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Aristo 400
Welding power source
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Service manual
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INTRODUCTION
This service manual is intended for use by personnel with appropriate technical training, to
provide assistance with fault--tracing and maintenance.
The Aristo MED 44 wire feed unit is described in a separate service manual.
To assist in understanding operation of the machine, the instruction manual is included at the
end of the service manual.
This manual contains details of all design changes incorporated up to and including May
1993.
The edition date on the front page is followed by a one (9305 - 1), this means that the layout
has been altered, the contents are still the same as in the 9305 edition, however the spare parts
list is updated and includes all design changes up to January 1996.
Layout and presentation of the material are intended to assist in quickly locating and
correcting any faults in the machine.
Use the diagrams in the manual as starting points when tracing faults. The interconnection
diagram is accompanied by a list of the machines components in alphabetical and numerical
order.
The Aristo 400 has been designed and tested in accordance with the international EN
60 974--1 standard (IEC 974--1).
On completion of service or repair, 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.
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RATING PLATE
The rating plate is secured to the rear of the machine. The following points describe what the
various items on it mean.
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1 LUC 400 is the type designation for the Aristo 400. The first letter, L, indicates
that Aristo is a rectifier, while U indicates a universal power unit and C indicates
the design generation.
The numerals 400 indicate the maximum welding current.
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3 Indicates the voltage/current characteristic when MIG/MAG welding, over a
current range of 15 -- 400 A.
The voltages of 15 V and 34 V indicate that we comply with the international arc
voltage characteristic as specified in IEC 974--1.
X = The intermittence factor, i.e. the length of time for which welding can be
performed at the specified welding data, expressed as a percentage of a
ten--minute period.
I2 = Current at the respective intermittence factor.
U2 = Voltage in accordance with the arc voltage characteristic.
Uo = Open--circuit voltage.
6 IP21 indicates the enclosure class with respect to protection against entry of foreign
bodies and/or water.
This symbol indicates that the unit is designed for use in areas of elevated
electrical hazard.
7 The machines serial number, consisting of three groups of figures (xxx yyy zzz).
The first group (xxx) indicates the version. The numerals indicate the year and
week of approval of the design version.
The second group (yyy) indicates the year and week of the machines final testing:
e.g. 203 indicates 1992, week 3.
The final group (zzz) consists of three or four numerals and is a consecutive serial
number from 0001 to 9999.
8 Shows that ESAB complies with the international IEC 974--1 standard.
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THE INVERTER PRINCIPLE
The Aristo 400 is a transistorised power unit that operates on the inverter principle.
The 400 V 3--phase mains voltage is rectified by rectifier bridge VC1 and smoothed by
capacitor C01.
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On open circuit and with a 400 V mains supply, the voltage across C01 is 565 V. This voltage
is then switched rapidly to the primary windings (TM1 and TM2) of the main transformer.
The time interval is controlled by circuit board AP5, which provides control pulses to the
transistors in switching units A, B and C, D.
The switching pairs A and B (in one pair) and C and D (in the other) operate in anti--phase.
Each pair operates at 24 kHz, and the anti--phase connection means that the frequency on the
welding side is 48 kHz.
1. The output voltage from the upper switching pair, A and B (40% duty cycle)
2. The output voltage from the lower switching pair, C and D (40% duty cycle)
3. The output voltage from the two pairs together (80% duty cycle)
4. The current in the welding circuit
Each voltage pulse on the primary sides of transformers TM1 and TM2 produces a
corresponding voltage pulse on the secondary sides. These voltage pulses are rectified by
welding diodes V5 and V7. The welding current flows through the arc, shunt RS1 and
welding current inductors L1 and L2. The shunt provides a voltage signal proportional to the
current.
As the control pulses must lie within 39.5 -- 41.5% of a whole cycle, and as the switching
units operate in anti--phase, it might be thought that current flows for only a maximum of
83% of the cycle. However, this is not the case, as the current is maintained by inductors L1
and L2 and the freewheel diodes V6 and V8.
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COMPONENT DESCRIPTION, LUC 400
This component description refers to interconnection diagram on page 12.
AP1--AP4 Circuit board with switching units. Fault--tracing instruction are on page 35.
AP5 Main circuit board with control electronics: see the block diagram on page 14
and DESCRIPTION OF OPERATION, CIRCUIT BOARD AP5 on page 19.
AP6 Circuit board with two LEDs: LD1 (yellow) for fault indication and LD2
(green) for indication of cooling water flow.
The board also provides 22 V to indicating lamp HL1 (Mains On) from
transformer TC1. See also Fault tracing on page 28 .
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AP10 Display board, fitted in the welding settings control unit. See SETTING
BOX on page 47.
AP11 Circuit board in the welding settings control unit. See SETTING BOX on
page 47.
AP12 Interference suppression board, fitted by the OKC (welding current) terminals.
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FU4 Fuse, 0,5 A. Fitted in the connection between E4 on circuit board AP5 and the
negative terminal of capacitor C01.
Protects the overvoltage protection circuits on circuit board AP5.
KT1 Timer relay, delays closing of contactor QF1 by about one second.
This delay is necessary to allow the smoothing capacitors to charge up via R1.
L1 Upper welding inductor. The core of this inductor has a 2 mm airgap.
L2 Lower welding inductor. The core of this inductor has no airgap.
L3 Primary inductor, fitted together with C11 and R13 when TV1 or TV2 is fitted.
When these components are fitted, three resistors (R1) must be fitted, in order
to reduce the heat produced when charging the capacitors.
With C11 and R13, L3 forms a voltage stabilisation filter. This filter is needed
in order to reduce the voltage ripple that can occur as a result of the inductance
of TV1/TV2
When operating on a supply system with unstable voltage, the mains filter may
be needed for stabilisation of the supply voltage.
C11, L3, R13 and two of the R1 resistors can be ordered as Filter Set, under
part no. 468 925--880.
M1 Motor, cooling water pump.
HL1 Indicating lamp, 28 V. It is supplied at 22 V from TC1 via circuit board AP6.
The lamp is lit when switch SA1 is on.
QF1 Main contactor, energised when switch SA1 is on.
If the contactor does not open again after having been energised, it must be
replaced, as must also resistor R1 if it is burnt out.
R1 Resistor, 10 50 W. Three of these resistors are fitted in machines in which
C11, L3 and R13 are fitted. In other machines, only the resistor that is
connected to wire 055 is fitted.
R2 Resistor, 25 k 50 W. This resistor is connected in series with the power
supply to the overvoltage protection circuitry on circuit board AP5.
R3,R4 Resistor, 10 50 W.
R5,R6 Resistor, 4.7 5 W. Forms part of the transient protection circuit across the
welding and freewheel diodes.
R7 Resistor, 40 50 W.
R8,R9 Resistors, 10 50 W.
R10,R11 Resistor, 4.7 5 W.
R12 Resistor, 40 50 W.
R13 Resistors, two, each 10 k 25 W.
Fitted together with C11 and L3 when TV1 or TV2 is fitted. See also L3.
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RS1 Shunt, gives 24 mV output signal at 100 A welding current.
SA1 Main switch.
SA2 Switch. Cooling water pump, On/Off.
ST1,ST2 Thermal cutouts, open at 100C, fitted on the heat sinks for the secondary
diodes (V5, V7). See also DIODE BRIDGE BOARD AP13 on page 40.
ST3,ST4 Thermal cutouts, open at 85C, fitted on the heat sinks for the switch units.
WARNING: the cutouts are in the 565 V circuit.
See also DIODE BRIDGE BOARD AP13 on page 40.
SF1 Water flow switch. Closes at flow rates above 0.7 litre per minute.
