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The New Aristo
System and Operation Handbook
0740 800 140 010706
1
The New Aristo
System and operation
Content
1 SYSTEM PHILOSOPHY ...................................................................... 3
POTENTIAL COMBINATIONS...................................................................................3
Power units ..............................................................................................................3
Trolleys ....................................................................................................................4
Other accessories for the power units .....................................................................5
Control panel ...........................................................................................................5
Wire feed units.........................................................................................................6
RATED DATA............................................................................................................. 8
Power unit capacities............................................................................................... 8
The cooling unit .......................................................................................................9
Wire feed units.........................................................................................................9
2 DESIGN PRINCIPLES ......................................................................... 11
THE MODULE SYSTEM ............................................................................................ 11
CONSTRUCTION AND AUXILIARY FUNCTIONS ....................................................12
Inverter circuit ..........................................................................................................12
Mains switch ............................................................................................................12
Fan cooling ..............................................................................................................13
Air filter ....................................................................................................................13
Overheating protection ............................................................................................ 14
Voltage protection....................................................................................................14
Cooling unit..............................................................................................................14
Water connection switch..........................................................................................14
Flow monitor switch .................................................................................................15
Arc voltage sensing .................................................................................................15
Arc current sensing..................................................................................................15
Wire feed speed sensing .........................................................................................16
Computer control .....................................................................................................16
New wire feed rollers ............................................................................................... 20
Remote control ........................................................................................................20
3 THE WELDING PROCESS.................................................................. 21
STRIKING THE ARC..................................................................................................21
MIG/MAG welding ...................................................................................................21
TIG welding .............................................................................................................22
MMA-welding...........................................................................................................23
WELDING ...................................................................................................................23
Inductance ............................................................................................................... 24
Voltage ....................................................................................................................24
Wire feed .................................................................................................................25
MIG/MAG welding data bank................................................................................... 25
Pulsed MIG welding................................................................................................. 25
Settings available for TIG welding ...........................................................................28
MMA welding settings..............................................................................................28
2
FINISHING A WELD ...................................................................................................29
Crater filling ..............................................................................................................29
Slope Down..............................................................................................................29
Burn-back time.........................................................................................................30
Shake-off pulse........................................................................................................30
4 CONTROL PANELS ............................................................................31
Principles .................................................................................................................31
AristoMig..................................................................................................................31
AristoTig...................................................................................................................32
AristoArc ..................................................................................................................33
MENUS .......................................................................................................................33
The main and the measuring menu .........................................................................34
The setting menu .....................................................................................................34
Select menu.............................................................................................................35
ADJUSTABLE FUNCTIONS.......................................................................................36
Two-stroke or four-stroke.........................................................................................36
Trigger data..............................................................................................................38
Arc force...................................................................................................................38
Burn-back time.........................................................................................................38
Crater filling ..............................................................................................................38
Creep start ...............................................................................................................38
Gas post-flow...........................................................................................................38
Gas pre-flow.............................................................................................................39
Gas purging .............................................................................................................39
Hot start ...................................................................................................................39
HF-start....................................................................................................................39
Inching .....................................................................................................................39
Inductance ...............................................................................................................39
Lift Arc......................................................................................................................39
MIG/MAG.................................................................................................................39
MMA.........................................................................................................................39
Slope down ..............................................................................................................40
Slope up...................................................................................................................40
TIG ...........................................................................................................................40
1.1 POTENTIAL COMBINATIONS
3
1 System philosophy
The new Aristo range of welding products represent the first phase of a new, modularised
standard program which is intended to improve the manufacturing efficiency and delivery
performance of products made in Laxå.
The design of the power units is based on modern inverter technology, using only a small
number of components.
The use of modularisation enables us substantially to reduce the total number of components
required to produce a product family. This results in lower overheads, shorter production
through times and higher productivity, while also reducing the amount of capital tied up in
stock and work, thus improving ESAB's profitability.
