0740 800 172 GB

Origo™, Aristo®
Mig L3000i, Mig C3000i,

Tig 3000i, Tig 3000i AC/DC
Service manual
0740 800 172 GB 20180918 Valid for: serial no. 535-xxx-xxxx to 209-xxx-xxxx
TABLE OF CONTENTS
1 READ THIS FIRST.................................................................................... 5

2 INTRODUCTION ....................................................................................... 6
3 TECHNICAL DATA ................................................................................... 8
4 WIRING DIAGRAM ................................................................................... 11
4.1 Component description ......................................................................... 11
4.2 Mig L3000i ............................................................................................... 14
4.3 Mig C3000i, valid from serial no. 613-xxx-xxxx to 209-622-xxxx ....... 16
4.4 Mig C3000i, valid from serial no. 209-623-xxxx ................................... 18
4.5 Tig 3000i .................................................................................................. 20
4.6 Tig 3000i AC/DC...................................................................................... 22
5 DESCRIPTION OF OPERATION.............................................................. 24
5.1 1 MMC module ........................................................................................ 24
5.2 2AP1 Interference suppressor board and main rectifier .................... 25
5.3 10AP1 Tig board ..................................................................................... 27
5.3.1 10AP1:1 Power supply ......................................................................... 27
5.3.2 10AP1:2 Communication with the control board .................................. 27
5.3.3 10AP1:3 Gas valve............................................................................... 27
5.3.4 10AP1:4 HF generator ......................................................................... 27
5.3.5 10AP1:5 TIG Torch switch .................................................................... 28
5.3.6 10AP1 Component positions ................................................................ 28
5.4 13AP1 Wire feeder control board.......................................................... 28
5.4.1 13AP1:1 Power supply ......................................................................... 29
5.4.2 13AP1:2 Start / Stop............................................................................. 29
5.4.3 13AP1:3 Gas valve............................................................................... 30
5.4.4 13AP1:4 Motor driving / braking ........................................................... 30
5.4.5 13AP1:5 Pulse generator input ............................................................ 31
5.4.6 13AP1:6 The CAN bus ......................................................................... 31
5.4.7 13AP1:7 Arc voltage sensing ............................................................... 32
5.4.8 13AP1:8 Monitoring the ELP ................................................................ 32
5.5 15 The power module............................................................................. 34
5.6 15AP1 Power board................................................................................ 34
5.6.1 15AP1:1 Internal power supply ............................................................ 35
5.6.2 15AP1:2 Temperature monitoring......................................................... 35
5.6.3 15AP1:3 Overvoltage and undervoltage protection.............................. 36
5.6.4 15AP1:4 Charging circuit...................................................................... 37
5.6.5 15AP1:5 Gate driver stages and switching circuits .............................. 38
5.6.6 15AP1:6 Fan control............................................................................. 39
5.7 15AP2 Secondary board ........................................................................ 41
5.7.1 15AP2:1 Diode modules....................................................................... 41
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TABLE OF CONTENTS

5.8 18AP1 AC control board ........................................................................ 44
5.8.1 18AP1:1 Power supply ......................................................................... 45
5.8.2 18AP1:2 CAN bus ................................................................................ 46
5.8.4 18AP1:4 Arc voltage monitoring ........................................................... 48
5.8.5 18AP1:5 Fan control............................................................................. 48
5.8.6 18AP1:6 Switch driver .......................................................................... 49
5.9 18AP2 AC power board.......................................................................... 51
5.9.1 18AP2:1 Switching circuits ................................................................... 51
5.9.3 18AP2:3 Fan control............................................................................. 52
5.10 20AP1 Control board.............................................................................. 54
5.10.1 20AP1:1 Power supply ......................................................................... 55
5.10.2 20AP1:2 Fan control............................................................................. 56
5.10.3 20AP1:3 The CAN bus ......................................................................... 57
5.10.3. Communication interruptions............................................................. 58
1
5.10.3. Terminating resistors ......................................................................... 59
2
5.10.5 20AP1:5 Overvoltage and undervoltage protection.............................. 60
5.10.6 20AP1:6 Relay driver stages ................................................................ 60
5.10.7 20AP1:7 Gate pulses ........................................................................... 60
5.10.8 20AP1:8 Current sensor ....................................................................... 61
5.10.9 20AP1:9 Arc voltage feedback ............................................................. 62
5.10.9. Open-circuit voltage control............................................................... 63
1
5.10.1 20AP1:10 Control panel interface circuits ............................................ 64
0
5.10.11 20AP1 Circuit board versions ............................................................... 65
5.10.1 20AP1 Component positions, version 1 ............................................... 66
2
5.10.1 20AP1 Component positions, version 2 ............................................... 67
3
5.11 CAN adapter option Mig C3000i ............................................................ 68
5.11.1 Connection instructions ........................................................................ 69
6 REMOTE CONTROLS .............................................................................. 70

7 FAULT CODES ......................................................................................... 71
7.1 Fault log................................................................................................... 71
7.2 Summary of fault codes......................................................................... 71
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TABLE OF CONTENTS
7.3 Fault code description ........................................................................... 72

7.3.1 Power source ....................................................................................... 72
7.3.2 AC unit.................................................................................................. 75
7.3.3 Wire feed unit ....................................................................................... 77
8 SERVICE INSTRUCTIONS....................................................................... 79
8.1 What is ESD? .......................................................................................... 79
8.2 Service aid .............................................................................................. 79
8.3 Special tools ........................................................................................... 80
8.4 Checking power board 15AP1............................................................... 81
8.5 Checking secondary board 15AP2 ....................................................... 83
8.6 Checking the IGBT modules of AC power board 18AP2 .................... 86
8.7 Checking the gate signals to AC power board 18AP2 ........................ 88
8.8 Soft starting ............................................................................................ 90
8.9 Mounting components on the heat sink............................................... 95
8.9.1 Thermal paste ...................................................................................... 95
8.9.2 Rectifier bridge 2BR1 ........................................................................... 95
8.9.3 Power board 15AP1 with semicunductor modules ............................... 96
8.9.4 Diode modules 15D1, 15D2 and secondary board 15AP2................... 97
8.9.5 AC power board 18AP2 with IGBT modules ........................................ 98
8.10 Calibrating the current sensor signal................................................... 99
8.11 MIG machines, calibration of the arc voltage feedback ..................... 100
8.12 DC TIG machines, calibration of the arc voltage feedback ................ 102
8.13 AC TIG machines, calibration of the arc voltage display ................... 103
9 SPARE PARTS ......................................................................................... 104
Rights reserved to alter specifications without notice.
0740 800 172 © ESAB AB 2018

1 READ THIS FIRST
1 READ THIS FIRST
Maintenance and repair work must 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 the "SPARE PARTS" chapter
in this manual.
This manual contains details of all design changes that have been made up to and including
June 2016.
The manual is valid for:
AristoMig 300, ESABMig 300i, AristoMig C300 and ESABMig C300i with serial no.
535-xxx-xxxx.
Mig L3000i with serial no. 613-xxx-xxxx and 802-xxx-xxxx.
Mig C3000i with serial no. 613-xxx-xxxx, 802-xxx-xxxx, 950-xxx-xxxx, 039-xxx-xxxx and
209-xxx-xxxx.
Tig 3000i with serial no. 612-xxx-xxxx and 802-xxx-xxxx.
Tig 3000i AC/DC with serial no. 612-xxx-xxxx, 802-xxx-xxxx and 039-xxx-xxxx.

The Mig L3000i, Mig C3000i, Tig 3000i, Tig 3000i AC/DC, AristoMig 300, ESABMig 300i,
AristoMig C300 and ESABMig C300i are designed and tested in accordance with
applicable international and European standards series 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.