TA1,TA2 Current transformers.
TC1 Control power supply transformer. Supplied at 400 V through fuse FU1.
An autotransformer winding on the primary side provides 230 V to fans EV1
and EV2, as well as to the coil of contactor QF1.
Secondary voltages:
22 V to circuit boards AP5 and AP6.
9 and 15 V to circuit board AP5.
9 V from a separate winding to the welding data control unit.
TC2 Control power supply transformer. Supplied at 400 V via fuse FU1.
Secondary voltages:
230 V to pump M1 and fan EV3.
42 V via fuse FU2 to circuit board AP5 and to the wire feed unit via
interference suppressor board AP9 and connection XP3.
TM1,TM2 Main transformers.
TV1 Autotransformer for machines connected to 230 V mains power supplies.
TV2 Autotransformer for machines connected to 415 or 500 V mains power
supplies.
V1--V4 Switch units: see description on page 35.
V5,V7 Rectifier diodes for the welding current: 2 x 6 diodes. See also item 10 on
page 42.
V6,V8 Freewheel diodes: 2 x 4 diodes.
During the time interval between voltage pulses from transformers TM1 and
TM2, inductors L1 and L2 maintain the welding current through the freewheel
diodes. See also item 10 on page 42.
VC1 Mains rectifier diode bridge.
XP1 15--pole male connector.
XP2 15--pole female connector.
XP3 23--pole female connector for connection of the remote control device/wire
feed unit.
XP6,XP9 2--pole female connector.
XP7,XP8 2--pole male connector.
XS1 Welding current terminals.
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XT1--XT5 Terminal blocks for screw connections.
XT06 4--pole edge connector socket, for connection to connections E on circuit board
AP5.
XT08 5--pole edge connector socket, for connection to connections G on circuit board
AP5.
XT09 2--pole connector, for connection to connections B on circuit board AP6.
XT10 14--pole edge connector socket, for connection to connections I on circuit
board AP5.
XT11 11--pole edge connector socket, for connection to connections J on circuit
board AP5.
XT12 3--pole edge connector socket, for connection to connections K on circuit board
AP5.
XT13 9--pole edge connector socket, for connection to connections L on circuit board
AP5.
XT14 6--pole edge connector socket, for connection to connections A on circuit board
AP6.
XT15 18--pole connector, for connection to circuit board AP9.
XT17-XT22 Coaxial connectors.
XT23 3--pole connector, for connection to circuit board AP13.
XT24 2--pole connector, for connection to circuit board AP13.
XT25 2--pole connector, for connection to circuit board AP13.
XT26 4--pole connector, for connection to circuit board AP13.
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INTERCONNECTION DIAGRAM, LUC 400
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BLOCK DIAGRAM, CIRCUIT BOARD AP5
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COMPONENT POSITIONS, CIRCUIT BOARD AP5
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DESCRIPTION OF OPERATION, CIRCUIT BOARD AP5
This description refers to the block diagram on page 14 and to the component positions
diagram on page 16.
Only those parts connected to the inputs and outputs of the circuit board are described.
If a circuit board is faulty, it must be replaced in its entirety: do not attempt to repair it.
After replacing a circuit board, the machine must be soft--started: see the instructions on page
36.
The gate driver and overvoltage protection circuits are at mains voltage. A yellow warning
cover is fitted above them.
The remainder of the board is connected to the welding circuit. Pulse transformers and
optocouplers, capable of withstanding a test voltage of 4.5 kV, provide galvanic separation
between the parts.
The electronic neutral on the control board is directly connected to the mounting bolts, the
plate behind the board and the negative of the shunt.
The remote control devices have separate power supplies with their own neutral point (0VA),
connected to L2.
The contacts and connectors on the board are designated by the letters A - L. Contact A is at
the top and L at the bottom. The numbering in each contact runs from top to bottom.
DANGER
Many parts of the control circuit board (AP5) and the power units
are at mains voltage.
The metal parts of coaxial contacts A, B, C and D to the MOSFET transistors are at
mains voltage (565 V).
The plugs must not be allowed to hang freely or touch each other. This will result in
failure of the transistors.
The measurement points (test points) are indicated by Mp.... in the block diagram and the
component positions diagram.
The circuit board incorporates test points in the form of pins. The test point marked Mp0 is
connected to the electronic neutral.
Unless otherwise specified, measure test voltages relative to the electronic neutral.
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1 POWER SUPPLY
Power supply to all parts of the circuit board except blocks 3, 10, 14 and 16.
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Bridge rectifier BR2 is supplied at 9 V from transformer TC1 via connections L6 and
L7. Voltage regulator VR1 stabilises the voltage to +5 0.03 V. This voltage can be
measured at test point Mp1.
Fuse S1 (2.5 A anti--surge) prevents the foil on the circuit board or the transformer
from being destroyed in the event of a short circuit on the board.
Rectifier BR3 is supplied at 22 V from transformator TC1 via connections L8 and L9.
Fuse S2 (2.5 A anti--surge) protects the board. Voltage regulator VR2 stabilises the
voltage. Potentiometer R10 adjusts the voltage at Mp3 to +15.2 0.1 V.
The voltage at test point Mp2 is +22 1 V.
The white indicating lamp (HL1) on the front panel is supplied at 22 V AC from TC1.
VR3 is a voltage converter which, with capacitors C43 and C44, converts +15 V to
- 13.2 1.2 V. Measure at test point Mp4.
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2 ARC VOLTAGE SENSING
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S K1, external sensing from the filler wire via the casing of the wire feed motor,
and
S K3 internal sensing of the voltage at the positive welding current terminal.
The negative welding current terminal (which is also the electronic neutral) is the zero
point for arc voltage sensing in cases 1 and 2 below.
There are three different arc voltage sensing modes:
1. Internal sensing of the voltage at the positive terminal for MMA welding.
The board senses the voltage between the positive terminal and the electronic
neutral.
2. External sensing of the voltage on the welding wire (at positive polarity) for
MIG/MAG welding. The board measures the voltage between the wire in the wire
feed unit and the negative welding current terminal on the power source.
The voltage signal is received via the control cable from the wire feed unit and
pin E in the 23--pole connector at the rear of the machine, and to connection K1
on the circuit board
3. External sensing on the welding wire, at negative polarity for MIG/MAG hollow
wire. The board measures the voltage between the welding wire in the wire feed
unit (K1) and the positive welding current terminal on the power source (K3).
The electronic circuitry on the board automatically measures the correct arc voltage in
all three cases, without manual intervention. Check that the voltage as received at the
board is the same as the true arc voltage in each case above.
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3 REMOTE CONTROL INPUTS
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Power supply
Rectifier BR4 is supplied at 15 V from transformer TC1 via connections L4 and L5. The
supply is protected by fuse S3 (2.5 A anti--surge).
Voltage regulator VR4 stabilises the voltage to about +10 V. This is referred to as the +10VA
supply: its neutral point is 0VA.
The output voltage from VR4 is adjusted so that the maximum reference signal at J11, i.e.
+10VA, gives +5.15 0.05 V across diode D8.
Control Synergic remote control device
This remote control input has its own galvanically insulated power supply, with its own 0VA
neutral connected to L2. The input is connected to other electronic circuity via differential
inputs. The input can withstand short--circuiting of the power supply and connection to the
welding circuit without being destroyed.
The remote control reference signal for the welding voltage (MIG/MAG) is connected to L1.
The minimum reference is 0 V and the maximum reference voltage is 10.4 V.
The remote control reference signal for the wire feed speed is connected to J11. The
minimum reference is 0 V and the maximum reference voltage is 10.4 V.
This input becomes the remote control reference input for welding current in the MMA
welding mode.