Modularisation also means that we can produce a range of different end products, built up
around the same modules, in order better to meet market requirements. The modules are
used in products intended for use with various welding methods, although a new factor is the
customisation of them to suit different customer segments. This applies particularly to the
design of control panels, for which various advanced alternatives are available.
The project also lays the foundation for further development of our other ranges of products,
thus improving their cost efficiency through greater use of the new modules and components.
In first hand the power sources LHL 315, LTL 315, LUA 400, LTG 400 will be replaced by the
new Aristo system.
1.1 Potential combinations
Power units
Different versions of the power unit are available, as appropriate to the particular welding
method: AristoArc 400 (for MMA welding), AristoTig 400 and AristoMig 400, the respective
internal type designations for which are LHR 400, LTC 400 and LAU 400.
The AristoTig and AristoMig are available in four versions:
• As power unit only
• As power unit with water cooling unit
• As power unit with mains voltage autotransformer
• As power unit with water cooling unit and autotransformer
1 SYSTEM PHILOSOPHY
4
Figure 1. The AristoTig 400 and AristoMig 400 power units are available with or without water cooling
and/or autotransformer options.
The design of the AristoArc 400 differs somewhat from the other power units, and cannot be
combined with the cooling unit or autotransformer options.
Figure 2. The AristoArc 400 power source.
Figure 3. Trolleys for the AristoArc (left), the AristoTig, AristoMig and a larger trolley for the AristoMig
when using a counterbalance arm.
Trolleys
Three different trolleys are available as accessories for the power units: for the AristoArc, a
trolley with large wheels and a folding handle, as shown in Figure 3, while for MIG and TIG a
common trolley is used, the only difference is the guide pin. If the counterbalance arm is being
used, the larger trolley, as shown on the right, should be used in order to provide sufficient
stability against tipping.
1.1 POTENTIAL COMBINATIONS
5
Other accessories for the power units
When portability is not required, it can be practical to mount the wire feed units on a pillar,
perhaps in combination with a counterbalance arm. The pillar can support two wire feed units
and two gas bottles, and is intended to be bolted to the floor.
Figure 4. Pillar for supporting a wire feed unit.
Control panel
Various control panels are available, providing different degrees of advanced control, depend-
ing on the user's requirements (customer segment/application). The panel is mounted on the
power unit for MMA and TIG welding, but on the wire feed unit for MIG/MAG welding.
In order to simplify description and identification of the panels, unit designations are comple-
mented by a combination of a letter plus a numeral, e.g. AristoArc 400 A2, where A2 means
that the control panel is intended for use with a Type A power unit (= MMA), and the 2 indi-
cates the simple design with control knobs. The following panels are available.
Figure 5. The panels M2, MA4 and MA6 shows the different degrees of advancement.
TABLE 1.
Control panel identifications.
Designation
Welding
method Description
A2 MMA Knobs only
A4 MMA Display with symbols
M2 MIG Knobs only
MA4 MIG + MMA Display with symbols
MA6 MIG + MMA Display with text
T4 TIG + MMA Display with symbols
T6 TIG + MMA Display with text
1 SYSTEM PHILOSOPHY
6
Wire feed units
The AristoFeed wire feed unit is available in two versions, depending on the size of the feed
rollers: with small rollers, in the AristoFeed 30, or with large rollers in the AristoFeed 48. The
respective designations for these two wire feed units are MEL 30 and MEL 48. The
AristoFeed 30 is intended for use with 0.6- 1.6 mm wire, while the AristoFeed 48 can provide
a higher feed force and deal with wires in the 0.6-2.4 mm diameter range.
There are then further variants, depending on whether the wire feed units have water cooling
connections or not, and on the control panel used. An AristoFeed 48 W MA4, for example,
indicates that it is a wire feed unit with 48 mm diameter feed rollers, a water cooling connec-
tion and fitted with a MIG + MMA control panel with a display with symbols, as shown in
Ta bl e 1 .
Figure 6. The AristoFeed 30 and AristoFeed 48 wire feed mechanisms.