WARNING!
Many parts of the power source are at mains voltage.
0740 800 172 -5- © ESAB AB 2018

2 INTRODUCTION
2 INTRODUCTION
The AristoMig and ESABMig power sources are renamed:
New name Old name
Mig L3000i AristoMig 300 / ESABMig 300i
Mig C3000i AristoMig C300 / ESABMig C300i

There are two different product families, Aristo and Origo, to which the power sources
belong. The product family is depending on the type of control panel that is used. The control
panels are not described in this manual, this manual describes the power sources: Mig
L3000i, Mig C3000i, Tig 3000i and Tig 3000i AC/DC

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.
13 Wire feeder module
Comprises all wire feeder 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.
18 AC module
Comprises all AC TIG functions.
20 Processor board module (controller module)
This is the controller board, 20AP1, with a microprocessor, that monitors and controls the
voltage and current.
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2 INTRODUCTION
Block diagram of the Mig C3000i.
0740 800 172 -7- © ESAB AB 2018

3 TECHNICAL DATA
3 TECHNICAL DATA
Mig L3000i, Mig C3000i

Mains voltage 400 V, ±10%, 3~ 50/60 Hz
Primary current
Imax MIG/MAG (21 A) 17 A
Imax MMA (23 A) 18 A
Imax TIG 3) 14 A
No-load power demand when in the 30 W
energy-saving mode, 6.5 min. after welding
Setting range
MIG/MAG 16 A / 14.8 V - 300 A / 29.0 V
MMA 16 A / 20.6 V - 300 A / 32.0 V
TIG 3) 4 A / 10.2 V - 300 A / 22.0 V
Permissible load at MIG/MAG
35% duty cycle 300 A / 29 V
100% duty cycle 200 A / 24 V
Permissible load at MMA
60% duty cycle 230 A / 29.2 V
100% duty cycle 190 A / 27.6 V
Permissible load at TIG 3)
35 % duty cycle 300 A / 22 V
60 % duty cycle 240 A / 19.6 V
100 % duty cycle 200 A / 18 V
Power factor at maximum current
MIG/MAG (0.70) 0.90
MMA (0.73) 0.87
TIG 3) 0.89
Efficiency at maximum current
MIG/MAG (84 %) 82.3 %
MMA (83 %) 85.7 %
TIG 3) 75.9 %
Open-circuit voltage U0
without VRD function 1) MIG/MAG: 70 - 80 V MMA: 57 - 67 V
VRD function deactivated, only Mig C3000i 2) 60 V DC
VRD function activated, only Mig C3000i 2) < 35 V
Operating temperature -10 to +40°C
Constant A-weighed sound pressure < 70 dB
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3 TECHNICAL DATA
Dimensions l × w × h
Mig L3000i 652 × 249 × 423 mm
Mig C3000i 652 × 412 × 423 mm
Weight
Mig L3000i (26.5 kg) 29 kg
Mig C3000i (38 kg) 40.5 kg
Insulation class transformer H
Enclosure class IP23C
Application class
Mig C3000i
Torch connection EURO
Max. diameter wire bobbin 300 mm
Wire feed speed 0.8 - 25.0 m/min
Wire dimension
Fe & Ss 0.6 - 1.2 mm
Al 1.0 - 1.2 mm
Cored wire 0.8 - 1.2 mm
Shielding gas All types intended for MIG/MAG welding
max pressure 5 bar
Motor current Imax 3.5 A
1) Valid for power sources without VRD specification on the rating plate.
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.
3) Valid for a power source controlled from a U6 control panel

Tig 3000i AC/DC Tig 3000i
Mains voltage 400 V, ±10%, 1-3~ 50/60 Hz 400 V, ±10%, 3~ 50/60 Hz
Primary current
Imax TIG 18 A (19 A) 14 A
Imax MMA 22 A (23 A) 19 A
No-load power demand 26 W 30 W
when in the energy-saving
mode, 6.5 min. after welding
Setting range
TIG, AC* / DC 4-300 A 4-300 A
MMA 16-300 A 16-300 A
Permissible load at TIG, AC/DC
35% duty cycle 300 A / 22 V 300 A / 22 V
60% duty cycle 240 A / 19.6 V 240 A / 19.6 V
100% duty cycle 200 A / 18 V 200 A / 18 V
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3 TECHNICAL DATA
Tig 3000i AC/DC Tig 3000i

Permissible load at MMA
35% duty cycle 300 A / 32 V -
60% duty cycle 230 A / 29.2 V -
100% duty cycle 190 A / 27.6 V -
Power factor at maximum current
TIG - (0.65) 0.89
TIG AC 0.85 -
TIG DC 0.90 -
MMA 0.91 (0.73) 0.90
Efficiency at maximum current
TIG - (77%) 82%
TIG AC 71% -
TIG DC 71% -
MMA 76% (83%) 84%
Open-circuit voltage
MMA 58 V 57-67 V
Operating temperature -10 to +40°C -10 to +40°C
Constant A-weighted sound <70 dB <70 dB
pressure
Dimensions l × w × h 652 × 249 × 423 mm 652 × 249 × 423 mm
Insulation class H H
transformer
Enclosure class IP 23 IP 23
Application class
Data in brackets (x x x x) are valid for power sources without primary inductor.
*) The minimum current during AC welding depends on the alloy used for the aluminium
plates and their surface cleanliness.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40 °C / 104 °F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP 23S is intended for indoor and outdoor use; however, should not be
operated in precipitation.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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4 WIRING DIAGRAM
4 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
4.1 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 "1 MMC module",
page 24.
2 Mains module. Wire numbers 200-299.
2AP1, 2BR1 Interference suppressor board with main rectifier. See diagram in "2AP1
Interference suppressor board and main rectifier", page 25 and the
assembly instructions for the rectifier in "Rectifier bridge 2BR1", page
95.
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, 5 A, slow blow (anti-surge).
2L1 - 2L4 Ferrite ring cores.
2L5 - 2L6 Ferrite ring cores, used from serial number xxx-551-xxxx.
2QF1 Main On / Off switch.
2TC1 Auxiliary transformer.
3 Primary inductor module. Wire numbers 300-399.
3L1 Primary inductor. From serial number 802-xxx-xxxx all power sourcess are
equipped with the inductor. For earlier power sources it is an option.
10 TIG module. Wire numbers 1000-1199
10AP1 TIG board. See the description in "10AP1 Tig board", page 27.
0740 800 172 - 11 - © ESAB AB 2018

4 WIRING DIAGRAM
10C1, 10C2 Interference suppression capacitors.

10EV1 Fan, 24 V DC. See the description of 20AP1:2 in "20AP1:2 Fan control",
page 56.
10TV1 HF transformer. See HF generator in "10AP1:4 HF generator", page 27.
10L1 Ferrite ring core.
10YV1 Gas valve. See "10AP1:3 Gas valve", page 27.
13 Wire feeder module. Wire numbers 1300-1499.
13AP1 Wire feeder controller circuit board. See the description in "13AP1 Wire
feeder control board", page 28.
13C5 Interference suppression capacitor.
13G1 Pulse generator. Incorporated in motor 13M1.
See the description in "13AP1:5 Pulse generator input", page 31.
13L1, 13L2 Ferrite ring cores.
13M1 Motor with pulse generator.
13YV1 Solenoid valve. See the description in "13AP1:3 Gas valve", page 30.
15 Power module. Wire numbers 1500-1699. See the schematic diagram
and description in "15 The power module", page 34.
15AP1 Power board. See the description in "15AP1 Power board", page 34.
15AP2 Filter board with rectifier modules. See the description in "15AP2
Secondary board", page 41.
15AP3 Current sensor. See the description in "20AP1:8 Current sensor", page
61.
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 "Mounting components on the heat sink", page 95 for assembly
instructions for the diode modules.
15D3, 15D4, Transient voltage suppressors, only fitted to the Tig 3000i AC/DC.
15D5
The suppressors must always be fitted, otherwise the diode modules 15D1
and 15D2 will be damaged when AC welding is active.
15EV1, 15EV2 Fans, 24 V DC. See the description in "20AP1:2 Fan control", page 56.
15L3 Inductor.
15TM1, 15TM2 Main transformers.
18 AC module. Wire numbers 1800-1999.
18AP1 AC control board. See the description in "18AP1 AC control board", page
44.
18AP2 AC power board. See the description in "18AP2 AC power board", page
51.
0740 800 172 - 12 - © ESAB AB 2018

4 WIRING DIAGRAM
18EV1, 18EV2 Fans, 24 V DC. See the description in "18AP1:5 Fan control", page 48.
18L1 Inductor.
20AP1 Controller circuit board. See the description in "20AP1 Control board",
page 54.
20L1 Ferrite ring core. Not used from serial no. xxx-601-xxxx, does not need to
be replaced if broken.
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
0740 800 172 - 13 - © ESAB AB 2018

4 WIRING DIAGRAM
4.2 Mig L3000i
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4 WIRING DIAGRAM
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4 WIRING DIAGRAM
4.3 Mig C3000i, valid from serial no. 613-xxx-xxxx to 209-622-xxxx
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4 WIRING DIAGRAM
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4 WIRING DIAGRAM
4.4 Mig C3000i, valid from serial no. 209-623-xxxx
0740 800 172 - 18 - © ESAB AB 2018

4 WIRING DIAGRAM
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4 WIRING DIAGRAM
4.5 Tig 3000i
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4 WIRING DIAGRAM
0740 800 172 - 21 - © ESAB AB 2018

4 WIRING DIAGRAM
4.6 Tig 3000i AC/DC
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4 WIRING DIAGRAM
0740 800 172 - 23 - © ESAB AB 2018

5 DESCRIPTION OF OPERATION
This section 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.
5.1 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.
The TA23 TA24 and TA 24 AC/DC control panels does not have a welding data board. The
functions of the welding data board are incorporated in the power source control board.
The control panels are described in separate instruction and service manuals.
Mig L3000i: Control panel MA6, MA23 or MA23A fitted in the wire feeder.

MigC3000i:
Control panel MA6 or U6.