Control 5 Program remote control device
This remote control input has its own galvanically insulated power supply, with its own 0VA
neutral connected to L2. It can withstand short--circuiting of the power supply and connection
to the welding circuit without being destroyed.
The remote control unit provides selection of a number of sets of welding data parameters for
remote control: see page 85 in the Instruction manual. Either 5 or 31 sets of welding data
parameters are available.
The five--program choice is used together with the Control 5 Program remote control
device.
The 31--choice selection is intended for use with mechanised welding to provide a simple
means of calling up different sets of welding parameters. The five inputs then form the
number to the welding parameter set in binary--coded form.
The table below shows the data sets selected in response to each activated input in the two
modes. i.e. 5 programs or 31 programs. In the 31--program mode, it is the sum of the selected
inputs that selects the welding parameter data set.
The activated input is connected to 0VA (= XP3, connector L) via the remote control device.
The voltage at the unactivated inputs is 10.4 V.
Contact XP3 Circuit board AP5 Control 5 Program 31 sets, binary value
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Increase/decrease
Increase: input I14. Activation of this input results in 0 V between I14 and L2.
Deactivation of this input results in 10.4 V between I14 and L2.
Decrease: input J1. Activation of this input results in 0 V between J1 and L2.
Deactivation of this input results in 10.4 V between J1 and L2.
4 START/STOP INPUT
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This input accepts the Start/Stop signal from the welding gun when MIG/MAG
welding.
Operating the trigger on the welding gun applies 42 V AC between I9 and I10.
5 GAS AND HF CONTROL
This function is not used in the LUC 400.
6 OPTO INTERFACE
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7 SHUNT VOLTAGE AMPLIFIER
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When a fault occurs, the error detector sends a blocking signal to the pulse width
modulator (15), together with an error indication signal to the error indication unit
(11).
The yellow LED on the front panel indicates that a fault/error has occurred. It is
controlled by output G1 on the control board, which is at a voltage of about +1.7 V
when the diode is lit and 0 V when it is extinguished.
Conditions that can cause a fault or error state are as follows:
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Thermal cutout
If one of the thermal cutouts has operated, it will result in the message MACHINE
ERROR: HEATSINK TEMP appearing on the control unit display.
The yellow LED on the front panel of the power source and D19 on the control panel
circuit board also light up.
When the thermal cutout contacts are closed, the voltage between connection I3 and
the electronic neutral is about 8 V. The method of operation of the thermal cutout
protection circuit is described on page 41.
Cooler On/Off
When the cooler is ON, contact SA2 is closed and the voltage at connection G3 is 0 V.
When the cooler is OFF, the voltage on G3 rises to +28 V.
Water flow monitor
The water flow monitor switch, SF1, is closed when the water flow rate exceeds 1
litre/minute. This results in a voltage of +15 V on I1, as opposed to 0 V when the
cooling water flow is less than this.
The signals from switch SA2 and water flow monitor SF1 are compared on the
control board. The green LED on the front panel of the machine indicates that
cooling water is flowing. The supply to the diode is +2 V when cooling water is
flowing, and 0 V with no flow.
If the cooler is ON, but the flow monitor switch is open, the fault message
MACHINE ERROR: NO WATER FLOW will be displayed.
The green LED on the front panel will be extinguished, and the yellow LED lit.
Diode D18 on the control board will also be lit.
Overcurrent protection
Operation of the overcurrent protection lights the yellow LED connected to G1.
See also item 9, below.
Overvoltage protection
Operation of the overvoltage protection lights the yellow LED connected to G1.
See also item 10, below.
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9 OVERCURRENT PROTECTION
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The two current transformers, TA1 and TA2, measure the primary current to the two
pairs of switches. Their ratio is 400:1.
The output voltages from TA1 and TA2 are connected to I5 - I7 and I6 - I8.
The combined signal can be measured at Mp14 (the upper terminal of R131).
The overcurrent protection operates at a peak voltage of 8.2 V as measured at Mp14,
which is equivalent to a welding current of 1400 A and 200 A transistor current.
The circuit also trips if the difference in the currents from the two pairs of switches
exceeds about 150 A.
Operation of the circuit results in the fault message MACHINE ERROR: HIGH
CURRENT, and the yellow LED on the front panel of the machine lights up.
Diode D20 on the control board also lights.
The circuit can be reset by momentarily turning off the machine.
The polarity of the signals is important. Make sure that the wires are correctly
connected and that the current transformers are correctly orientated.
Loading the power source with a resistive load to produce a current of 100 A at 24 V
produces a waveform at Mp14 as shown in the trace below. In order to avoid
interference, the oscilloscope must be connected to the mains through an interposing
transformer.
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10 OVERVOLTAGE PROTECTION
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11 ERROR INDICATION
The error indication circuit provides indication of the cause of faults by lighting one
of LEDs D19 - D21 and sending an appropriate error message to the control unit for
display there via block 12.
D18 MACHINE ERROR: NO WATER FLOW No cooling water although the pump is on
D19 MACHINE ERROR: HEATSINK TEMP Excess temperature: see description on page 41
D20 MACHINE ERROR: HIGH CURRENT Too high primary current through the transistors
D21 MACHINE ERROR: HIGH VOLTAGE Too high voltage across C01
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12 WELDING PROCESS CONTROL
The processor senses the set welding data parameters and the arc voltage. It also
calculates a setpoint value for the current and supplies it to the current control
amplifier (13).
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For use when MIG/MAG--welding, it also supplies a wire feed speed reference
signal to the wire feed unit.
The speed reference is connected to J9 and must be +3.92 V at a wire feed speed of
10 metres per minute. The maximum reference voltage is 8.6 volt, which represents
a speed of 22 metres per minute. The relationship is linear.
Arc voltage feed back
Current
feed back
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13 CURRENT CONTROL AMPLIFIER
The current setpoint value signal to the amplifier can be measured at test point Mp9.
Measure the value of the signal for MMA welding and with an ARC FORCE setting
of 0.
In order to be able to adjust the ARC FORCE setting, it is necessary first to change
to non--synergic control mode, i.e. allowing independent adjustment of arc voltage and
welding current. See the Instruction manual under the heading Settings without
synergic functions on page 80.
The machine must be loaded so that the arc voltage is in the range 15 - 40 V.
The reference voltage at test point Mp9 must be 0.92 V at 100 A. The reference is linear
in relation to the current.
The reference signal voltage is determined by the welding process data control unit
and the welding process regulator.
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15 PULSE WIDTH MODULATOR
The pulse width modulator controls the time during which the transistors in the
power unit conduct.
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16 TRANSISTOR GATE DRIVERS
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The four gate circuits are identical: the following description, relating to one of
them, is therefore applicable to all of them.
The pulse from connection 3 on transformer TR1 passes D44, D45 and connection
A1 to the gate of the power transistors, with the return circuit via D47 and C114.
Capacitor C114 is charged to about 4.0 V by the gate pulse.
The peak pulse voltage is about +15 V. When the pulse goes negative, transistor
Q19 starts to conduct and supplies base current to transistor Q20, which pulls down
the gate voltage to --4 V.
Fuses S4 - S7 are not fitted: instead, they are replaced by links. The signal is
protected by fuses on circuit boards AP1 - AP4.
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CHECKING THE GATE PULSES
DANGER
The four gate circuits are at mains potential.
The metal bodies of the coaxial plugs are live.
Check the gate pulses from the control board with an oscilloscope.
S In order to avoid connecting mains voltage to the oscilloscope, remove gate connections
A, B, C and D from the control board (AP5) and insulate them from each other.
