ESAB Aristo® 500ix User manual

Aristo®

Service manual

0463 700 001 GB 20201119

Valid for: 941-xxx-xxxx

Aristo®500ix

TABLE OF CONTENTS

0463 700 001 © ESAB AB 2020

READ THIS FIRST

....................................................................................

5

BEFORE STARTING SERVICE

................................................................

6

Service aid

..............................................................................................

6

ESAB Tools

.............................................................................................

6

What is ESD?

..........................................................................................

7

INTRODUCTION

.......................................................................................

8

Design structure of the power source

..................................................

8

Working principle

...................................................................................

8

TECHNICAL DATA

...................................................................................

9

SOFTWARE UPDATE AND CONFIGURATION

.......................................

12

WIRING DIAGRAM

...................................................................................

14

Component description

.........................................................................

14

Aristo®500ix

..........................................................................................

16

Position of the components

..................................................................

17

FAULT CODES

.........................................................................................

20

List of fault codes

...................................................................................

20

Fault code description

...........................................................................

20

TROUBLESHOOTING

..............................................................................

24

Pre power up checks

.............................................................................

24

Visual inspection................................................................................... 24

Input measurements............................................................................. 25

Power board 15AP1 measurements .................................................... 26

Checking the secondary rectifier diode modules............................... 29

Input voltage selection....................................................................... 29

Testing the electrolytic DC link capacitors ............................................ 30

Restoring the power source after pre power up checks ...................... 30

Power up checks

....................................................................................

31

General................................................................................................. 31

Electrical test ........................................................................................ 31

Filter board 2AP1 measurement ....................................................... 31

Power board 15AP1 measurements ................................................. 31

Fan functionality ................................................................................ 35

CALIBRATION AND VALIDATION

...........................................................

36

Measurement methods and tolerances

................................................

36

Requirements specifications and standards

.......................................

36

Accuracy out of tolerance

.....................................................................

36

DISASSEMBLY AND REASSEMBLY

......................................................

37

Tightening torque for screw joints on power components

................

39

First power-up after reassembly

...........................................................

42

TABLE OF CONTENTS

0463 700 001 © ESAB AB 2020

AC power supply – preparations before first power-up after

reassembly ...........................................................................................

43

DC power supply – preparations before first power-up after

reassembly ...........................................................................................

44

Checking the IGBT gate pulses............................................................ 47

Connectings for scope observation ................................................... 48

Gate Pulse to the IGBT for 15PM1 module....................................... 48

Gate pulses to the IGBT for 15PM2 module ..................................... 49

Checking the main transformer primary voltage................................ 50

Checking the welding outlet voltage.................................................. 51

Restoring the power source after soft starting

...................................

51

REPLACEMENT INSTRUCTIONS

...........................................................

52

Replacing the mains switch

..................................................................

52

Replacing the DC bus capacitor

...........................................................

53

Replacing the fan

....................................................................................

54

Replacing the power board

...................................................................

54

Replacing the secondary rectifier diode modules

..............................

56

Replacing the current sensor

................................................................

57

Replacing the control board

..................................................................

57

Replacing the mains cable

....................................................................

59

Replacing the IGBT modules

.................................................................

59

Replacing the rectifier bridge

................................................................

60

TRIMMING AND ADJUSTMENTS

...........................................................

62

Accuracy out of tolerance

.....................................................................

62

Adjust/trim the current sensor signal

...................................................

62

MIG power source

..................................................................................

63

IN-SERVICE, MAINTENANCE AND PERIODIC INSPECTION

PROCEDURE

..........................................................................................

66

Cleaning the equipment

.........................................................................

66

After repair, inspection and test

...........................................................

66

Visual inspection in accordance with 5.1 IEC 60974-4

.......................

66

Intermediate cables .............................................................................. 67

Enclosure ............................................................................................. 67

Return clamp ........................................................................................ 67

Welding gun/torch................................................................................. 67

Welding circuit ...................................................................................... 68

General condition ................................................................................. 68

Wire feeder/ wear parts ........................................................................ 68

Magnetic gas valve............................................................................... 68

Controls and indicators......................................................................... 68

Electrical test

..........................................................................................