Knobs for setting the voltage and wire feed speed / welding current.
Other parameters are controlled by pushbuttons, with text in the
display panel.
Control panel MA23 and MA23A.

Knobs for setting the voltage and wire feed
speed / welding current. Other settings by
pushbuttons.
Control panel MA24.

Knobs for setting the voltage and wire feed speed / welding current.
Other parameters are controlled by pushbuttons.
0740 800 172 - 24 - © ESAB AB 2018

Tig 3000i:
Control panel TA23 or TA24.

Pushbuttons for parameter selection and one
knob for the setting of the parameters.
Tig 3000i AC/DC:
Control panel TA24 AC/DC.

Pushbuttons for parameter selection and one knob for the setting of
the parameters.
5.2 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.
From serial no. 039-xxx-xxxx all suppressor boards are supplied with terminal F. Terminal F
is not fitted to suppressor boards prior to serial no. 039-xxx-xxxx. Terminal F has no function
for the power sources mentioned in this manual.
Main rectifier 2BR1 is fitted on the heat sink. See the fitting instruction in "Mounting
components on the heat sink", page 95.
0740 800 172 - 25 - © ESAB AB 2018

Component positions, 2AP1 with terminal F

Component positions, 2AP1 without terminal F

0740 800 172 - 26 - © ESAB AB 2018

5.3 10AP1 Tig board
The TIG board is fitted to the Tig 3000i and Tig 3000i AC/DC. Sections 10AP1:1 to 10AP1:5
refer to the wiring diagrams in "10AP1 Tig board", page 27.
Circuit diagram of the TIG functions

5.3.1 10AP1:1 Power supply

42 V AC is supplied from transformer 2TC1.
5.3.2 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.
5.3.3 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.
5.3.4 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 0.7 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.
0740 800 172 - 27 - © ESAB AB 2018

5.3.5 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.
5.3.6 10AP1 Component positions
5.4 13AP1 Wire feeder control board
The wire feeder control board is fitted to the Mig C3000i. Sections 13AP1:1 to 13AP1:7 refer
to the wiring diagram in "Mig C3000i, valid from serial no. 613-xxx-xxxx to 209-622-xxxx",
page 16.
Circuit board identity
The wire feeder control board has a machine ID, a hardware ID and a unit type number. To
read this you need the ESAT service kit, see "Service aid", page 79.
• The machine ID determines which motor type and wire feed mechanism the board is
intended for. If the board is to be used for another type of motor or mechanism, the
machine ID can be changed by ESAT.
• 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 this board are:
Machine ID = 29
Hardware ID = 5
Unit type = 3 (wire feed unit)
0740 800 172 - 28 - © ESAB AB 2018

The control board obtains a 42 V AC supply from transformer 2TC1. 42 V AC is used for the
welding torch trigger switch and as the power supply to the gas solenoid valve.
Rectifier BR1 rectifies the 42 V supply to 60 V. This voltage supplies the wire feeder motor.
Transistor Q8 is a pre-regulator which reduces the voltage from 60 V to 20 V. Q8 is
current-limited to about 200 mA. If the 20 V supply drops below 13 V, the wire feed unit
stops.

Voltage monitoring
If the +60 V supply drops below 42 V or exceeds 78 V, the MMC panel displays fault code 9.
This fault does not disable any functions.
The +20 V is monitored by a reset circuit. If the voltage drops to 13 V or less, this circuit
generates a reset signal to the processor, which responds by stopping the wire feed and
then all communication on the bus. This fault does not generate a fault code.
The +15 V is monitored by the processor. If the 15 V supply drops below 13 V or exceeds 17
V, the MMC panel displays fault code 8. This fault does not disable any functions.
5.4.2 13AP1:2 Start / Stop
The welding torch switch is supplied with 42 V AC. Closing the switch activates optocoupler
IC1, causing the voltage across C35 to go low.
When wire feed starts, the power source generates welding voltage. If this is not followed by
a flow of welding current within three seconds, the power source shuts down the welding
power supply, although wire feed continues until the welding torch switch is released.
0740 800 172 - 29 - © ESAB AB 2018

5.4.3 13AP1:3 Gas valve
The gas valve is controlled by the microprocessor. In normal operation the gas valve opens
when the start signal is activated by the welding torch switch.
5.4.4 13AP1:4 Motor driving / braking
Schematic diagram of the motor drive stage

Driving
The motor is powered from the smoothed +60 V supply. Motor speed is controlled by pulse
width modulation of transistor Q1. The pulse frequency is 39 kHz. The maximum conducting
time of the pulses is 99% of the pulse cycle time. During the pulse spaces, the motor current
freewheels through diode D8. A wire feed speed of 25 m/min. requires a roller speed of 271
r/min, the motor voltage is then about 40 V.
Current limit
Resistor R19 produces a voltage drop proportional to the motor current. If the current
exceeds the current limit, IC5 turns off the gate pulses to Q1. When the current falls, Q1
conducts again at the next gate pulse.
The wire feeder has a dynamic current limit controlled by the processor. The current limit is
11 A on starting. When the set speed is achieved, this is reduced to 7 A.
0740 800 172 - 30 - © ESAB AB 2018

Braking
When the motor starts, capacitor C43 charges up via diode D28: the voltage is limited to 15
V by zener diodes D10 and D21. When the motor is to brake, the LED in optocoupler IC8
lights, causing the transistor in IC8 to conduct and discharge capacitor C43 (15 V) to the
gate of transistor Q3. The transistor conducts and short-circuits the motor voltage through
resistors R51 and R64, which limit the current to about 20 A.
Speed monitoring
Wire feed speed is monitored by the microprocessor on the circuit board. Wire feed is
stopped if the feed speed deviates from the set speed by more than 1.5 m/min for more than
5.1 seconds. The MMC panel displays fault code 11.
5.4.5 13AP1:5 Pulse generator input
The pulse generator, 13G1, is fitted to drive motor 13M1. It generates 60 pulses per
revolution, which means that, at a wire feed speed of 25 m/min, the pulse frequency is
10179 Hz.
5.4.6 13AP1:6 The CAN bus
The circuit board includes a driver for the CAN bus, IC12, which looks after communication
with the other units in the system. Although the CAN bus supplies a +12 V power supply,
this is not used on circuit board 13AP1. 0 V on the circuit board is connected to 0 V CAN.
0740 800 172 - 31 - © ESAB AB 2018

Starting sequence
On power-up, the board's CAN controller reads in the bus
speed from the micro processor: 400 kbit/s.
The circuit board displays the starting sequence from
power-up.
LED1 lights red. Then LED1, LED2 and LED3 lights green.
When the board has been initiated, and the wire feed unit is
in the application program, LED1 flashes continously with a
green light.
Read more about the CAN bus in "20AP1:3 The CAN bus",
page 57. LED's on circuit board 13AP1
5.4.7 13AP1:7 Arc voltage sensing
In order to avoid spurious volt drops when measuring the welding arc voltage, the power
source senses the arc voltage via the filler wire and the feeder unit motor.
5.4.8 13AP1:8 Monitoring the ELP
Wire feed units with water connection are equipped with a detection system ELP (ESAB
Logic Pump) which checks that the water hoses are connected. When connecting a
water-cooled welding torch, the water pump starts.
A microswitch connected between contacts R1 and R2, senses whether a water-cooled
welding torch is connected to the wire feed unit. This function is not used for the Mig C3000i.
When a water-cooled welding torch is connected to this equipment, the ELP function is
monitored by the cooling unit.
Spare part boards are configured for units not having the ELP function. The configuration of
the board may be checked by using the service function selection of ESAT and select:
Service function / Assign ELP exist / Argument 2: Set ELP does not exist.
For more information on ESAT, see "Service aid", page 79.
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5.5 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 equipment must be soft-started. See "Soft starting", page 90. See the
instructions concerning mounting of the components on the heat sink (2BR1, 15AP1 with
IC3 and IC8, 15D1 and 15D2) in "Mounting components on the heat sink", page 95.
WARNING!
The power module is at mains voltage.
0 V in the power module is connected to mains voltage.
5.6 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 equipment is connected to the mains supply.
In "Checking power board 15AP1", page 81 and "Soft starting", page 90 there are
instructions on how to check the power board.
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5.6.1 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.
5.6.2 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 principle diagram in "20AP1:4 Temperature monitoring", page
60.
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5.6.3 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.
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5.6.4 15AP1:4 Charging circuit
When the mains power supply is turned on, smoothing capacitors 15C1 and 15C2 charge
up via resistors R15 and R16.
When there are gate pulses present at pulse transformer TR2, transistor Q19 pulls the
'shutdown' signal to 0VA.
PWM circuit IC2 generates gate pulses to the thyristor in IGBT module IC8, the thyristor
short-circuits resistors R15 and R16.
Resistors R17 and R18 are potential dividers and discharge resistors for 15C1 and 15C2.
The PWM circuit generates a reference voltage +5.1 V, this is used by the over/under
voltage and temperature monitoring circuits.
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5.6.5 15AP1:5 Gate driver stages and switching circuits
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 40 kHz. See "Soft starting", page 90 for screen traces of
waveforms and measurement instructions.
Transformers TR2 and TR3 are gate driver transformers for galvanic isolation of the drive
circuits from controller board 20AP1.
If an IGBT module has failed, both the power board and the modules Q3 and Q8 must be
replaced. Failure of either module always subjects rectifier bridge 2BR1 to a high current
surge, which substantially reduces its life. We therefore recommend that the rectifier bridge
should also be replaced if the modules have failed. See "Checking power board 15AP1",
page 81 for instructions on checking the IGBT modules.
The IGBT modules and circuit board 15AP1 must be mounted in accordance with the
instructions in "Mounting components on the heat sink", page 95.
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5.6.6 15AP1:6 Fan control
See "20AP1:2 Fan control", page 56.
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5.7 15AP2 Secondary board