S NOTE, the overvoltage protection circuit on the control board and the switch units are
still at mains potential.
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S To measure the gate pulses, you will need a separate, dummy load connected to a BNC
plug. This load consists of a 33 nF capacitor and a 4.7 W resistor, connected in
series.
Connect the probe to the gate (A1) and the earth to the source (A2). Connect the gate
load to circuit board AP5 via the BNC contact.
S When you have made the connections, turn on the mains power supply. Select the MMA
welding mode and a current setting on the control unit sufficient to display control pulses
on the oscilloscope screen.
S Check that the pulses are within the range 39.5 -- 41.5% of the cycle time, and that the
total cycle time is within the range of 40.8 - 42.6 microseconds. Measure the pulse and
cycle times at a level of +5 V.
S Transfer the gate load as necessary and measure the pulses between A1- A2, B1 - B2,
C1 - C2 and D1 - D2.
S If any of the control pulses is outside the above limits, replace control board AP5.
If any of the pulses displays a long sloping decay time, the board is faulty and must be
replaced.
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SWITCH UNITS
The switch units consist of four heat sinks, each with twelve power transistors and a circuit
board (AP1 - AP4).
The transistors control the welding current. Maximum current is supplied when the
transistors are conducting for 39.5 - 41.5% of the cycle time.
MOS TESTER
A MOS tester is needed in order to test the switch units.
This is a special instrument, and can be ordered only from ESABs Service Department in
Lax. Its order number is 468 469--001.
The following instructions describe how to use the MOS tester to test the switch units.
Connection:
Testing:
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IMPORTANT
Even if only one switch unit is faulty, both
units in the same pair must be replaced.
Check the gate pulses from AP5 before operating the new
switch units. See instructions on page 33.
After repair, the machine must be soft--started.
SOFT STARTING
After replacing the control board and/or the switch units, it is important to soft--start the
machine. If any fault is still present, you will be able to detect it when soft starting.
S Disconnect and insulate wires 019 and 020 from capacitor C01. See the circuit diagram
on page 12.
S Disconnect connector C and D from circuit board AP13. See the circuit diagram and
component positions diagram on page 40. Connect a jumper between 1 and 2 at con-
nector D so that wire 074 is connected to wire 017.
S Connect a suitable power supply, having a current limit of 0.5 A, across capacitor C01.
Connect the positive line to wire 031 or to the copper busbar between the switch units.
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S Measure the secondary voltage from main transformers TM1 and TM2 on an oscillo-
scope. Connect the probe to the junction of R5 and TM1 when measuring the signal from
TM1, and to the junction of R10 and TM2 when measuring the signal from TM2.
See the circuit diagram on page 13.
Connect the earth connection to the terminal connected to inductor L1.
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S If the waveform from the transformers is similar to that shown in the diagram below, the
machine is almost certainly healthy and can be connected to the normal mains voltage
supply.
S Turn off the power supply, disconnect the temporary power supply unit and reconnect
wires 019 and 020.
S Connect a load resistor (RC 500), a shunt and an instrument for measuring welding
current and voltage.
S Start the machine on no load (open circuit). Select MMA welding mode, Arc Force = 0
and 10 A welding current from the control unit.
S Increase the current setting and check that the actual current is the same as the set value.
S Load the machine fully in accordance with the arc characteristic, 400 A - 36 V.
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CIRCUIT DIAGRAM, CIRCUIT BOARD AP9
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DIODE BRIDGE BOARD AP13
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DESCRIPTION OF OPERATION, DIODE BRIDGE BOARD AP13
This circuit board has two functions: suppression of line interference to the three--phase
bridge and galvanic insulation of the thermal overload cutouts on the switch units from the
welding circuit.
DANGER
Most of this board is at mains potential.
POWER SUPPLY
The board is supplied at +565 V from rectifier VC1, via fuse F1 on the board. Resistor R2,
which is mounted on the copper busbar in the control area, controls the current through diode
D1 in the power supply circuit. D1 is a zener diode with a 56 V zener voltage.
cny1ade1 -- 41 --
FAULT TRACING
If the mains fuse blows when the unit is turned on, check the following points:
1. Check that too small a mains fuse has not been fitted.
A 35 A anti--surge fuse must be fitted for a 400 V mains supply. See the instructions,
under the heading Installation, for details of fuse ratings for other supply voltages.
2. Check that contactor QF1 is in good condition and capable of carrying the current.
3. Check that resistor R1 on contactor QF1 has not burnt out. Its value must be 10 .
If mains voltage transformers TV1 or TV2 are fitted, there will be three resistors.
The resistance of each must be 10
4. Measure all diodes in mains rectifier bridge VC1, using the Diode position of a digital
multimeter.
5. Check the mains rectifier smoothing filter on AP13 for burnt--out components.
6. Check transient overvoltage protection board AP8 for burnt--out components or leads.
8. Check all the switch units using the MOS tester. See SWITCH UNITS on page 35.
9. Check the control pulses: see the description of the gate pulses on page 33.
10. Check the welding and freewheel diodes V5, V6, V7 and V8 using a DMM.
Disconnect the welding cables and measure between the welding current terminals.
The anodes of the diodes are connected to the negative terminal. A discharge resistor of
2.2 k (R1 on circuit board AP12) is fitted between the welding current terminals, and
can interfere with measurement in some cases.
11. The machine is now ready for soft starting: see on page 36.
cny1ade1 -- 42 --
DISASSEMBLY
S Remove the side panels, the top cover and the rear panel from the machine. Take care
that the centre plate does not drop out.
S Remove the nipple on the water tank so that the rear panel can be slid backwards a little
way.
S Remove rectifier bridge VC1.
S Remove the insulation sheet so that the copper busbar can be removed from beside the
lower heat sink.
S Remove the screws from the supports (a) closest to the fans and bend back the insulating
sheet so that the fan panel is not in the notch of the insulating sheet, see the picture
below.
S Pull the switch units and the fan panel apart to allow the supports to be removed.
Remove the bolt that passes through the upper current transformer TA1.
S Remove the copper busbar from the main transformer from the switch unit and bend it
backwards. Undo the nut and disconnect the cables and the copper busbar underneath the
main transformer from the switch unit.
The switch units must be replaced only in pairs.
Replace the lower pair in the same way as the upper pair.
Fit the new units in the reverse order.
WARNING !
Do not replace individual transistors.
If you do, there is a risk of further transistor failure.
cny1aae1 -- 43 --
REMOVING THE RECTIFIER AND FREEWHEEL DIODES
S Remove the side panels, cover and front panel and lift out the air grille.
S Remove circuit board AP12, the bolts from the machine units and the circuit board plate.
S Remove the front supports and bend the insulating sheet out of the way so that the front
panel can be removed.
S Remove the bolts (a) shown below. Remove the insulating panel so that the copper bar
from the side of the lower switch unit can be removed.
S Remove the insulation sheet from the other side and bend it outwards slightly.
Remove the nut from the bolt that passes through the current transformer.
S Remove the copper bar between the main transformer and the switch unit and bend it
backwards. Remove the nut and disconnect the cables and the lower copper bar on the
main transformer from the switch unit. Remove the supports by separating the main
transformer and the switch units.
cny1aae1 -- 44 --
S Lift the main transformer so that the diodes are accessible, as shown in the picture below.
S Use a DMM to find which row of diodes is faulty, but do not allow the copper busbars to
contact each other.
S Remove the anode connections of the diodes from the copper busbar.
S When fitting the diodes, do not tighten them harder than 2.0 - 2.5 Nm.