The feed unit is available either without a wire bobbin holder, if it is intended for use with the
Marathon Pac™, with a bobbin holder or with an enclosed bobbin, all as shown in Figure 7.
Figure 7. Wire feed units for Marathon Pac, for a normal wire bobbin and for an encapsulated bobbin.
Mounting
The wire feed unit is normally mounted on the power unit, located by a guide pin as shown in
Figure 8.
Figure 8. Mounting with guide pin on the wire feed unit.
1.1 POTENTIAL COMBINATIONS
7
Alternatively, wheels, a lifting eye and a counterbalance arm, all as shown in Figure 9, are
available as accessories for the wire feed units.
Figure 9. Wire feed units can also be fitted with a lifting eye (A), or mounted on a trolley (B) or be
mounted on a counterbalance arm (C).
Other wire feed unit accessories
A support arm for the hose bundle, together with a quick connector for the wire guide from a
Marathon Pac, are also available, as shown in Figure 10. When the wire feeder is delivered
for Marathon Pac the quick connector is included.
Figure 10. Other accessories are a support arm and a quick connector for the Marathon Pac wire
guide.
1 SYSTEM PHILOSOPHY
8
1.2 Rated data
Power unit capacities
The various power units use the same internal power unit. Maximum rating is 400 A at 35 %
duty cycle, or 320 A at 60 %. Power units are intended for supply from a three-phase 400 V
supply: the special autotransformer is required if they are to be used from any other supply.
Duty cycle
The duty cycle indicates the time, expressed as a percentage of a ten-minute period, for which
welding can be carried out at a particular load without overloading the power unit.
TABLE 2. Technical data for the power units.
AristoMig 400 AristoTig 400 AristoArc 400
Mains voltage
without autotransformer
with autotransformer
400V
±10%, 3~ 50 Hz
208/230/460/475/500/575 V
±10%, 3~ 50/60 Hz
400V
±10%, 3~ 50 Hz
208/230/460/475/500/575 V
±10%, 3~ 50/60 Hz
400 V,
±10%,
3~ 50 Hz
Primary current I
max
without autotransformer MIG
with autotransformer MIG
with autotransformer MMA
36 A / 38 A
61/54/28/28/25/19 A
65/57/30/30/26/20 A
29 A / 38 A
50/44/23/23/20/16 A
65/57/30/30/26/20 A
- / 38 A
-
-
No-load power in the energy
saving mode, 6,5 min.
after
welding
without autotransformer
with autotransformer
60 W
235 W
60 W
235 W
50 W
-
Setting range
18
-60 V, 20-400 A 8-60 V, 4- 400 A 16-400 A
Permissible load at 25°C
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
400 A / 26 V
320 A / 23 V
250 A / 20 V
400 A / 36 V
320 A / 33 V
250 A / 30 V
Power factor at max. current 0,65 0,65 0,65
Efficiency at max. current 85% 85% 85%
Open-circuit voltage
78
-90 V 78-90 V 78-90 V
Working temperature range -10 to +40°C -10 to +40°C -10 to +40°C
Dimensions lxbxh
with cooling unit
with autotransformer
with cooling unit and
autotransformer
625 x 394 x 496 mm
625 x 394 x 776 mm
625 x 394 x 776 mm
625 x 394 x 1056 mm
625 x 394 x 496
625 x 394 x 776
625 x 394 x 776
625 x 394 x 1056
625 x 294 x 492
Weight
with cooling unit
with autotransformer
with cooling unit and
autotransformer
57 kg
77 kg
114 kg
134 kg
59 kg
79 kg
116 kg
136 kg
45 kg
Insulation class HHH
Enclosure class IP 23 IP 23 IP 23
Application class
Plasma
1.2 RATED DATA
9
Recommended cable area and fuse sizes
The cooling unit
Wire feed units
Standard for welding power sources
The International and European Standard IEC/EN 60974-1 specifies demands on power
sources regarding electrical safety. It defines important design principles, rating and testing of
TABLE 3. Cable area and fuse sizes recommended for AristoMIG 400.