The secondary board is fitted on the main transformers 15TM1, 15TM2 and the diode
modules 15D1, 15D2.
In "Checking secondary board 15AP2", page 83 there are instructions on how to check
the secondary board.
5.7.1 15AP2:1 Diode modules
The diode modules comprises two diodes each, rectifier and freewheel diode. During the
time interval between two voltage pulses, the freewheel diode maintain the welding current
from inductor 15L3.
The transient voltage suppressors 15D3, 15D4 and 15D5 are only fitted to the Tig 3000i
AC/DC.
If a diode module has failed, both diode modules must be replaced and fitted in accordance
with the instructions in "Mounting components on the heat sink", page 95.
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NTC D1 and NTC D2 are fitted inside the diode modules 15D1 and 15D2. NTC R28 is fitted
on the copper foil of circuit board 15AP2.
resets at 50 °C.
See also the description and principle diagram in "20AP1:4 Temperature monitoring", page
60.
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NOTE!
There are two versions of 15AP2. The second version of the board includes filter
components (R33, C13 and D6) that are important for the VRD function. Any of
the circuit board versions can be used for power sources without VRD
specification on the rating plate.
0740 800 172 - 43 - © ESAB AB 2018

5.8 18AP1 AC control board
The AC control board is fitted to the Tig 3000i AC/DC. Sections 18AP1:1 to 18AP1:6 refer to
the wiring diagram in "Tig 3000i AC/DC", page 22.
The processor on the AC control board monitors the temperature monitoring circuits and
controls the cooling fans of the AC module. The AC control commands are generated by the
processor on circuit board 20AP1 and executed by the local processor.

The AC control board has a machine ID, a hardware ID and a unit type number. To read this
you need the ESAT service kit, see "Service aid", page 79.
• The machine ID determines which type of power source the board is intended for.
• The unit type is used for identification on the can bus.
The ID numbers of this board are:
Machine ID = 1
Hardware ID = 1
Unit type = 5
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The AC control board comprises a switched voltage regulator. This is used in order to
provide galvanic separation of the IGBT drive voltages, 4 x 17 V and 4 x -11 V. The voltages
can be tested by checking the gate signals to the AC power board, see "Checking the gate
signals to AC power board 18AP2", page 88. If the -11 volt is outside the limits 10.45 to
11.55 V, fault code 9 is displayed.
The +5 V and +15 V are used for internal power supply on the board.
If the +5 V is outside the limits 4.75 to 5.25 V, fault code 4 is displayed.
If the +15 V is outside the limits 14.25 to 15.75 V, fault code 8 is displayed.
Measuring points are shown in "18AP1 Component positions", page 50.
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5.8.2 18AP1:2 CAN bus
Bus communication circuits

The circuit board includes a driver for the CAN bus, IC17, which looks after communication
with the other units of the system.
Starting sequence
On power-up, the board's CAN controller reads in the bus speed from the micro processor:
400 kbit/s.
The light-emitting diodes D30, D31 and D32 displays the starting sequence from power-up:
D30 lights red. Then D30, D31 and D32 lights green.
When the board has been initiated, and the power source is in the application program, D30
flashes continously with a green light.
LEDs D30, D31 and D32 on circuit board 18AP1

Read more about the CAN bus in "20AP1:3 The CAN bus", page 57.
0740 800 172 - 46 - © ESAB AB 2018

Principle diagram of the temperature monitoring circuits

The temperature monitoring circuit senses the temperature of the IGBT modules, IC1 and
IC2, that are fitted to circuit board 18AP2. Two NTC resistors, NTC_IC1 and NTC_IC2, are
used as sensors.
The output of the monitoring circuit is sensed by the processor, which in turn controls the
cooling fans and stops the equipment if overtemperature occurs. The fan control circuit is
described in "18AP1:5 Fan control", page 48.
If the temperature exceeds 110 °C the power source is stopped. It cannot be restarted until
the temperature is below 55 °C.
If overtemperature is sensed by NTC_IC1, fault code 7 is displayed and if overtemperature
is sensed by NTC_IC2, fault code 6 is displayed.
To check the NTC resistors: see "Checking the gate signals to AC power board 18AP2",
page 88.
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5.8.4 18AP1:4 Arc voltage monitoring
The arc voltage monitoring circuits measures the output voltage from the power source. The
voltage is displayed by the control panel.
See "AC TIG machines, calibration of the arc voltage display", page 103 for calibrating
instructions.
The welding process control and no-load voltage reduction are maintained by circuit board
20AP1, see "20AP1:9 Arc voltage feedback", page 62.
The fan speed depends on the temperature of the IGBT modules on circuit board 18AP2,
see "18AP1:3 Temperature monitoring", page 47.
When the mains power supply is turned on, the fans are off.
When the temperature increases to:
• 40 °C they run at low speed.
• 50 °C they run at high speed.
When the temperature decreases to:
• 40 °C they run at low speed.
• 30 °C they are stopped.
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5.8.6 18AP1:6 Switch driver
See also "18AP2:1 Switching circuits", page 51.
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5.9 18AP2 AC power board

The AC power board is fitted to the Tig 3000i AC/DC. Sections 18AP2:1 to 18AP2:3 refer to
the wiring diagram in "Tig 3000i AC/DC", page 22.
5.9.1 18AP2:1 Switching circuits
The circuit board carries two IGBT modules IC1 and IC2, with 2 IGBTs each. In the
description below the IGBTs are named IGBT1, IGBT2, IGBT3 and IGBT4.
The IGBTs are controlled by the processor.
All IGBTs are conducting during the starting sequence of the power source (mains switch
power on).
MMA
IGBT1 and IGBT4 are conducting. If MMA with negative electrode is selected, IGBT2 and
IGBT3 are conducting.
TIG DC
When welding start is activated IGBT1 and IGBT4 conducts. During welding IGBT2 and
IGBT3 are conducting.
TIG AC
When welding start is activated IGBT1 and IGBT4 conducts. During welding IGBT1 and
IGBT4 conducts in turns with IGBT2 and IGBT3.
IGBT gate signals
The IGBT gate signals can be measured across resistors R10, R11, R20 and R21. See
"Checking the gate signals to AC power board 18AP2", page 88 for test instructions.
0740 800 172 - 51 - © ESAB AB 2018


See "18AP1:3 Temperature monitoring", page 47.
See "18AP1:5 Fan control", page 48.
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5.10 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
unit.
Depending on the type of control panel, the power source control board is set up for combi
mode or power source mode.
In combi mode the board handles the control of the power source, the welding data unit and
the MMC panel.
In power source mode it handles the control of the power source. The MMC panel and
welding data unit are controlled by a board fitted in the MMC panel.
There are two hardware versions of the control board, for identification see "20AP1 Circuit
board versions", page 65.

Spare part boards
There are four boards, one for power source mode and three for combi mode, one for each
control panel. When replacing the board, do not forget to move the “terminal D jumper” and
the “Y2-Y3 jumper” to the new board. See "Terminating resistors", page 59 and
"20AP1:9 Arc voltage feedback", page 62.
CAUTION!
This circuit board looks identical to the control board used in other power sources,
but there are differences both in hardware and software. If wrong board is used, it
might cause serious damage to the power source. Make sure that the
replacement board has correct article number, see the spare parts list.

Mig L3000i, Mig C3000i, Tig 3000i and Tig 3000i AC/DC, power source unit
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 "Service aid", page 79.
• The machine ID defines which type of power source the board is intended for.
• The unit type is used for identification on the CAN bus.
The ID numbers of the power source units are:
Mig L3000i Mig C3000i Tig 3000i Tig 3000i AC/DC

Machine ID = 22 22 22 or 45* 22
Hardware ID = 3 or 9* 3 or 9 3 or 9* 3
Unit type = 2 2 2 2
* = only for spare parts
Hardware ID 3 is used for version 1 of 20AP1

0740 800 172 - 54 - © ESAB AB 2018

Tig 3000i TA23, Tig 3000i TA24 and Tig 3000i TA24 AC/DC, welding data unit and MMC
The ID numbers above refers to the power source control. The machine ID for the MMC part
of the board determines which type of control panel that is used.
The ID numbers of the MMC units are:
TA23 TA24 TA24 AC/DC
Machine ID = 21 20 19
Hardware ID = 3 or 9* 3 or 9* 3
Unit type = 0 0 0
* = only for spare parts
+24 V Internal and external power supply.