S Take care when reassembling the unit so that a short circuit is not formed between the
shunt and chassis and/or between the copper busbar from the freewheel diodes and the
bottom plate.
cny1aae1 -- 45 --
cny1ade2 -- 46 --
SETTING BOX
The welding settings control unit contains two circuit boards: a keyboard/display board and a
microprocessor board. The microprocessor board has its own microprocessor and associated
memory capacity, in the same way as has the main AP5 control circuit board.
Communication between the power source and the welding settings control unit is through a
5 m long bidirectional optical fibre cable. This cable also contains two ordinary copper
conductors for power supply to the unit.
The 9 V AC power supply comes from a separate winding on control transformer TC1, and is
protected by means of fuse FU3 in the power source.
The welding settings control unit contains functions for setting, measuring and storing the
required welding parameters. The unit also displays fault/error messages.
The welding parameters can be set manually and individually, or by synergic control.
100 sets of values can be stored. When the machine is turned off, a lithium battery maintains
the power supply to the memory.
The display, which incorporates a HOLD function, can display welding current or voltage.
The Operators Instructions contain a description of use of the unit.
cny1ade2 -- 47 --
DISPLAY BOARD, AP10
CIRCUIT DIAGRAM, DISPLAY BOARD
cny1ade2 -- 48 --
COMPONENT POSITIONS, DISPLAY BOARD
cny1ae26
cny1ade2 -- 49 --
MICROPROCESSOR BOARD, AP11
CIRCUIT DIAGRAM, AP11
cny1ae25
cny1ade2 -- 50 --
COMPONENT POSITIONS, AP11
cny1ae24
cny1ade2 -- 51 --
Mp8 Test point Mp8, which is connected to pin 8 of IC2, enables the signal from
the welding settings control unit microprocessor to the optical fibre transmitter
to be monitored.
When the welding settings control unit transmits information to the power
source (e.g. when changing the welding method at the control unit), the signal
pulses between 0 V and +3.8 V.
In the event of failure of the optical fibre communication link, the following
fault messages may appear after turning the machine on:
MEMORY PROBLEMS
If you suspect that the memory has become corrupted, all programmed data should be erased.
The data should also be erased when changing software.
S Press the NEXT key. This erases all the stored welding data. All other preset values re-
turn to their default values.
The default value for display language, for example, is English.
S The display shows the message NV--RAM INITIALIZED, as acknowledgement that the
memory has been erased. The unit then defaults to the welding method selection state.
cny1ade2 -- 52 --
BATTERY REPLACEMENT
S Slide out circuit boards 6 and 7 and fold them apart so that the battery is accessible.
S When replacing the battery, all programmed data will be lost unless the 3 V power supply
is maintained all the time. To avoid this, solder the new battery into position, in the un-
used space, before removing the old battery.
S The lithium battery can be expected to have a life of about five years of normal oper-
ation.
The battery is a BR 2325 -- 1HC battery.
cny1ade2 -- 53 --
FAULT/ERROR MESSAGES ON THE DISPLAY
In general, fault/error messages remain displayed until a key is pressed on the unit, or until
the main welding power source is turned off and restarted.
cny1ade2 -- 54 --
2. Memory errors/faults
The machine automatically performs a self--test of all memory cells on power--up.
If any of the cells is found to be faulty, one of the following fault/error messages will be
displayed. These messages are displayed only immediately after power--up.
It may be possible to use the machine despite the fault/error message. However, be care-
ful when using it, as welding performance may be affected, despite the fact the machine
appears to be operating normally.
a. RAM ERROR IN POWER SOURCE
Check that each memory position can be written to and read from. If this message
appears, it indicates that a memory cell in the machines read/write memory is defec-
tive.
Replace circuit board AP5.
cny1ade2 -- 55 --
f. EXT. RAM ERROR IN CONTROL UNIT
Check that each memory position can be written to and read from. If this message
appears, it indicates that a memory cell in the memory chip (IC6) in the control unit
is defective.
Replace the microprocessor circuit board in the control unit.
3. Communication faults/errors
These fault/error messages relate to the serial communications link between the power
source and the control unit. They can occur as a result of random events. In such cases,
deal with them by turning the machine off and then on again.
If these faults occur more frequently, there is probably an underlying reason, which needs
to be found.
cny1ade2 -- 56 --
d. POWER SOURCE TIME OUT
The power source has sent a message/instruction to the control unit, but has not re-
ceived acknowledgement.
Check the optical fibre as described above.
cny1ade2 -- 57 --
REMOTE CONTROL DEVICES
The following four pages show the Aristo Control Synergic and Aristo Control 5--Program
remote control devices. The instructions for the remote control devices explain how they are
intended to be used. Here we list only the spare part numbers for some of the components in
them.
cny1ade2 -- 58 --
ARISTO CONTROL SYNERGIC BOX 466 801 -- 880
cny1ade2 -- 59 --
ARISTO CONTROL 5--PROGRAM TORCH 466 515 - 881
cny1ade2 -- 60 --
ARISTO CONTROL 5--PROGRAM BOX 466 801 - 881
cny1ade2 -- 61 --
ORDERING SPARE PARTS
Order spare parts through your nearest ESAB representative. Give details of the machine type
(e.g. LUC 400), machine serial number, names of the spare parts and their numbers.
This information simplifies dealing with your order and ensures that the correct parts will be
supplied.
cny1ade2 -- 62 --
INSTRUCTION MANUAL ARISTO 400
cny1ap00
A400e -- 63 --
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS HAZARD DATA.
A400e -- 64 --
TECHNICAL DESCRIPTION
ARISTO 400 is a transistor--controlled welding power source of universal type, built in
modules to facilitate erection. handling and accessibility at the work place.
It is programmable. adapted for co--operation with a welding robot and can be controlled by
way of a PC system.
ARISTO 400 is programmed and controlled directly from the work place by way of small
portable cable--connected boxes.
With ARISTO 400 the following arc welding methods can be applied:
MMA Welding with coated electrodes
MIG/MAG Semi--automatic welding
CAC Carbon arc gouging
ARISTO 400 is a machine of inverter type. which means that the mains voltage first is
rectified and then converted back to alternating current of very high frequency. After this
occurs the transformation to welding current.
The size of the transformer depends on the frequency: the higher the frequency, the smaller
the transformer needed to obtain a given power. The same is applicable to the inductor.
Control system
In other words. welding machines of inverter type are considerably smaller and lighter than
conventional machines supplying the same power.
The inverter principle makes it possible to control every sequence of the welding process by
means of electronics. which results in better welding properties.
A400e -- 65 --
ARISTO 400 is a flexible system composed of the following units that can be built together
in accordance with your needs:
Power source, containing:
S Setting box for welding methods and parameters, measuring and storing.
A400e -- 66 --
FLOW CHART FOR COOLING MODULE
DEAEREATION FILLING
TANK
COOLER
PUMP
FLOW GUARD
QUICK--COUPLINGS
A400e -- 67 --
TECHNICAL DATA:
Enclosure type IP 21 AF
Temperature class F (155C)
Mains connection 3--phase
Mains voltage 400 V
Mains frequency 50/60 Hz
Primary current 26 A
Mains fuses 35 A
Permissible load
at 100% duty cycle 400 A
36 V
Open--circuit voltage 65 V
A400e -- 68 --
For MIG/MAG welding
Current range 30 - 400 A
Arc voltage (mean value) 10 - 46 V
Wire feed speed 0 - 22 m/min
Cooling module
Mains voltage 230 V
Mains frequency 50/60 Hz
Power 130 W
Cooling capacity 1.5 kW
Fluid volume 1.5 - 1.7 l
A400e -- 69 --
SETTING BOX
*
ARISTO 400 is programmed for welding by way of a portable box. connected to the machine
with a 5 m cable.