69

Functional test

........................................................................................

71

Labelling and report

...............................................................................

72

TABLE OF CONTENTS

0463 700 001 © ESAB AB 2020

Maintenance and inspection procedure

...............................................

73

SPARE PARTS AND ACCESSORIES

.....................................................

74

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 700 001

- 5 -

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.

Before and after service, repair and maintenance work are performed, the safety procedure

described in the Safety test manual must be followed! The Safety test manual can be

downloaded from the Internet: manuals.esab.com

The circuit boards are divided into numbered blocks. 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.

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service

technician. Use only ESAB original spare and wear parts.

This manual contains details of design changes that have been made up to and including

December 2019.

The manual is valid for:

• 941-xxx-xxxx

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

The Aristo®500ix is designed and tested in accordance with the standards stated in the

instruction manual. 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 involved standards.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and

Safety Data Sheets (SDSs).

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

BEFORE STARTING SERVICE

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BEFORE STARTING SERVICE

NOTE!

When performing service work on the equipment, follow the instructions in chapter

"IN-SERVICE, MAINTENANCE AND PERIODIC INSPECTION PROCEDURE ",

page66!

Service aid

ESAB can offer a number of service tools that will simplify the service.

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

ESAB Tools

Tool Ordering number

ESAB test box TB1 0460 868 880

Checkmaster 9000 0740 505 880

Checkmaster 9000 DC 0740 505 881

Tool-Service kit W750i / Aristo 500ix 0446 599 880

NOTE!

Checkmaster 9000 and Checkmaster 9000 DC are not available for ordering.

Recommended measuring devices:

• For safety test: Fluke 1503, Fluke 1507, Fluke 1577 and Fluke 1587.

• For measurements: Fluke 175, Fluke 177 and Fluke 179 or with equal performance.

• Tools for disassembly and reassembly.

Required equipments for Soft start:

• Oscilloscope (50 MHz -100 MHz, 1- 2 GSa/s)

• Differential probe (1.4 kV, 100 MHz)

• Multimeter ( 0-600V AC/DC)

• Va (Power Supply 1)- 24 VDC, 5A

• Vb (Power supply 2) - 40 - 60 VDC, 5A

• Auxiliary Transformer – Secondary 42 VAC

BEFORE STARTING SERVICE

0463 700 001

- 7 -

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

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.

INTRODUCTION

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INTRODUCTION

The Aristo®500ix is a welding power source which is mainly intended for MIG/MAG welding

together with a wire feeder, but has the capabilities to weld coated electrodes (MMA), Live

Tig and Gauging.

Design structure of the power source

The Aristo®500ix power source is transistor-controlled, operating on the inverter principle.

It consists of a number of function modules. 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:

2 - Mains module

Mains filter board, primary inductor, mains switch, auxiliary transformer.

15 - Power module

Power board including primary rectifier and IGBT transistor modules. Capacitor board, main

transformer, secondary inductor, secondary diode modules.

20 - Control module

The control board, with a microprocessor, that monitors and controls the welding process.

Working principle

The mains input voltage range is three-phase 380±10%VAC to 460±10%VAC or 380±10%

to 575±10%VAC at rated load.

The auxiliary transformer 2T1 has multiple primary connections and has to be correctly

connected depending on the mains voltage. The primary rectifier creates the DC bus voltage

by rectifying the input AC voltage.

The primary inverter of the Aristo® 500ix power source is a 4-transistor IGBT fullbridge,

operating at a switching frequency of 22kHz. All power semiconductors are built into

modules.

The primary inverter output is connected to a main transformer with a 7:1 turn ratio ( 9:1 turn

ratio only in 0446 200 881 variant). The main transformer output is connected to a secondary

rectifier which contains four diode modules. The Aristo®500ix power source is rated

400A/36VDC or 500A/40VDC at 60% duty cycle.