Frequency 60 Hz 50/60 Hz 50 Hz 60 Hz 60 Hz 50 Hz 60 Hz
Mains voltage, V 208 230 400 460 475 500 575
Mains cable area, mm
2
4G6 4G6 4G2,5 4G2,5 4G2,5 4G2,5 4G2,5
Phase current, A
rms
38 33 22 18 18 16 11
Fuse
Anti-surge 50 50 25 20 20 16 16
Type C MCB 50 50 32 - - - -
TABLE 4. Technical data for the cooling unit.
Cooling power 2500 W at 40 °C temperature difference, 1.5 l/min
Coolant 50% water / 50% glycol
Coolant quantity 5.5 l
Maximum coolant flow 2.0 l/min
TABLE 5. Technical data for the wire feed units.
AristoFeed 30 AristoFeed 48
Supply voltage
42 V, 50
-60 Hz 42 V, 50-60 Hz
Power requirement 336 VA 378 VA
Motor current, I
max
8 A 9 A
Wire feed speed
0,8
-25 m/min 0,8-25 m/min
Pistol connection EURO EURO
Max. wire bobbin diameter 300 mm 300 mm
Wire size 0,6-1,6 mm 0,6-2,4 mm
Weight:
basic version
with bobbin holder
with encapsulated bobbin holder
13 kg
16 kg
17,5 kg
18 kg
21 kg
22,5 kg
Dimensions (l x b x h)
basic version
with bobbin holder
with encapsulated bobbin holder
380 x 265 x 340 mm
560 x 265 x 350 mm
680 x 285 x 420 mm
380 x 265 x 340 mm
560 x 265 x 350 mm
680 x 285 x 420 mm
Enclosure class
basic version
with bobbin holder
with encapsulated bobbin holder
IP23
IP2X
IP23
IP23
IP2X
IP23
1 SYSTEM PHILOSOPHY
10
the equipment to ensure a safe operation.
Application class
This symbol shows that the power unit is designed for use in areas of elevated electrical risk,
i.e. where conditions are cramped (with electrically conducting walls or equipment etc.), or
where it is damp.
Enclosure class
The IP code indicates the enclosure class, with the first figure indicating the degree of protec-
tion against penetration of solid objects, and the second figure indicating the degree of protec-
tion against water. IP 23 is suitable for use indoors and outdoors.
Equipment marked IP 2X is intended only for use indoors.
Class of insulation
The transformer and inductor insulation material limits the maximum temperature on the wind-
ings. The new Aristo uses class H insulation material. That means it is made for 180 °C
(20 000 hours). At a heating test of the power source it is controlled that the rise of tempera-
ture in windings not exceed 125 degrees above room temperature.
Limitations
If using the AristoMig for pulsed MIG welding, the welding cables must not be too long.
Performance is guaranteed for cable lengths of up to 8 m between the power unit and the wire
feed unit. The reason for this limitation of this length is the cable inductance. If the return cable
are placed close to the welding cable the inductance will be reduced. Voltage feedback from
the arc is another preventive measure, see page 15.
2.1 THE MODULE SYSTEM
11
2 Design principles
The new Aristo family of welding equipment has been developed with a view to achieving the
most important characteristics of welding equipment, i.e. good welding performance, quality
and reliability. In comparison with earlier generations, it can be noted that the characteristics
and features are better in several respects.
The whole structure of these units is based on a new modular approach, which aims to use a
few basic components to produce equipment more closely tailored to different customers'
needs and applications. The use of these modules also simplifies our production and develop-
ment work, leading to future savings in resources and costs. Service work is also facilitated, in
that the same modules recur in several products, and fewer spare parts are needed.
2.1 The module system
Why modules?
ESAB today has a substantial, and still growing, range of products and parts. Supply of parts
and materials has become cumbersome, sometimes resulting in shortages. In the worst
cases, this can result in delivery delays.
In addition, if a company is steadily to launch a range of new products/variants on the market,
development project lead times must be substantially reduced. It is no longer acceptable to
start each development project from the ground.