The setting box has four main areas of application. represented by the keys SEL, SET, MEA
and MEM. The other keys are used for the selection of settings after activation of one of the
main keys.
SEL: Shows alternatives within a number of different levels. which are shown on the
display in a certain order. First come the welding methods. The alternatives are
called with the key NEXT. With the desired alternative on the display. the selection
is done by going over to the following level, using the key with the arrow pointing
diagonally downwards.
Depending on the selected welding method, the levels will appear in the following
order:
A400e -- 70 --
For available alternatives, see table on page 73.
SET. After completed selection. the following welding parameters can be set:
MIG/MAG: Wire feed speed voltage
MMA: Welding current
The values are presented on the display on two horizontally parallel lines and can be adjusted
by way of the four large arrow keys.
SYNERGIC FUNCTIONS
Based on the settings made, the computer caiculates a number of further welding parameters
to control the power source.
The following is valid for the voltage in MIG/MAG mode:
The computer caiculates a suitable value with regard to the settings made under SEL and
the selected wire feed speed.
When adjusting the voltage. other values will not be affected. It simply involves an
adjustment of the preprogrammed relation between current and voltage. The adjustment
concerns only the one program.
Voltage U
Adjusted curve
Preprogrammed curve
A400e -- 71 --
The SEL key functions.
A400e -- 72 --
TABLE OF SYNERGIC DATA IN THE SETTING BOX
WELDING ARC ELECTRODE SHIELDING ELECTRODE
METHOD TYPE QUALITY GAS DIAMETER
Al Si Ar 1.0 1.2
Ar50He 1.0 1.2
Al Mg Ar 1.0 1.2
Ss Ar2O2 0.8 1.0 1.2
Ar2CO2 0.8 1.0 1.2
Ar3OHe1O2 0.8 1.0 1.2
Ar32He3,2CO21H 0.8 1.0 1.2
Ar3CO2IH2 0.8 1.0 1.2
Fe Ar16CO2 0.8 1.0 1.2
Ar2CO2 0.8 1.0 1.2
Ar8CO2 0.8 1.0 1.2
Ar20CO2 0.8 1.0 1.2
Ar5CO2502 0.8 1.0 1.2
Ar2O2 0.8 1.0 1.2
MCW Fe Ar5CO2 1.2
MCW Ss Ar2CO2 1.2
Ar20CO2 1.2
FCW Ss Ar8CO2 1.2
Ar20CO2 1.2
PULSE BFCW Fe Ar5CO2 1.2
* When welding aluminium using an Ar/He-- gas mixture, which has another mixture correlation, the voltage should be adjusted.
With a high helium content the arc voltage is increased and with a low helium content the arc voltage is decreased.
* Due to the limitations of the display window certain gas combinations cannot be displayed correctly.
Ar 15%CO2 5%O2 is shown as ArCO2O2
Ar 5%CO2 5%O2 is shown as ArO2CO2
A400e -- 73 --
SEL. Selection of welding method
Example:
(This is to show the principle of the selection of welding method. The pictures vary in
accordance with the program of the computer.)
For MIG welding with 1 mm stainless electrode, pulsed arc and a shielding gas of 69% argon,
30% helium and 1 % carbon dioxide, proceed as follows:
Press
[MIG/MAG]
[DIP/SPR] Fe
Brackets indicates short and spray arc.
CO2 1.2 mm
Press
The right type of arc has now been selected, and the [PULSE] Fe
computer suggests a new type of shielding gas. Ar20CO2 1.2 mm
A400e -- 74 --
PULSE [Fe] PULSE [Ss]
Ar20CO2 1.2 mm Ar20CO2 1.2 mm
PULSE Ss PULSE Ss
[Ar20CO2] 1.2 mm [ArHeCO2] 1.2 mm
PULSE Ss PULSE Ss
ArHeCO2 [1.2 mm] ArHeCO2 [1.0 mm]
The selection of welding method, gas and electrode is now finished. Go to SET
Example:
The wire feed speed value, Wfs=, remains from the previous setting. Based on the Wfs
value and the selections made under SEL, the computer calculates the voltage.
A400e -- 75 --
Short arc/spray arc (KB/SPRAY)
Voltage
= Length of arc.
A higher voltage gives a longer arc and hotter welding.
Wire feed (Wfs)
Corresponds to the joint and material thickness.
Dynamic (Dyn)
Inductance. Higher dynamic gives hotter welding and a need for increased voltage.
A400e -- 76 --
Type of regulator (REG. TYPE)
Using the regulator type you can select which welding characteristics the machine should
have. There are five options, one for mixed gas and one for each of the wire dimensions
when CO2 welding.
Final pulse (FIN. PUL.)
The amplitude of the finishing pulse as a percentage of the nominal value. The nominal value
is calculated by taking the wire speed and the average current into consideration and lies in
the interval 400--700 A. The percentage can be set between 10--120%.
Background current (lb)
The size of the current in between the pulses. A higher lb gives hotter welding. A low lb
gives rise to the risk of the arc being extinguished.
The background current acts as pre--heating of the electrode.
Frequency (FREQ)
The number of pulses per second. An increased wire feed needs a higher frequency.
Slope--time
Inclination of the pulse rise and fall. A lower number gives a steeper inclination and results in
a higher sound level and a harder arc.
Arc length-- (Ka and Ki) regulator--factors
Decides to what degree the power source shall react when the welder tries to change the arc
length.
Standard values Ka approx. 40 %
Ki = 0%
Fin. pul. Amplitude modification of the final pulse.
MMA
Current
Welding current.
Arc--force
High arc--force gives a higher current with short circuiting and a harder arc.
A too high setting gives a risk of spatter.
Start display
ARISTO 400
VER 1.XX 89XXXX
A400e -- 77 --
MEA. Measuring of welding data.
Example:
The average value of the arc voltage is measured continuously during the welding process.
After completing the weld the measurement value taken 2--3 seconds before finishing is
displayed.
The set value can be changed even when the setting
box shows the measurement value by using the # VOLT AGE = 23 V
*
increase/decrease buttons. CURRENT = 150 A
With short puising the setting box indicates the average
value of the arc voltage during the pulses.
The brackets are already in store position, STO, and the figure 12 is the number that will be
given to the data to be stored. A higher registration number can be chosen with the arrow
keys in the lower key row.
*
In the memory handling these keys are used for selection of
registration numbers:
To the right at the bottom, the figure 27/1 00 indicates that 27 out
of the 100 spaces are occupied.
Memory 0.
If welding data are stored in memory 0 they will automatically be recalled when the power
source is switched on. If no welding data are stored in memory 0, the data last used will
automatically be recalled.
A400e -- 78 --
Recall:
When recalling e.g. data set no. 35, activate the memory function and move the brackets to
RCL.
The setting box confirms operations and then returns to show the same picture.
Delete:
To delete a data set, proceed as follows (if the memory function is not already activated):
STO 12 RCL
[DEL1] 27/100
A400e -- 79 --
Settings without synergy functions
ARISTO 400 can be disconnected from the synergy functions, e.g. when welding with
electrodes or gas mixtures which are not specified in the setting box. This means, however,
that a great number of parameters will have to be manually set at their right values in relation
to one another.
Disconnection:
After SET, press the adjoining keys at the
same time for a couple of seconds
SYNERGIC
When this picture appears: press
CHANGE: [NEXT]
S For MMA
Arc--Force
A400e -- 80 --
Return to synergy functions
Return to synergy functions can be executed in two different ways.
Alternativ 1.
Alternativ 2.
Return to synergy functions can also be made by connecting a remote control unit.
A400e -- 81 --
REM--REMOTE CONTROL UNIT.