TECHNICAL DATA

0463 700 001

- 9 -

TECHNICAL DATA

For 0446 200 880, 0446 200 882 and 0446 200 883 variants:

Aristo

®

500ix

Mains voltage 380-460V, ±10%, 3~ 50/60Hz

Mains supply S

scmin

7.2 MVA

Primary current I

max

380V 400V 460V

MIG/MAG 38A 35A 30A

MMA 40A 35A 31A

TIG 30A 27A 24A

Idle power 24W 25W 27W

Setting range (DC)

MIG/MAG 16A / 14.8V - 500A / 39V

MMA 16A / 20.6V - 500A / 40V

TIG 5A / 10.2V - 500A / 30V

Permissible load at MIG/MAG

60 % duty cycle 500A / 39.0V

100% duty cycle 400A / 34.0V

Permissible load at MMA

60 % duty cycle 500A / 40.0V

100% duty cycle 400A / 36.0V

Permissible load at TIG

60 % duty cycle 500A / 30.0V

100% duty cycle 400A / 26.0V

Power factor at maximum current 0.91

Efficiency at maximum current 88 %

Open circuit voltage 58V

Operating temperature -20 to 40°C (-4 to 104°F)

Transport temperature -20 to 55°C (-4 to 131°F)

Constant sound pressure when

idling

<70dB (A)

Dimensions l×w×h 712 × 325 × 470mm (28.0 × 12.8 × 18.5in.)

Weight 58.5kg (128.9lb)

Insulation class H

Enclosure class IP23

Application classification

For 0446 200 881 variant:

Aristo

®

500ix

Mains voltage 380-575V, ±10%, 3~ 50/60Hz

Mains supply S

scmin

7.2 MVA

TECHNICAL DATA

0463 700 001

- 10 -

Aristo

®

500ix

Primary current I

max

380V 460V 575V

MIG/MAG 38A 30A 26A

MMA 40A 31A 26A

TIG 30A 24A 20A

Idle power 25W 28W 33W

Setting range (DC)

MIG/MAG 16A / 14.8V - 500A / 39V

MMA 16A / 20.6V - 500A / 40V

TIG 5A / 10.2V - 500A / 30V

Permissible load at MIG/MAG

60 % duty cycle 500A / 39.0V

100% duty cycle 400A / 34.0V

Permissible load at MMA

60 % duty cycle 500A / 40.0V

100% duty cycle 400A / 36.0V

Permissible load at TIG

60 % duty cycle 500A / 30.0V

100% duty cycle 400A / 26.0V

Power factor at maximum

current

0.9

Efficiency at maximum current 88 %

Open circuit voltage 58V

Operating temperature -20 to 40°C (-4 to 104°F)

Transport temperature -20 to 55°C (-4 to 131°F)

Constant sound pressure

when idling

<70dB (A)

Dimensions l×w×h 712 × 325 × 470mm (28.0 × 12.8 × 18.5in.)

Weight 58.5kg (128.9lb)

Insulation class H

Enclosure class IP23

Application classification

Mains supply, S

sc min

Minimum short circuit power on the network in accordance with IEC 61000-3-12.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld 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 IP23 is intended for indoor and outdoor use.

TECHNICAL DATA

0463 700 001

- 11 -

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

SOFTWARE UPDATE AND CONFIGURATION

0463 700 001

- 12 -

SOFTWARE UPDATE AND CONFIGURATION

ESAT Service kit

The software update is made from a PC, it has to be managed by a trained service

technician. 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 a PC with Windows operating system is needed.

The ESAT service kit contents:

• CAN adapter with connection cables

• Software

• Instruction manual for ESAT

Ordering no:

0458847881 USB2CAN for connection to the USB port of the PC

0460 772 881 ESAT adapter kit

SOFTWARE UPDATE AND CONFIGURATION

0463 700 001

- 13 -

WIRING DIAGRAM

0463 700 001

- 14 -

WIRING DIAGRAM

The power source consists of a number of function modules, which are described in the

component descriptions on the following pages. Wire numbers and component names in the

wiring diagrams show to which module each component belongs.