The ability to handle a wide range of product variants in a cost-efficient manner, and
also quickly to develop new products, are two important keys to improved profitability
for ESAB. In order to achieve this, we intend to work with modularised products.
What are the objectives?
ESAB intends to offer a well-defined range of products, based on a modular approach, and
meeting the needs of different customers and applications, all at competitive prices.
This will result in:
• A wider product range for priority customer segments
• High production volumes for common modules
• A smaller number of parts.
ESAB's product plan foresees the rapid development and launch of products by concentrating
development work on only a few modules at a time.
This will result in:
• Concentration of resources on new modules
• Parallel development in smaller projects
• More frequent product launches.
2 DESIGN PRINCIPLES
12
ESAB's production system will be based on low stock levels and short through times through
the use of parallel production/assembly of modules, with strategically important modules
being produced in Laxå, while other modules are produced by subcontractors. This will result
in:
• Reduced production lead times
• Less tying-up of capital
• Concentration on strategically important modules
• Purchase of complete modules (functions).
2.2 Construction and auxiliary functions
Much of the internal chassis is manufactured of aluminium alloy. The front panel and cover of
the power unit are made from aluminium extrusions. The wire feed unit covers, and the front
frame of the power unit, are aluminium die-castings. All this gives a solid feel of quality, good
mechanical stability and excellent functional characteristics.
The power unit handles are designed and positioned so that they can also serve as lifting
eyes: they have been test-loaded to 1400 kg.
Inverter circuit
The power unit is of inverter type with IGBT-transistors. The circuit is a forward inverter. That
is the same as for the Caddy power sources. The Aristo 2000 uses however a half bridge
circuit. The reason for change of circuit is that it admit faster control of the output current. An
example on this i that the base current at pulsed MIG welding could be reduced from 20 A to
12 A without arc-out problems. This increases the setting range in the new Aristo when pulsed
MIG welding is used.
Figure 11. Schematic diagram of the power circuit.
Mains switch
At the startup of the power source, the mains switch is turned to a start position. When it´s
released it will go back to position 1 (On position). After a voltage drop-out the machine have
to be started again to the start position. Settings that have been made are preserved also after
the machine has been out of voltage.
2.2 CONSTRUCTION AND AUXILIARY FUNCTIONS
13
Figure 12. The mains switch has to be turned to the start position.
Fan cooling
The power unit fans are temperature-controlled. If the unit is not used for 6.5 minutes, it
switches off to energy saving mode, in which the fans stop, in order to:
• avoid unnecessary noise
• reduce clogging of the air filters
• save energy
• reduce draughts
The fans are two-speed units, running at half speed for welding currents less than 144 A.
The cooling unit fan - which is not to be confused with the main power unit fans - is thermo-
statically controlled, depending on the temperature of the return water. All fans and pumps
stop 6.5 minutes after welding.
Air filter
The power unit is fitted with an air filter in order to
reduce internal accumulation of dust. It is fitted
over the air inlet to the front of the power unit, the
mains power supply electronics and the cooling
unit.
Cleaning the air filter
• Release the cover plate with dust filter (1)
• Swing out the cover plate (2)
• Remove the dust filter (3)
• Blow it clean with compressed air at reduced
pressure
• Replace the filter with the finer mesh on the
side against the the cover plate (2)
• Replace the cover plate with the filter
2 DESIGN PRINCIPLES
14
Overheating protection
The power unit incorporates two thermal overload switches, which operate if the temperature
on the heat sink or the transformer becomes too high. This interrupts the welding current, and
lights an orange indicating lamp on the power unit front panel. It resets automatically when the
temperature drops.
Voltage protection
The power sources are protected against over voltage (495 V) and under voltage (235 V) on
the input mains voltage. Panels with a display shows error signal 5. The power source will
automatically shut off.
To protect the welder from too high open circuit voltage (OCV) there is a normal open circuit
voltage limitation keeping the OCV in the range of 78-90 V. This control is not working during
welding. However, if the output voltage would exceed 113 V more than one second the output
is immediate shut off and the error signal 16 will be shown.