Two types of remote control units are available for ARISTO 400.
U and I indicate measured (real) values for voltage and current. REM WELD DATA 1
indicates the number of the actual program.
Shifting between the programs 1--5 in the setting box and adjustment of the voltage can
now be done with the resp. knobs on the remote control unit.
Set the desired values with the remote control unit. The result can be read off on the set-
ting box.
U= I= U= I=
Wfs = CURRENT = A
NOTE! When remote condition is ordered by pressing the REM key, the other key
functions of the setting box will be blocked.
A400e -- 82 --
3. Codelock
Settings can be locked in the remote control mode so that the operator cannot change
other parameters other than those that are accessible via the remote control unit. To leave
the remote control mode requires the operator to state a four number code. To install the
code: refer to basic values.
Example: Assume that the setting unit is in the SET mode.
Example:
When you are in the remote control mode and press
LOCK CODE =
The displays shows
1234
Now the correct code number can be set by using the increase/decrease buttons in the
same manner as described under basic values.
NOTE! When you switch on the machine it will go into the remote control mode, if it was in
this mode when the machine was switched on.
A400e -- 83 --
BASIC VALUES
When being in mode of method selection and when pressing SEL and SET for two seconds
you enter a mode where permanent selections can be made. These selections are usually made
when the machine is new however, they can also be made at any other suitable time.
The selections available are:
1. Language
2. Lock function or no lock function. If the lock function is selected the code can be set by
using the increase/decrease buttons. By using the increase or decrease number sign one of
the four number positions is pointed out. Using the increase/decrease asterisk changes the
value of the selected number.
3. 5 or 31 welding data sets accessible through the remote inlets.
Example
LANGUAGE
CODELOCK Press
[NO CODELOCK]
The display can then indicate
5 REM DATA
A400e -- 84 --
If you wish to use the codelock press
[LOCK CODE=1234]
The display can then indicate
5 REM DATA
By using
*
and
Press
31- selections are intended to be utilized when, for example, you want to call different
welding data easily while using mechanized welding.
The five inputs on the 23 pole contact (on the wire feed or at the rear of the machine) forms
the welding data number into binary code. The five contacts are:
one number (20) contact N four numbers (22) contact R sixteen numbers (24) contact T
two numbers (21) contact P eight numbers (23) contact S Common contact L
If, for example, you want the welding data number 10 you add contact S and contact P with
contact L.
FINISHING
Press one of
or
A400e -- 85 --
ERROR MESSAGES
Generally the error message remains on the screen until any key on the setting box is pressed,
or the machine is switched off and on again.
2. Storage error
2.1 RAM ERROR IN POWER SOURCE
2.2 RAM ERROR IN CONTROL UNIT
2.3 ROM ERROR IN POWER SOURCE
2.4 ROM ERROR IN CONTROL UNIT
2.5 WELD DATA ERROR IN CONTROL UNIT
3. Communication error
3.1 COMM. ERROR: RECEIVE CH. SUM
3.2 COMM. ERROR: TRANSM. CH. SUM
3.3 COMM. ERROR: TIMEOUT
3.4 POWER SOURCE TIMEOUT
3.5 COMM. ERROR: RECIVE BUFFER
3.6 COMM. ERROR: SEND BUFFER
3.7 WAITING FOR MACHINE IDENT
A400e -- 86 --
1.3 MACHINE ERROR: HEAT SINK TEMP
Too high temperature in the diode heatsinks, which may be caused by overload,
defective cooling fan or other defective component.
2. Storage error
Each time the machine is switched on and voltage is supplied, all the storage cells are
tested. The program storage is tested by means of a checking sum. If any storage
cell is defective, one of the following four messages comes up on the screen. Thus
they can only appear directly after switching on the machine. The machine can be in
working order despite the error message. Caution must be used, however, as the
welding result might be affected even though the machine seems to behave perfectly.
A400e -- 87 --
3. Communication error
All these error messages have got something to do with the series communication
between the machine and the setting box. The error messages may appear only
occasionally. Reset by switching the machine off and on. When the messages appear
more frequently, the equipment must be seen to.
A400e -- 88 --
EXPLANATION OF ABBREVIATIONS AND CONCEPTS
SEL SELECT DATA
MMA Hand welding
MIG/MAG Semi--automatic welding
Basic Basic electrode
Rutile Rutile electrode
Cellul. Cellulose electrode
Carbon.Arc/Air Carbon arc gouging
Dip/Spr Short--arc/Spray--arc
Pulse Short--pulse welding
Fe Non--alloy steel OK 12.51
Ss Stainless steel OK 16.32
AI Si Aluminium, AlSi OK 18.04
AI Mg AlMg OK 18.15
MCW Fe Metal cored wire, iron OK 14.00, OK 14.03
MCW Ss Metal cored wire, stainless OK 15.30
FCWf Ss Flux cored wire, stainless OK 14.30
Ar 100% argon
Ar CO2 H2 96% Argon, 3% carbon dioxide, 1 % hydrogen
Ar 2 O2 98% argon, 2% oxygen
Ar 2 CO2 98% argon, 2% carbon dioxide
Ar 20 CO2 80% argon, 20% carbon dioxide
Ar CO2 O2 90% argon, 5% carbon dioxide, 5% oxygen
CO2 100% carbon dioxide
Ar He O2 69% argon, 30% helium, 1 % oxygen
Noxalic 63% argon, 33% helium, 3% carbon dioxide, 1 % hydrogen
B FCW Fe Basic Flux cored wire, OK 15.00
R FCW Fe Rutile Flux cored wire, OK 15.15, OK 15.18
FIN. PUL Modified final pulse
A400e -- 89 --
SET Setting of welding data
MIG/MAG
Voltage Set voltage (8--50 V MIG/MAG, 10--50 V Pulse)
Wfs Set wire feed speed (0--22 m/min)
SYNERGIC The computer calculates welding data
NON SYNERGIC Manual setting of welding data
lp Pulse amplitude (100--640 A)
Tp Pulse time (Max 1.75--25.5 ms)
lb Background current (12--300 A)
Freq Pulse frequency (max 20--332 Hz)
Slope time Flank inclination of the pulse (1 - 9)
Ka Arc length regulation factor, short time (10--100%)
Ki Arc length regulation factor, longer time (0--1 00%)
Dyn Dynamic (stepless inductance) for MIG/MAG (0--100%)
MMA
Arc force Arc pressure for MMA (1 - 100 %)
A400e -- 90 --
INSTALLATION
1. Place the machine so that there is nothing to prevent the cooling air from passing
through it.
2. Connection should be made to 3--phase terminals. Phase sequence is unimportant.
3. Recommendations: Mains voltage Cable area Fuse size
50 Hz 230V 10 mm2 50 A
400 6 20
415 6 20
500 6 20
4. Dismount the right side panel.
Check the connection of the mains adaptation unit.
A400e -- 91 --
OPERATION
1. Set the starting switch to position 1. The indicating lamp goes on to show that mains
voltage is supplied.
2. Connect the return cable between the workpiece and the machine terminal. Make sure
that good contact is obtained!
3. Select welding mode on the setting box.
4. Set welding data by means of the setting box. Press the keys in accordance with the fol-
lowing until the desired data appear on the display:
e. Set the wire feed speed (Wfs). The voltage that is dependent
on the wire feed speed will change automatically. When the
value of the voltage is adjusted the wire feed speed will not be
affected.
g. If welding data are stored in Memory 0 they will automatically be recalled when
the power source is switched on. If no data are stored in Memory 0 the data last
used will automatically be recalled.
See also the chapter SETTING BOX.