+15 V Internal power supply on 20AP1.
-15 V Internal power supply on 20AP1.
+5 V Internal power supply on 20AP1.
+2.5 V Internal power supply on 20AP1.
Uan 5 V internal reference voltage on 20AP1.
Uref 2.5 V internal reference voltage on 20AP1.
0740 800 172 - 55 - © ESAB AB 2018

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 110 A, the fans run at low
speed, supplied at about 18 V. At load currents above 110 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.
If the welding current is above 110 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.
If overtemperature is detected, the fans run at high speed until the power source has cooled
down to normal temperature.
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5.10.3 20AP1:3 The CAN bus
A standardised communication (CAN - Controller Area Network) bus is used for

communication between the units of the equipment. Communication speed is 400 kbit/s.
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.
Voltage regulator VR1 supplies a 5 V power supply to the CAN circuits on 20AP1.
Bus communication circuits to and from the control board
0740 800 172 - 57 - © ESAB AB 2018

Starting sequence
On power-up, the board's CAN controller reads in the bus speed from the micro processor:
400 kbit/s.
The circuit board displays the starting sequence from power-up.
LED1 lights red. Then LED1, LED2 and LED3 lights green.
When the board has been initiated, and the power source is in the application program,
LED1 flashes continously with a green light.
LEDs on circuit board 20AP1

5.10.3.1 Communication interruptions
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:
• 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 connector socket XS3.
• All screen connections must be sound. Measure the resistance between the shell of
the CAN connector connected to the MMC unit and the shell of the most distant CAN
connector on the CAN bus. There must be a short circuit between those two end
points.
• Good contact with the chassis connections from/to the control board and suppressor
capacitors. See the main circuit diagram.
• 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.
0740 800 172 - 58 - © ESAB AB 2018

5.10.3.2 Terminating resistors
In order to avoid communication interference, the ends of the CAN bus must be terminated
by resistive loads.
Principle diagram of the CAN bus and connecting up of the terminating resistors
One end of the CAN bus of the Mig power sources is at the welding data unit, which
incorporates a terminating resistor. The other end is in the power source and it must be fitted
with a terminating resistor, R28 in the circuit diagram in "20AP1:3 The CAN bus", page
57. If a CAN remote control with terminating resistor is connected to the power source,
the terminating resistor must be disconnected from the power source. To disconnect the
terminating resistor: remove the jumper from terminal D.
Terminal D, version 2 of 20AP1 Terminal D, version 1 of 20AP1

The CAN remote controls and CAN adapters have a built-in terminating resistors. This
resistors can be connected or disconnected by moving a jumper: See the service manual for
the CAN based remote controls.
0740 800 172 - 59 - © ESAB AB 2018

Principle diagram of the temperature monitoring circuits

resets at 50 °C.
NTC D1 and NTC D2 are fitted inside the diode modules D1 and D2.
NTC R28 is fitted on the cupper foil of circuit board 15AP2.
NTC IC3 and NTC IC8 are fitted inside the IGBT modules IC3 and IC8.
If the monitoring circuit operates, the power source is stopped. The power source cannot be
restarted until it has cooled sufficiently.
5.10.5 20AP1:5 Overvoltage and undervoltage protection

See "15AP1:3 Overvoltage and undervoltage protection", page 36.
5.10.6 20AP1:6 Relay driver stages
The relay driver stages are only used in the Tig 3000i and Tig 3000i AC/DC.
See "10AP1 Tig board", page 27.
5.10.7 20AP1:7 Gate pulses

See "15AP1:5 Gate driver stages and switching circuits", page 38.
0740 800 172 - 60 - © ESAB AB 2018

5.10.8 20AP1:8 Current sensor
The current signal supplied to contact S3 on circuit board 20AP1 is 150 mA at 300 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 gives 3.91 x
0.05 = 0.195)
If circuit boards 20AP1 or 15AP3 are replaced, the equipment must be recalibrated. See
"Calibrating the current sensor signal", page 99 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.
0740 800 172 - 61 - © ESAB AB 2018

5.10.9 20AP1:9 Arc voltage feedback
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.
The signal from the arc voltage feedback is used as an input 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 open-circuit voltage
reduction function.
The arc voltage feedback provides a voltage signal to the display panel of the MIG and DC
TIG power sources.
MIG: see "MIG machines, calibration of the arc voltage feedback", page 100 for
instructions for calibrating the arc voltage display.
DC TIG: see "DC TIG machines, calibration of the arc voltage feedback", page 102 for
AC TIG: see "AC TIG machines, calibration of the arc voltage display", page 103 for
0740 800 172 - 62 - © ESAB AB 2018

Methods of measuring the arc voltage

Tig 3000i AC/DC: see "18AP1:4 Arc voltage monitoring", page 48 for description of the
arc voltage monitoring. Various methods of measurement are available. The jumper
between contacts Y2 and Y3 must always be connected.
• Welding with the filler wire positive: voltage sensing from the wire.
This is the commonest arrangement for MIG welding.
This method of measurement compensates for the voltage drop in the supply
conductor (= to the welding torch). The input signal is measured between inputs X1
and W2. Amplifier IC8:14 is active.
• Welding with the filler wire negative: voltage sensing from the wire
This method of measurement compensates for the voltage drop in the supply
conductor. The input signal is measured between inputs X1 and W5. Amplifier IC8:8 is
active.
• Welding with the filler wire positive or negative, without external sensing from
the wire or workpiece.
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.
5.10.9.1 Open-circuit voltage control
The open-circuit voltage control is active when:

• there is an open welding circuit and no arc.
The open-circuit voltage control is inactive when:
• the HF ignition is activated during TIG welding with HF.
• there is contact between electrode and workpiece.
• there is an arc.
Version 1 of 20AP1
The open-circuit voltage control holds the voltage at about 70 V.
Version 2 of 20AP1
High level control:
The mean value of the open-circuit voltage is 58 V (55 - 60 V).
Low level control:
The open-circuit voltage is < 35 V (24 - 30 V). The low level control can only be activated or
deactivated by the ESAT, see "Service aid", page 79.
The low level control is also named the VRD function, Voltage-Reducing Device.
Monitoring:
The processor monitors the open-circuit voltage (OCV). If the mean value of the OCV
exceeds the actual limit for more than 0.3 seconds after conclusion of welding, the output
voltage is turned off and the display shows fault code 16.
• OCV limits before software version 1.15: 60 V respectively 30 V.
• OCV limits from software version 1.15: 62 V respectively 32 V.
0740 800 172 - 63 - © ESAB AB 2018

All welding methodes, all versions of 20AP1

If the welding arc extinguishes the open circuit voltage is about 90 V, peak voltage. Within
0.3 seconds the open-circuit voltage is at a level controlled by the open-circuit voltage
control or at a lower level.
NOTE!
Spare part boards are delivered with the VRD function deactivated.
See "20AP1 Circuit board versions", page 65 for identification of circuit board versions.
MIG welding mode

1. The torch switch is pressed.
2. The power source generates open-circuit voltage.
3. Welding starts, the open-circuit voltage control is inactive.
4. Welding stops, the open-circuit voltage control is activated and then the output
voltage is shut down.
MMA welding mode

2. Contact between electrode and workpiece. When the open-circuit voltage goes
below 45 V (16 V when VRD is active), the open-circuit voltage control is disabled.
3. When the current exceeds 8 A the hot start current is activated.
4. When the arc voltage exceeds 52 V, welding stops and the open-circuit voltage
control is activated.
TIG welding mode

HF start
For TIG welding with HF starting, the open-circuit voltage is 86 - 90 V, while the starting
function is active. This is normally a maximum of 0.5 seconds.
Live TIG start
2. When there is contact between electrode and workpiece. The power source
produces a current of about 24 A.
3. When the electrode is lifted from the workpiece. The arc strikes, the open-circuit
voltage control is deactivated and the current increases to 30 A.
4. When the arc voltage exceeds 8 V, the current increases / decreases to the set
current.
5. If the arc voltage is above 45 V for more than 100 milliseconds the open-circuit
voltage control is activated.
5.10.10 20AP1:10 Control panel interface circuits

These circuits are only used by the Tig 3000i and Tig 3000i AC/DC. See the service manual
for the TA23, TA24 and TA24 AC/DC control panels.
0740 800 172 - 64 - © ESAB AB 2018