Cooling unit
The cooling unit has different energy saving measures. The fan is temperature controlled, it
goes on at 50 and off at 40 degrees. The water pump stops, when the unit switches to the
energy saving mode, 6.5 minutes after welding has stopped. The water connection switch,
see below, makes it impossible to forget the pump switched on without a water cooled gun
connected.
Water connection switch
There is nowadays no On/Off switch for the water cooling unit, in order to avoid the risk of a
water-cooled welding torch being destroyed by overheating due to the operator having forgot-
ten to turn on the cooling unit. Instead, there is a combination switch and check valve on the
water connection on the power source and on the wire feed unit, as shown in Figure 13. It
must be raised in order to enable the hose to be connected, and the cooling unit will not start
if the hoses are not connected. This also avoids the risk of leaving the cooling unit pump and
fan running even when no water-cooled welding torch is connected.
Figure 13. The hose connection on the wire feed unit.
2.2 CONSTRUCTION AND AUXILIARY FUNCTIONS
15
The power unit must be turned off when the hoses are connected or disconnected as, if not,
the pump will start immediately the connection cover is raised.
Flow monitor switch
The flow monitor switch is an accessory for the cooling unit, interrupting the welding current
and displaying an error message on the control panel in the event of loss of coolant.
When welding first starts, the water pump starts when the welder presses the torch trigger
switch. When the flow monitor senses that an adequate coolant flow rate has been estab-
lished, the power unit energises the wire and starts wire feed. The use of the flow switch
reduces the risk of damage to the welding torch through overheating.
Arc voltage sensing
One of the parameters required by the welding regulator in order to control the welding proc-
ess is the arc voltage, with which the regulator controls the welding current to suit the particu-
lar welding method and any synergic relationships selected by the user. It is therefore
important that the arc voltage is sensed as correctly as possible. For MIG/MAG welding, the
voltage is measured at the wire where it passes through the wire feed unit, which means that
there is no allowance for the voltage drop between the contact tip and the welding torch. If the
voltage signal is lost for any reason, the power unit instead measures the voltage at the weld-
ing cable connectors on the power unit.
To be able to sense the true arc voltage on welding wire, it is important that the wire is insu-
lated from the welding current connection at the feeding unit. ESAB steel spiral liners are
therefore equipped with a plastic nipple. Metal nipples that are used by some competitor liners
are not recommended.
Voltage sensing can be further improved by fitting a measurement connection between the
power unit and the workpiece, although this requires a jumper to be changed on the power
unit control board. In this case, if the voltage signal is lost, the machine loses control of the arc
voltage. In a critical situation when extra long welding cables are used at pulsed MIG, such a
sensing cable may help. Normally an extension set of up to 8 m length (between power
source and wire feeder) can be used without problem.
For TIG and MMA welding, the voltage is measured at the power unit welding current cable
connections.
The wire polarity can be changed from positive to negative without causing problems for volt-
age sensing.
Arc current sensing
A new type of current sensor is used in the new Aristo. It is of a hall element type and has
improved accuracy (0.5%) and response time in a wide temperature range.
2 DESIGN PRINCIPLES
16
Figure 14. Principle for the process control system.
Wire feed speed sensing
Also the sensing of speed of the wire feed motor is improved compared with older types. A
pulse generator gives 60 pulses per revolution which improves the control of the wire feed
speed. That makes it possible to run the wire at a speed from only 0.8 m/min up to 25 m/min.
Computer control
The power unit, the wire feed unit and the control panel each have their own microprocessor.
The control panel is the central unit in the system: in addition to controlling the welding data, it
also exercises overall control of the entire system.
Setting the welding data
Although the new technology facilitates man/machine communication (MMC), it can some-
times also make it seen more complicated. The modular approach to the control panels
means that there is a choice between the simplest mode of operation or the ability to achieve
more optimised settings for the best welding performance.