If operating disturbances in the form of overheating in the power circuit, over--current,
over--voltage or a stop in the water flow occur, this is then indicated by the machine
stopping and the yellow signal lamp coming on and an actual message being displayed
on the min. setting box.
A400e -- 92 --
MAINTENANCE
ARISTO 400 is to be cleaned regularly with dry compressed air at reduced pressure.
No further maintenance is needed.
S Carriage
Chassis 369 580--880
TROLLEY SEMI 369 580--884
TROLLEY MAXI 369 580--885
TROLLEY MAXI 2 BOTTLES 369 580--886
For MIG/MAG
S Wire feed unit MED 44 ARISTO 369 341--880
Turning device for mounting of the feed unit on the power source 156 681--880
S Counterbalancing arm for torch with cable bundle 156 682 880
For MMA
S Welding accessories 160 302--883
A400e -- 93 --
A400e -- 94 --
STATIC CHARACTERISTICS
A400e -- 95 --
EFFICIENCY/POWER FACTOR
A400e -- 96 --
DIMENSION DRAWING
A400e -- 97 --
A400e -- 98 --
SPARE PARTS LIST LUC 400
Edition 9601
cny1ap00
Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover. Kindly indicate type of unit, serial number,
denominations and ordering numbers according to the spare parts list.
Reservdelar bestlls genom nrmaste ESAB--representant, se sista sidan. Vid bestllning var vnlig uppge typ och tillverkningsnummer samt
benmningar och bestllningsnummer enligt reservdelsfrteckningen.
Die Ersatzteile knnen bei der nchsten ESAB--Vertretung bestellt werden, siehe letzte Seite. Bitte geben Sie Typenbezeichnung und
Herstellungsnummer sowie Bezeichnungen und Bestellnummern laut Ersatzteilverzeichnis an.
Au dos de la brochure, vous trouverez ladresse du reprsentant ESAB le plus proche. Prire de lui adresser votre commande, aprs avoir pris le
soin de mentionner le type et le numro de srie de lunit ainsi que le numro de commande et la dsignation conformment la liste de pices
dtaches.
cny1se1 -- 99 --
Spare parts list -- Reservdelsfrteckning -- Ersatzteilverzeichnis -- Liste de pices dtaches
C = component designation in the circuit diagram
Item
Qty Ordering no. Denomination Remarks C
no.
Welding rectifier
cny1se1 -- 100 --
cny1se1 -- 101 --
Spare parts list -- Reservdelsfrteckning -- Ersatzteilverzeichnis -- Liste de pices dtaches
C = component designation in the circuit diagram
Item
Qty Ordering no. Denomination Remarks C
no.
Power module
201 1 192 579--538 Resistor R2
202 1 481 948--880 PC--board AP13
204 1 193 045--002 Connection block XT4
205 1 369 325--880 Transient protection C03, C04
207 6 192 903--505 Capacitor Only when item 237 is fitted C11
208 1 481 764--886 Control board AP5
209 1 193 661--110 Capacitor C01
210 1 193 769--001 Rectifier bridge VC1
212 2 320 729--001 Current transformer TA1, TA2
213 1 366 589--001 Insulation
214 1 162 532--001 Bushing
215 1 481 413--880 PC board Lightning protection AP8
217 1 468 943--001 Control transformer TC2
218 1 162 781--002 Connection block
219 1 469 950--880 Cable inlet From machine no. 550 . . .
1 191 309--110 Clip D= 22
Before machine no. 550 . . .
1 191 309--107 Clip D= 16
Before machine no. 550 . . .
220 1 467 753--001 Auto--transformer 230/400 V 50Hz TV 1
1 369 245--001 Auto--transformer 400/415/500 V 50Hz TV2
221 1 192 784--016 Sleeve plug XP2
222 1 192 784--015 Pin plug XP1
223 1 193 669--004 Connector 4--pole
224 1 193 260--151 Connector 3--pole XT12
1 193 260--153 Connector 5--pole XT8
1 193 260--157 Connector 9--pole XT13
1 193 260--159 Connector 11--pole XT11
1 193 260--162 Connector 14--pole XT10
225 1 369 124--181 Cover for XT12
1 369 124--183 Cover for XT8
1 369 124--187 Cover for XT13
1 369 124--189 Cover for XT11
1 369 124--192 Cover for XT10
227 1 466 517--880 Fuse holder
228 1 5679 001--23 Fuse 0.5 A FU4
229 1 466 837--880 Capacitor C7
231 1 481 158--880 Suppressor board Before machine no. 550 . . . AP7
(mains connection)
232 1 162 781--002 Connection block Before machine no. 550 . . . XT2
233 1 193 502--103 Contactor QF1
234 1 193 502--104 Time relay KT1
235 2 192 579--136 Resistor Only when item 237 is fitted R13
236 2 192 579--315 Resistor Only when item 237 is fitted R1b, R1c
237 1 193 758--001 lnductor When item 220 is fitted or option L3
1 468 925--880 Filter kit Contains: C11, L3, R1b and R1c
238 1 486 360-880 Suppressor board (EMC) From machine no. 550 . . . AP7
cny1se1 -- 102 --
223
237
221
224 201
222
225
cny1se1 -- 103 --
Spare parts list -- Reservdelsfrteckning -- Ersatzteilverzeichnis -- Liste de pices dtaches
C = component designation in the circuit diagram
Item
Qty Ordering no. Denomination Remarks C
no.
Power module
301 1 369 228--001 Insulating plate
302 1 369 230--001 Insulating plate
303 1 468 944--001 Insulating plate
304 1 369 229--001 Insulating plate
305 1 369 227--001 Insulating plate
306 1 368 827--880 lnductor, upper Ll
307 2 368 824--880 Main transformer TM1, TM2
308 2 Switching unit (See item no. 350) V1, V3
309 1 192 753--003 Connection block XT5
310 2 320 655--001 Thermal cutout ST1, ST2
311 2 Switching unit (See item no. 350) V2, V4
312 20 320 759--003 Diode V5, V6,
V7, V8
313 1 368 827--881 lnductor, lower L2
314 1 481 606--880 Suppressor board AP12
315 2 160 362--881 Welding current terminal OKC XS1
316 1 368 830--880 Shunt RS1
317 12 466 658--001 Support
318 2 368 260--880 Rectifier unit Items 310 and 312 are included
319 1 369 327--148 Shunt cable
320 4 369 335 880 RC--filter
321 1 192 579--221 Resistor R7, R12
322 1 468 941--001 Insulating plate
323 1 468 942--001 Insulating plate
350 468 515-889 Set of switch units Contains items 308 and 311, one of each.
cny1se1 -- 104 --
cny1se1 -- 105 --
Spare parts list -- Reservdelsfrteckning -- Ersatzteilverzeichnis -- Liste de pices dtaches
C = component designation in the circuit diagram
Item
Qty Ordering no. Denomination Remarks C
no.
Power module
cny1se1 -- 106 --
cny1se1 -- 107 --
Spare parts list -- Reservdelsfrteckning -- Ersatzteilverzeichnis -- Liste de pices dtaches
C = component designation in the circuit diagram
Item
Qty Orderingno. Denomination Remarks C
no.
Cooling unit
cny1se1 -- 108 --
cny1se1 -- 109 --
Spare parts list -- Reservdelsfrteckning -- Ersatzteilverzeichnis -- Liste de pices dtaches
C = component designation in the circuit diagram
Item
Qty Orderingno. Denomination Remarks C
no.
NOTE
When ordering a complete data setting box even the machine number must be indicated so
as to receive the right version of program.
cny1se1 -- 110 --
611
cny1se1 -- 111 --
ESAB subsidiaries, representative offices and agents
www.esab.com
990922