Wires/cables within modules are marked 100 - 6999.

Wires/cables between modules are marked 7000 - 7999.

Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors

XS1 - XS99 (S = socket), XP1 - XP99 (P = plug), XT1 - XT99 (T = terminal).

Circuit boards within each module have names such as 20AP1 - 20AP99.

20 = module association, 1-69

AP = circuit board

1 = individual identification number, 0-99

Transistors within particular modules have identification numbers such as 15Q1 - 15Q99.

15 = module association, 1-69

Q = transistor

1 = individual identification number, 0-99

Component description

Component Description

2 Mains module. Wire numbers 200-299.

2AP1 Filter board

2L1, 2L2, 2L3 Ferrite cores

2L4 Primary inductor

2QF1 Mains switch

2T1 Auxiliary transformer, with multiple input windings

Input voltage windings:

• 380V

• 400V

• 415V

• 440V

• 460V

• 575V (Only in 0446 200 881 variant)

Output voltages:

• 20V (primary)

• 40V (secondary)

• 42V (secondary)

15 Power module. Wire numbers 1500-1699.

15AP1 Power board

15AP2 Capacitor board

15BR1 Primary rectifier bridge, 3 phase

WIRING DIAGRAM

0463 700 001

- 15 -

15C1 Capacitor 0.1µF

15C2 Capacitor 0.1µF

15C3 Capacitor 0.1µF

15CS1 Secondary current sensor, 1:2000

15EV1 Fan, 24VDC

15FU1 Automatic fuse 10A

15L1 Secondary inductor

15L2-15L9 Ferrite ring cores

15PM1, 15PM2 IGBT power transistor modules. Each module consists of two

transistors and two freewheel diodes.

15PM3, 15PM4, 15PM5,

15PM6

Secondary rectifier diode modules. Each module consists of

two diodes.

15R1 Resistor 150 ohm, 50 W

15ST2 Temperature switch, on the primary heatsink

15ST3 Temperature switch, on the secondary heatsink

15T1 Main transformer, 7:1 turns ratio

( 9:1 turn ratio only in 0446 200 881 variant)

20 Control module. Wire numbers 2000-2099.

20AP1 Control board

XS. Socket (sleeve)

24AP1 Interface board

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

WIRING DIAGRAM

0463 700 001

- 16 -

Aristo®500ix

WIRING DIAGRAM

0463 700 001

- 17 -

Position of the components

Left view

WIRING DIAGRAM

0463 700 001

- 18 -

Right view

WIRING DIAGRAM

0463 700 001

- 19 -

Right view, power modules

FAULT CODES

0463 700 001

- 20 -

FAULT CODES

Fault codes are used in order to indicate and identify a fault in the equipment.

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 power source must be connected to the ESAT, for tools see chapter "Service

instructions".

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.

For fault messages see also the service manual for the control panel.

List of fault codes

The control panel displays a unit number to indicate which unit has generated the fault. The

following unit numbers are used:

U0 = welding data unit U1 = cooling unit U2 = power source

U3 = wire feed unit U4 = remote control unit

Fault code description

Below are described event codes at which the user himself can take corrective action. If any

other code is shown, send for a service technician.

 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.

1. Restart.

2. If the fault persists, load new software via ESAT.

3. If the fault still persists, replace circuit board 20AP1, which carries the memory chip.

4. If the error persists, send for a service technician.

 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.

1. Restart.

2. If the fault persists, replace circuit board 20AP1, which carries the microprocessor chip.

3. If the error persists, send for a service technician.

 3  External RAM error

The microprocessor is unable to read/write from/to a particular memory address in its external

memory. This test is performed only on initiation after power−up. This fault does not disable any

functions.

1. Restart.

2. If the fault persists, replace circuit board 20AP1, which carries the microprocessor chip.

3. If the error persists, send for a service technician.

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ESAB Aristo® 500ix User manual

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