300 A
16 - 300 A
4 - 300 A
16 - 300 A
Permissible load at MIG/MAG
35 % duty cycle
60 % duty cycle
100% duty cycle
300 A / 29 V
240 A / 26 V
200 A / 24 V
Permissible load at TIG
35 % duty cycle
60 % duty cycle
100% duty cycle
300 A / 22 V
240 A / 19.6 V
200 A / 18 V
300 A / 22 V
240 A / 19.6 V
200 A / 18 V
Permissible load at MMA
30 % duty cycle
60 % duty cycle
100% duty cycle
300 A / 32 V
230 A / 29.2 V
190 A / 27.6 V
300 A / 32 V
230 A / 29.2 V
190 A / 27.6 V
Power factor at maximum current
MIG/MAG
TIG
MMA
0.90
0.89
0.90
0.89
0.90
Efficiency at maximum current
MIG/MAG
TIG
MMA
85 %
82%
84 %
81%
84 %
Open-circuit voltage
without VRD function 1)
VRD function deactivated 2)
VRD function activated 2)
67 V DC
60 V DC
< 35 V
67 V DC
60 V DC
< 35 V
Operating temperature -10 to +40°C-10 to +40°C
Transportation temperature -20 to +55°C-20 to +55°C
Continual sound pressure at no-load <70 db (A) <70 db (A)
Dimensions lxwxh
with cooling unit
652 x 249 x 423 mm
714 x 249 x 693 mm
652 x 249 x 423 mm
714 x 249 x 693 mm
Weight
with cooling unit
33 kg
53.5 kg
33.5 kg
54 kg
Insulation class transformer H H
Enclosure class IP23 IP23
Application class
1) Valid for power sources without VRD specification on the rating plate.

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2) Valid for power sources with VRD specification on the rating plate. The VRD function is explained in
the instruction manual for the control panel, if the control panel has this function.
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12
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.
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.

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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,
connectors XS1 - XS99 (S = socket), XP1 - XP99 (P = plug), XT1 - XT99 (T = terminal).
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
Component description
Component Description
1 MMC module. Wire numbers 100-199. This module is described in a
separate service manual for the control panels. See page 14.
2 Mains module. Wire numbers 200-299.
2AP1, 2BR1 Interference suppressor board with main rectifier. Power sources with
cooling unit have a different version of the suppressor board than power
sources without cooling unit.
See wiring and component positions diagram on page 15 and the
assembly instructions for the rectifier on page 54.
2FU1 Fuse, 0.5 A, slow blow (anti-surge).
2FU2 Fuse, 3.15 A, slow blow (anti-surge).
2FU3 Fuse, 4 A, slow blow (anti-surge).
2FU4 Fuse, slow blow (anti-surge). Tig: 5 A, Mig 10 A
2L1 - 2L4 Ferrite ring cores.
2QF1 Main On / Off switch.
2TC1 Auxiliary transformer.
3 Primary inductor module. Wire numbers 300-399.
5 Cooling unit, CoolMidi 1000. Wire numbers 500-599.
The CoolMidi 1000 is described in a separate service manual with
filename 0740 800 195.
3L1 Primary inductor.
7L1, 7L2 Ferrite ring cores, fitted to each end of cable 7200.

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Component Description
10 TIG module. Wire numbers 1000-1199
10AP1 TIG board. See the description on page 16.
10C1, 10C2 Interference suppression capacitors.
10EV1 Fan, 24 V DC. See the description of 20AP1:2 on page 27.
10TV1 HF transformer. See HF generator on page 16.
10L1 Ferrite ring core.
10YV1 Gas valve. See page 16.
15 Power module. Wire numbers 1500-1699. See the schematic diagram
and description on Page 18.
15AP1 Power board. See the description on Pages 19 - 23.
15AP2 Filter board with rectifier modules. See the description on page 24.
15AP3 Current sensor. See the description of 20AP1:8 on page 31.
15C1, 15C2 Smoothing capacitors.
15D1, 15D2 Rectifier and freewheel diode modules. Each module consists of two
diodes.
During the time interval between the voltage pulses from transformers
15TM1 and 15TM2, the freewheel diodes maintain the welding current
from inductor 15L3.
See page 54 for assembly instructions for the diode modules.
15EV1, 15EV2 Fans, 24 V DC. See the description of 20AP1:2 on page 27.
15L3 Inductor.
15TM1, 15TM2 Main transformers.
20AP1 Control circuit board. See the description on page 27.
20AP2 Relay board. See the description on page 37.
The relay board is only fitted to power sources with cooling unit.
CAUTION !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
Observe precautions for handling electrostatic-
sensitive devices.
Use proper static-proof bags and boxes.
ESD

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Mig 3001i
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Placement of the circuit boards, Mig 3001i
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Tig 3001i
Placement of the circuit boards, Tig 3001i
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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.
1 MMC unit
The MMC unit can either be fitted to the wire feed unit and/or the power source.
The MMC unit consists of an operator's control panel and a welding data board with a
welding data unit. In some applications the welding data unit is a part of the power source
control board, then there is no welding data board included in the MMC unit.
The power source, the wire feed unit and the welding data unit each have their own
microprocessor for control, with the welding data unit 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.
MMC unit for the Mig 3001i
A24 is a MMC unit with welding data board.
The Mig 3001i can also be delivered without MMC unit.
A24
MMC units for the Tig 3001i
TA23 and TA24 are MMC units without welding data board. The welding data unit is a part
of the power source control board.
TA23 TA24
The MMC units are described in separate instruction and service manuals.