5.10.11 20AP1 Circuit board versions
There are two hardware versions of the control board. See "Open-circuit voltage control",
page 63 for description of the difference in function between the two versions.
The hardware ID and/or the print number of the circuit board is used to identify the hardware
version of the board.
To read the hardware ID you need the ESAT service kit, see "Service aid", page 79.
The print number is to the right in the component positions diagrams in "20AP1 Component
positions, version 1", page 66 and "20AP1 Component positions, version 2", page 67.
(The print number is NOT the same as the ordering number of the board.)
Version 1 of 20AP1:
Hardware ID 3. Print numbers up to and including 487200-003.
Power sources with serial no. 535-xxx-xxxx, 612-xxx-xxxx, 613-xxx-xxxx and 802-xxx-xxxx
are delivered with version 1 of 20AP1.
Version 2 of 20AP1:
Hardware ID 9. Print numbers from 487200-004 and there above.
Power sources with serial no. 950-xxx-xxxx and there above are delivered with version 2 of
20AP1.
Spare parts:
Version 2 of 20AP1 is delivered as spare part to all power sources, except for the Tig 3000i
AC/DC.
0740 800 172 - 65 - © ESAB AB 2018

5.10.12 20AP1 Component positions, version 1
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5.10.13 20AP1 Component positions, version 2
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5.11 CAN adapter option Mig C3000i
Pull motor option with wire feed speed adjustment 0459 681 891
The pull motor option with CAN adapter is used when a welding torch with pull motor and
wire feed speed adjustment is connected to the wire feeder.
The adapter board has a software identity, machine ID. The ID defines how the welding
equipment reacts on the commands from the connected equipment. The CAN adapter
options are delivered with correct machine ID. Spare part boards are delivered without
machine ID. To read or change the machine ID you need the ESAT service kit, see "Service
aid", page 79.
The adapter board is delivered with machine ID 7.
The CAN adapter board has a built-in terminating resistor. The resistor is disconnected on
delivery of this option. In most operating cases it should be disconnected. It can however be
connected by a jumper on the CAN adapter board.
Can adapter board, filter board and cable set connected to the control board of the wire
feeder
Switch 13S2 is used for activating / deactivating the wire feed speed potentiometer on the
welding torch. When the switch is in position B, the potentiometer on the torch is active and
the control panel of the feeder is inactive. In position A the control panel is active and the
potentiometer on the torch is inactive.
0740 800 172 - 68 - © ESAB AB 2018

5.11.1 Connection instructions
0740 800 172 - 69 - © ESAB AB 2018

6 REMOTE CONTROLS
6 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 0740 800 170.
0740 800 172 - 70 - © ESAB AB 2018

7 FAULT CODES
7 FAULT CODES
Fault codes are used in order to indicate and identify a fault in the equipment.
7.1 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 equipment must be connected to the ESAT: see service tools in "Service aid", page
79.
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 U1 = cooling unit U2 = power source
U3 = wire feed unit U4 = remote control unit U5 = AC unit
7.2 Summary of fault codes
Fault Description Welding Cooling Power Wire Remote AC unit

code data unit unit source feed control
unit unit
1 Memory error, EPROM X X X X X X
2 Memory error, RAM X X X X X
3 Memory error, external X X X X
RAM
4 +5 V power supply X X X
5 Intermediate DC voltage X
outside limits
6 High temperature X X X
7 High temperature X
8 Power supply 1 X X X X X X
9 Power supply 2 X X X X
10 Power supply 3 X
11 Wire feed speed servo X
12 Communication error X X X X X X
(warning)
13 High temperature external X
14 Communication error (bus X
off)
15 Lost messages X X X X X
16 High open-circuit voltage X X
(VRD)
0740 800 172 - 71 - © ESAB AB 2018

7 FAULT CODES
Fault Description Welding Cooling Power Wire Remote AC unit

code data unit unit source feed control
unit unit
17 Lost contact with the wire X
feed unit
18 Lost contact with the power X
source
19 Memory error in data X
memory
20 High inductance in the X
welding circuit
22 Transmitter buffer overflow X X X X X
23 Receiver buffer overflow X X X X X
25 Lost contact with AC unit X
26 Program operating fault X X
27 Out of wire X
28 Stack overflow X X X X X
29 No cooling water flow X
32 No gas flow X
40 Incompatible units X
41 Lost contact with the X
cooling unit

7.3 Fault code description

This manual describes the fault codes for the power source, the AC unit and the built-in wire
feed unit. The fault codes for the other units are described in the manuals for these units.
7.3.1 Power source
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 power source. 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 performed only on initiation after power-up. This fault
does not disable any functions.
Action: Restart the power source. If the fault persists, replace circuit board 20AP1,
which carries the microprocessor chip.
0740 800 172 - 72 - © ESAB AB 2018

7 FAULT CODES
Code Description
3 Error in external RAM
Read/write test of the processor's internal external RAM. This test is preformed only
as part of initiation after power-up. The microprocessor is unable to read/write from/to
a particular memory address in its external memory. This fault does not disable any
functions.
4 5 V power supply too low
The unregulated power supply voltage (+30 V) 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.
5 Intermediate DC voltage outside limits
The DC voltage from the main rectifier, 2BR1, 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 "15AP1:3
Overvoltage and undervoltage protection", page 36.
6 High temperature
The temperature monitoring circuit has operated. The power source is stopped, and
cannot be restarted until the circuit has reset. See also "15AP1:2 Temperature
monitoring", page 35, "15AP2:2 Temperature monitoring", page 42 and
"20AP1:4 Temperature monitoring", page 60.
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 to 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 to -16.4 V. This
The voltage is too high or too low: it must be within the range 22.1 to 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 "20AP1:3 The CAN bus", page 57.
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
"20AP1:3 The CAN bus", page 57.
0740 800 172 - 73 - © ESAB AB 2018

7 FAULT CODES
Code Description
16 High open-circuit voltage (VRD)The open-circuit voltage has been too high.
the arc voltage feedback: see "20AP1:9 Arc voltage feedback", page 62.
20 High inductance in the welding circuit
The power source cannot produce the desired current because the measured
inductance in the welding circuit is too high. The fault indication is reset if the
inductance reading receives a sufficiently low value at weld start. Resetting can also
be achieved by turning off the power.
Action: Use shorter welding cables and ensure that the cables are not coiled up.
Place the welding cable and connector cable next to each other. If possible, the
inductance can be reduced by welding with a shorter arc.
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.
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.

0740 800 172 - 74 - © ESAB AB 2018

7 FAULT CODES
7.3.2 AC unit
Code Description
effects.
functions.
4 5 V power supply too low
The unregulated power supply voltage (+30 V) 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.
the power supply to circuit board 18AP1.
6 High temperature NTC_IC2
monitoring", page 47.
7 High temperature NTC_IC1
monitoring", page 47.
9 -11 V power supply on circuit board 18AP1
0740 800 172 - 75 - © ESAB AB 2018

7 FAULT CODES
Code Description
the bus.
Action: Check the equipment to ensure that only one remote control unit is
connected. See also "Service aid", page 79.
13 High temperature external
cannot be restarted until the circuit has reset.
Fault code 13 does not normally occur at standard equipment. The sensing input is
bridged by a resistor on circuit board 18AP1, see "18AP1:3 Temperature monitoring",
page 47.
15 Lost messages
high speed.
microprocessor.
28 Stack overflow

0740 800 172 - 76 - © ESAB AB 2018

7 FAULT CODES
7.3.3 Wire feed unit
Code Description
effects.
functions.
11 Wire feed speed
The wire feed speed differs from the set value by more than 1.5 m/min for more than
5.1 seconds. This fault stops the wire feed.
the bus.
Action: Check the equipment to ensure that only one remote control unit is
connected. See also "20AP1:3 The CAN bus", page 57.
15 Lost messages
high speed.
0740 800 172 - 77 - © ESAB AB 2018

7 FAULT CODES
Code Description
microprocessor.
27 Out of wire
The wire feed unit is not feeding any wire. The current welding process will be
stopped, and cannot be restarted.
Action: Load new wire.
At present, wire monitoring is fitted only to special versions of wire feed units.
28 Stack overflow
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 wire feed units.
0740 800 172 - 78 - © ESAB AB 2018

8 SERVICE INSTRUCTIONS
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
8.1 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.
8.2 Service aid

We can offer a number of service tools that will simplify the service.
0740 800 172 - 79 - © ESAB AB 2018

Antistatic service kit

Ordering no. 0740 511 001
The kit makes it easier to protect sensitive
components from electrostatic discharge.
Contents:
• A conductive mat (size 610×610 mm /
24×24 in)
• A 1.5 m (3.28 ft) long ground cable with
a crocodile clip
• An adjustable wrist strap and cable with
a built-in protective resistor
Antistatic service kit
ESAT service kit
The software update is made from a PC, it has to be managed by a trained serviceman. For
this a PC 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. ESAT also contains service functions by which it
is possible to control, change or read the different functions of the equipment.
For the installation and use of the ESAT you need a PC with operating system Windows.
The ESAT service kit contents:
• CAN adapter with connection cables
• CD with software
• Instruction manual for ESAT
USB2CAN for connection to the USB port of the PC - ordering no: 0458 847 881
8.3 Special tools

Soft-starting tool SST 2
The SST 2 is originally made for the 3000i series. (From March 2008 it is delivered with an
adapter cable so that it also can be used for the 4000i and 5000i series, from serial no.
803-xxx-xxxx.)
Ordering no. 0460 040 880.
0740 800 172 - 80 - © ESAB AB 2018

8.4 Checking power board 15AP1
Disconnect the power source from the mains and follow the instructions below. The numbers
of the instructions refer to the diagrams on this and next page.
1. The thyristor in IC8 is connected in
parallel with resistors R16 and R15.
The resistance must be 24 ohm.
2. Modules IC8 and IC3: Measure the
resistance between collector and
gate of the transistors, it must be
higher than 100 kohm.
All transistors must have
approximately the same resistance
value.
A faulty transistor is in most cases
short-circuited between collector
and gate.
3. Use a multimeter in diode test
position. Measure with the positive
and negative of the multimeter
connected as shown in the pictures.
The main transformers must be
connected to the circuit board.
The forward voltage drop of the
deenergization diode connected in
parallel with the antiparallel diode of
the transistor must be 0.3 to 0.5 V.
4. The NTC resistors that senses the
temperature are connected in a
resistance network. When the
temperature of the module is 20°C,
the resistance between pins 18 and
19 is about 1.6 kohm.
Depending of the temperature of
the module, the resistance may be
in the range of 0.5 to 10 kohm.
The treshold level for
overtemperature is 390 ohm.
Both NTC resistors must have the
same resistance value.
0740 800 172 - 81 - © ESAB AB 2018

Power board 15AP1, measuring points
0740 800 172 - 82 - © ESAB AB 2018

8.5 Checking secondary board 15AP2

Disconnect the equipment from the mains and follow the instructions below. The item
numbers below refer to the circuit and component position diagrams on this and next pages.
Checking the diode modules
1. Remove the screws marked 1a and 1b. see illustrations on this and the following
pages.
a) Insert a thin insulating material between connection T11 and transformer
15TM1.
b) Insert a thin insulating material between connection T22 and transformer
15TM2.
○ Be very careful when inserting the insulation. If the board is bent too much,
the components on it will be destroyed.
2. Use a multimeter in diode test position.
a) Measure with the positive and negative of the multimeter connected as
shown in the pictures.
The forward voltage drop of the diodes must be 0.2 to 0.45 V. The voltage
drop over the freewheel diodes is slightly lower than the voltage drop over
the rectifier diodes. This because the freewheel diodes are connected in
parallel.
b) Remove the insulation between the transformers and the circuit board.
Refit the screws, 1a and 1b, tighten the screws on the circuit board to the
torque that is shown in the picture in "Diode modules 15D1, 15D2 and
secondary board 15AP2", page 97.
0740 800 172 - 83 - © ESAB AB 2018

Checking the NTC resistors

The NTC resistors that senses the temperature are connected in a resistance network.
3. When the temperature of the diode
module is 20°C, the resistance between
pins 3 and 4 is about 1.8 kohm.
Depending of the temperature of the
module, the resistance may be in the
range of 0.5 to 10 kohm. The treshold
level for overtemperature is 390 ohm.
Both NTC resistors must have the same
resistance value.
4. NTC_R28 is fitted on the cupper foil of
the circuit board. When the temperature
is 20°C, the resistance is about 2.3
kohm.
Depending of the temperature, the
resistance may be in the range of 0.5 to
10 kohm.
0740 800 172 - 84 - © ESAB AB 2018

Secondary board 15AP2, measuring points
0740 800 172 - 85 - © ESAB AB 2018

8.6 Checking the IGBT modules of AC power board 18AP2
Disconnect the equipment from the mains and follow the instructions below. The numbers of
the instructions refer to the diagrams on this and next page.
Before measuring: disconnect connector 18XS3 from terminal CN1 and the positive and
negative voltage supply bars from the circuit board.
1. Use a multimeter in diode test position. Measure with the positive and negative of
the multimeter connected as shown in the pictures. The forward voltage drop of the
diode must be 0.3 to 0.5 V.
2. Measure the resistance between collector and gate of the transistors, it must be
higher than 100 kohm. The measured resistance is partly depending on the meter
that is used, it may be in the range from 100 kohm to 4 Mohm. A faulty transistor is
in most cases short-circuited between collector and gate.
3. Measure the resistance between emitter and gate of the transistors, it must be
about 100 kohm. The measured resistance is the resistance of the gate resistor. A
faulty transistor may have a short-circuit between emitter and gate.
4. To check the NTC resistors:
a) Measure between pin 19 and 20 on each one of the modules.
b) The resistance must be 4 to 6 kohm at 20 °C.
Circuit diagram AC power board 18AP2, measuring points IGBT modules
0740 800 172 - 86 - © ESAB AB 2018

Component positions AC power board 18AP2, measuring points IGBT modules
0740 800 172 - 87 - © ESAB AB 2018

8.7 Checking the gate signals to AC power board 18AP2
The gate voltage is +15 V when the IGBTs are conducting.

The gate voltage is -10 V when the IGBTs are open.
Measure the gate voltage across resistors R10, R11, R20 and R21.
Measuring points a and b in the diagram.
1. Switch on the power source
2. Select MMA mode and positive polarity. IGBT1 and IGBT4 must be conducting.
3. Select MMA mode and negative polarity. IGBT2 and IGBT3 must be conducting.
If the gate voltage is missing at any of the measurings, check the output from 18AP1 by
measuring across measuring points c and b in the diagram.
Circuit diagram AC power board 18AP2, measuring points gate signals
0740 800 172 - 88 - © ESAB AB 2018

Component positions AC power board 18AP2, measuring points gate signals
0740 800 172 - 89 - © ESAB AB 2018

8.8 Soft starting
We recommend soft starting of the power source after replacing control circuit board 20AP1
or circuit boards or components in the power module. This supplies the power module with a
low DC 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 power source should be made only during soft starting.
The following description refers to the use of soft starting tool SST 2.
Changing wire connections prior to soft starting
1. Disconnect the power source from the mains supply.
2. Disconnect wires 1592 red (+) and 1591 black (-) from circuit board 15AP1.
3. Insulate the wires from each other and from all other parts.
4. Connect soft starting tool SST 2 to 20AP1 and 15AP1 as shown below. Connector
C must only be connected if there is an interuption in the temperature monitoring
circuits.
SST 2 connected to 20AP1 and 15AP1
Measurements
The item numbers below refer to the circuit and component position diagrams on pages 78
and 79.
1. Connect the power source to the mains and switch it on.
2. 24 V AC from transformer 2TC1: must be 21 - 27 V
3. + 24 VA: must be 24 V ±5%.
4. + 15 VA: must be 15 V ±5%.
5. + 5.1 V, reference voltage for the over-/under voltage and temperature monitoring
circuits: must be 5.1 V ±5%.
Set the power source to the MMA mode. The voltage levels given below are depending on
the input voltage from SST 2. If this voltage is higher or lower than in this description, the
other voltages will change correspondingly.
6. Terminals CN09 1 and 2, intermediate voltage from SST 2: 23.4 V.
7. Intermediate voltage after the charge resistors and the short-circuiting thyristor: 23.4 V
8. The voltage across each one of the filter capacitors: 11.7 V. It is important that the
voltage is the same over both of the capacitors.
0740 800 172 - 90 - © ESAB AB 2018

9. Gate pulses from 20AP1.

• Measure with the screen (gnd) connected to +24 V.
• The pulse frequency must be 40 kHz ±1 kHz.
• The pulse duration must be 41-44% of the cycle time, measured at -10 V of the
negative pulse, as shown in the graph below.
• If there is an interruption in the connection to the pulse transformer, the pulses are
shaped as shown in the graph below
10. Gate pulses to the IGBTs.