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2AP1 Interference suppressor board and main rectifier
Circuit diagram, 2AP1
R7, R8 and R9 are varistors that 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.
Terminal F is not fitted to suppressor boards used in power sources without cooling unit.
From serial no. 039-xxx-xxxx all suppressor boards are supplied with terminal F.
Main rectifier 2BR1 is fitted on the heat sink. See the fitting instruction on page 54.
Component positions, 2AP1 with terminal F
Component positions, 2AP1 without terminal F

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10AP1 Tig board
The TIG board is fitted to the Tig 3001i. Sections 10AP1:1 to 10AP1:6 refer to the wiring
diagram on page 12.
Circuit diagram of the TIG functions
10AP1:1 Power supply
42 V AC is supplied from transformer 2TC1.
10AP1:2 Communication with the control board
The processor on circuit board 20AP1 controls the gas valve and the HF
generator.
The processor senses the start signal from the torch switch when optocoupler
IC1 is energized.
10AP1:3 Gas valve
When the torch switch is operated, relay RE1 closes and energizes the gas
valve. When the torch switch is released and the gas post-flow time has
elapsed, the gas valve is deactivated.
10AP1:4 HF generator
When the welding torch switch is operated, and the open-circuit voltage is over
50 V, relay RE2 closes and turns on the HF generator, TR1. It remains
activated until the arc strikes, or for a maximum of 0.5 seconds.
The voltage on the primary side of HF transformer 10TV1 is about 550 V. The
secondary voltage is about 11 kV if a 4 metre long welding torch is connected.
If the welding torch is 16 metre long, the HF spark is about 8 kV.
Due to electromagnetic interference regulations, the energy in the HF ignition
spark is limited, and so the HF spark weakens with increasing length of the
torch. The HF ignition is satisfactory for welding torches up to 16 metres.

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10AP1:5 TIG torch switch
The torch switch is supplied at 42 V AC. This voltage is rectified and energizes
optocoupler IC1 when the torch switch is closed.
10AP1:6 Signal transfer 20AP1 - 20AP2
Power supply and signal transfer for 20AP2, see 20AP2:1 on page 37.
10AP1 Component positions

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15 The power module
The power module converts the rectified 3-phase 400 V to the welding voltage. It consists of
a dual forward inverter, operating at a switching frequency of 2 x 40 kHz.
The mains rectifier bridge 2BR1, the IGBT modules IC3 and IC8 and the diode modules
15D1 and 15D2 are all mounted on a heat sink.
Schematic diagram of the power module
If circuit boards 15AP1 or 20AP1, are replaced, the gate pulse waveforms must be checked
afterwards and the machine must be soft-started. See page 50.
See the instructions on Page 54 concerning mounting of the components on the heat sink
(2BR1, 15AP1 with IC3 and IC8, 15D1 and 15D2).
WARNING!
The power module is at mains voltage.
0 V in the power module is connected to mains voltage.

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15AP1 Power board
The power board carries the charging circuit, the gate driver circuit, the switching circuit and
the overvoltage and undervoltage protection circuits.
WARNING!
Dangerous voltage - mains voltage. Never make any measurements on this board
when the machine is connected to the mains supply.
On pages 46 and 50 there are instructions on how to check the power board.
15AP1:1 Internal power supply
The board is supplied with 24 V AC from winding S1 on auxiliary transformer
2TC1. This winding must never be mixed-up with the other 24 V winding on
this transformer. 0 VA is galvanic connected to the mains supply.
15AP1:2 Temperature monitoring
NTC IC3 and NTC IC8 are fitted inside the IGBT modules IC3 and IC8.
The temperature monitoring circuit operates when the temperature exceeds
110 _C and resets at 50 _C.
See also the description and principal diagram on page 30.

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15AP1:3 Overvoltage and undervoltage protection
WARNING!
Dangerous voltage. Mains voltage on circuit board 15AP1 when
connected to the 400 V supply.
0 VA on power board 15AP1 is connected to the mains supply.
0 VA is galvanically isolated from 0 V.
The overvoltage and undervoltage protection generates a fault signal if the
voltage across capacitors 15C1 and 15C2 falls outside the permitted interval of
300 - 715 V DC, which is equivalent to a mains voltage of 212 - 505 V AC.
In the event of a fault, the display panel will show fault code 5.
The fault state will not be reset until the DC voltage is within 400 to 650 V.
During normal operating conditions, the voltage between pins CN08:6 and 7
on circuit board 15AP1 is about 0.1 V. Optocoupler IC4 is used for galvanic
isolation of the voltage monitoring circuit from control board 20AP1.
A break in any of the conductors to/from 15AP1, as shown in the diagram
above will result in a fault state.