• Measure with the probe connected to the gate.
• The pulse frequency must be 40 kHz ±1 kHz.
• The pulse duration must be 40-44% of the cycle time, measured at +5 V, as shown
in the graph below.
0740 800 172 - 91 - © ESAB AB 2018

11. Primary side of the main transformers

• Measure with the probe connected to DR1 and DR2 respectively.
• The shape of the pulses must be as in the graph below.
12. Secondary side of the main transformers

• Measure with the probe connected to T11 and T22 respectively.
• The shape of the pulses must be as in the graph below.
13. Measure the output voltage from the welding current terminals, XS1 and XS2. It must be
about 2.9 to 3.1 V.
0740 800 172 - 92 - © ESAB AB 2018

Soft starting measuring points
0740 800 172 - 93 - © ESAB AB 2018

Soft starting measuring points, power board 15AP1
0740 800 172 - 94 - © ESAB AB 2018

8.9 Mounting components on the heat sink

8.9.1 Thermal paste
Apply thermal conducting paste to the components before fitting them to the heat sink.
See the spare parts list for the order number for thermal paste. Use only the paste
recommended by us.
1. Start by cleaning the heat sink from dirt and old thermal paste.
2. 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 already have good thermal contact.
3. Mount the components as described below.
8.9.2 Rectifier bridge 2BR1
1. Clean the heat sink and apply thermal conducting paste as described above.
2. Fit the bridge and tighten the screws to a torque of 1 Nm, and then further tighten
them to 4.5 Nm.
3. Tighten the screws that connect the bridge to circuit board 2AP1 to 4.5 Nm.
Fitting of rectifier bridge 2BR1 and circuit board 2AP1
0740 800 172 - 95 - © ESAB AB 2018

8.9.3 Power board 15AP1 with semicunductor modules
1. Clean the heat sink and apply thermal conducting paste to the semiconductor
modules as described in "Mounting components on the heat sink", page 95.
2. Fit the board and tighten the screws that are securing the IGBT modules to the
heat sink to a torque of 2.5 Nm, and then further tighten them to 4.5 Nm.
WARNING!
Incorrectly fitted components can cause failure. Do not tighten the
screws to more than 4.5 Nm.
3. Tighten the remaining screws on the circuit board to the torque that is shown in the
picture below.
NOTE!
If capacitors 15C1, 15C2 or transformers 15TM1, 15TM2 have to be
replaced, the power board must be removed and then refitted as
described above.
Fitting of circuit board 15AP1
0740 800 172 - 96 - © ESAB AB 2018

8.9.4 Diode modules 15D1, 15D2 and secondary board 15AP2
1. Fit the diode modules to secondary board 15AP2.

2. Tighten the connection screws to a torque of 4.5 Nm, see the picture below.
3. Solder pins 3 and 4 of the diode modules to circuit board 15AP2.
Fitting of diode modules 15D1 and 15D2 to circuit board 15AP2
4. Clean the heat sink and apply thermal conducting paste to the diode modules as
described in "Mounting components on the heat sink", page 95.
5. Fit the the circuit board with the diode modules to the heat sink.
6. Tighten the screws that holds the modules on the heat sink to a torque of 2.5 Nm, and
then further tighten them to 4.5 Nm.
7. Tighten the remaining screws as shown in the picture below.

WARNING!
NOTE!
If transformers 15TM1 and 15TM2 have to be replaced, the secondary
board and the diode modules must be removed and then refitted.
Fitting of circuit board 15AP2 with diode modules
0740 800 172 - 97 - © ESAB AB 2018

8.9.5 AC power board 18AP2 with IGBT modules
1. Clean the heat sink and apply thermal conducting paste to the semiconductor
modules as described in "Mounting components on the heat sink", page 95.
2. Fit the board and tighten the screws that are securing the IGBT modules to the
heat sink to a torque of 2.5 Nm, and then further tighten them to 4.0 Nm.
WARNING!
3. Fit the three supporting screws and tighten them to 4.0 Nm.
4. Fit the busbars to the IGBTs and tighten the screws to 4.0 Nm.
Fitting of circuit board 18AP2
0740 800 172 - 98 - © ESAB AB 2018

8.10 Calibrating the current sensor signal
1. Connect the power source to a resistive load.

2. Connect a calibrated shunt in series with the load.
3. Set the power source to MMA mode.
4. Set a welding current of 100 A.
5. Load the power source so that the voltage across the load is 24 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 100 A ±1 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.
0740 800 172 - 99 - © ESAB AB 2018

8.11 MIG machines, calibration of the arc voltage feedback
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 jumper 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 torch 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
power source.
Positions of potentiometers R87 and R103 on circuit board 20AP1
0740 800 172 - 100 - © ESAB AB 2018

1. Welding with the filler wire positive: voltage sensing from the wire This is the most
common 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

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

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.
0740 800 172 - 101 - © ESAB AB 2018

8.12 DC TIG machines, calibration of the arc voltage feedback
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.
Use an accurately calibrated external voltmeter to measure the voltage at the welding
current terminals.
Disconnect the HF transformer 10TV1 by disconnecting plug 10XS1 from terminal F on
circuit board 10AP1: see the circuit diagram in "Tig 3000i", page 20. Set the power
source to the MMA welding mode.
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.
Position of potentiometer R87 on circuit board 20AP1
0740 800 172 - 102 - © ESAB AB 2018

8.13 AC TIG machines, calibration of the arc voltage display
The arc voltage that is displayed by the equipment can be calibrated using trimming
potentiometer R4 and R5 on circuit board 18AP1. The board has been calibrated in the
factory: further adjustment should not normally be necessary.
Use an accurately calibrated external voltmeter to measure the voltage at the welding
current terminals.
Set the power source to the MMA welding mode.
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 potentiometer R5, adjust the value shown on the display so that the voltage
The difference between the measured and the displayed voltages compensates for
the voltage drop in the welding current cables.
3. Select DC(-) on the control panel (reversed polarity).
4. Using potentiometer R4, adjust the value shown on the display so that the voltage
Position of potentiometers R4 and R5 on circuit board 18AP1
0740 800 172 - 103 - © ESAB AB 2018

9 SPARE PARTS
9 SPARE PARTS
The spare parts list is published in a separate document that can be downloaded from the
Internet: www.esab.com
File name Product
0459 839 002 Mig L3000i and Mig C3000i
0459 839 006 Tig 3000i and Tig 3000i AC/DC
0740 800 172 - 104 - © ESAB AB 2018

9 SPARE PARTS
0740 800 172 - 105 - © ESAB AB 2018

For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com

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Origo™, Aristo®

Mig L3000i, Mig C3000i,

1 READ THIS FIRST.................................................................................... 5

0740 800 172 © ESAB AB 2018

5.7.2 15AP2:2 Temperature monitoring......................................................... 42

6 REMOTE CONTROLS .............................................................................. 70

0740 800 172 © ESAB AB 2018

7.3 Fault code description ........................................................................... 72

9 SPARE PARTS ......................................................................................... 104

Rights reserved to alter specifications without notice.

0740 800 172 © ESAB AB 2018

1 READ THIS FIRST

0740 800 172 -5- © ESAB AB 2018

0740 800 172 -6- © ESAB AB 2018

Block diagram of the Mig C3000i.

0740 800 172 -7- © ESAB AB 2018

Mig L3000i, Mig C3000i

0740 800 172 -8- © ESAB AB 2018

0740 800 172 -9- © ESAB AB 2018

Tig 3000i AC/DC Tig 3000i

0740 800 172 - 10 - © ESAB AB 2018

4.1 Component description

0740 800 172 - 11 - © ESAB AB 2018

10C1, 10C2 Interference suppression capacitors.

0740 800 172 - 12 - © ESAB AB 2018

0740 800 172 - 13 - © ESAB AB 2018

4.2 Mig L3000i

0740 800 172 - 14 - © ESAB AB 2018

0740 800 172 - 15 - © ESAB AB 2018

4.3 Mig C3000i, valid from serial no. 613-xxx-xxxx to 209-622-xxxx

0740 800 172 - 16 - © ESAB AB 2018

0740 800 172 - 17 - © ESAB AB 2018

4.4 Mig C3000i, valid from serial no. 209-623-xxxx

0740 800 172 - 18 - © ESAB AB 2018

0740 800 172 - 19 - © ESAB AB 2018

4.5 Tig 3000i

0740 800 172 - 20 - © ESAB AB 2018

0740 800 172 - 21 - © ESAB AB 2018

4.6 Tig 3000i AC/DC

0740 800 172 - 22 - © ESAB AB 2018

0740 800 172 - 23 - © ESAB AB 2018

5.1 1 MMC module

Control panel MA6 or U6.

Control panel MA23 and MA23A.

Control panel MA24.

0740 800 172 - 24 - © ESAB AB 2018

Control panel TA23 or TA24.

Tig 3000i AC/DC:

Control panel TA24 AC/DC.

5.2 2AP1 Interference suppressor board and main rectifier

Circuit diagram, 2AP1

0740 800 172 - 25 - © ESAB AB 2018

Component positions, 2AP1 with terminal F

Component positions, 2AP1 without terminal F

0740 800 172 - 26 - © ESAB AB 2018

5.3 10AP1 Tig board

Circuit diagram of the TIG functions

5.3.1 10AP1:1 Power supply

5.3.3 10AP1:3 Gas valve

0740 800 172 - 27 - © ESAB AB 2018

5.3.5 10AP1:5 TIG Torch switch

5.4 13AP1 Wire feeder control board

0740 800 172 - 28 - © ESAB AB 2018

5.4.1 13AP1:1 Power supply