Synergy lines
The most advanced control panels MA6 and T6 have “synergy lines” for MIG and MMA weld-
ing. That means an individual set of data for a certain welding case. For MIG welding a
synergy line gives the relationship between wire feed speed and voltage setting. The welder
defines his case by the input of gas and wire type and wire diameter. When the welder change
the wire feed speed, the voltage will automatically be adjusted according to the synergy line.
The synergy line does not prevent the welder from adjusting the voltage if he wants. But the
voltage setting is not the only benefit from the synergy relationship, it also adapts the welding
process controller to the actual situation. Thus it can improve welding characteristics
compared to what is possible to do from a simpler control panel.
The number of MIG synergy lines in the control panel MA6 is limited to ten. If the user wants
something else there is a possibility to change the whole set of synergy lines. This is only
possible to do from a connected PC computer with the Esat program. A single synergy line
can not be changed.
2.2 CONSTRUCTION AND AUXILIARY FUNCTIONS
17
Five extra sets of synergy lines are available. They are concentrated to different areas of use.
However, all sets also contain the most ordinary steel wire/gas combinations.
Figure 15. The synergy line for MIG welding is defined from four points.
As shown in Figure 15 the synergy line for short and spray arc is defined from four points. The
synergy line for pulsed arc is defined by just two points. For MMA welding the there is no volt-
age line like for MIG welding, it just have the information that optimises the welding process
controller.
The CAN bus
A standardised communications bus is used for communication between the units: ESAB
uses the CAN bus. The CAN protocol was established more than ten years ago. CAN -
Controller Area Network - was originally developed by Intel and Robert Bosch AG for the auto-
motive industry. The number of sold CAN components has continuos increased during recent
years. There are many applications where the powerful fault detection and correction capabil-
ity of CAN is utilised to enable safe operation in harsh environment. It is estimated that there
are 15 million CAN-nodes in operation today.
The three units in the system, the power source, the wire feeder and the control panel are all
computerised, see Figure 16. The use of CAN bus communication between these parts
contributes to increase the performance to cost ratio of the equipment.
TABLE 6. Available groups of synergic lines.
Group number Range
0 Standard collection (default)
1 Aluminium
2 Stainless steel
3 Fe short arc
4 Fe pulsed arc
5 Cored wire
2 DESIGN PRINCIPLES
18
The user of Aristo welding equipment will take advantage of the new technique in different
ways, here are a few items:
• Less wiring - less problems due to bad connections.
• Better accuracy in the system, tolerance in transferred values is +/-0%.
• Better functionality, example: PC-communication to record setting data or measured data.
• Better flexibility, example: extra equipment or accessories can easily be added.
• Higher quality, more self-diagnostic functions that indicate if something is faulty to make it
possible to stop production and cure the problem before the product quality deteriorates.
The CAN communication will also be utilised in mechanised welding equipment where motor
drive units will be made as nodes on the CAN-bus.
Figure 16. Principle diagram of the CAN-bus. All communication is transported in just two wires.
Improved protection against electrical interference
Digital technology differs from analogue technology in being immune to variations in power
supply voltage or other interference, which guarantees that settings are reliable and remain
the same from one occasion to the next. The use of CAN bus communication between the
various parts of the machine, together with improved mechanical and electrical design (using
a zone system), has also reduced the vulnerability to electrical interference. One of the
features of the CAN bus protocol is its automatic error-checking function, which means that
messages are checked and retransmitted if necessary.
Error indication
The control panel indicates when a fault has occurred, such as running out of filler wire or gas,
problems with the cooling water, or failure of signal transmission between the units. On the
simplest panels, which have no LCD display, errors are indicated by a flashing or steadily lit
LED. Flashing light shows an error which the operator can take care of himself. Make sure
that the filters not are clogged up and shielding gas, wire and cooling water are OK. If the error
remains try to turn off mains power supply to reset the unit. If fault persists, send for a service
engineer.
Panels that have an LCD display show the above symbol together with a number that identi-
fies the type of fault. Also the number indication will be flashing for the type of error the opera-
tor is able to take care of. See the operating or service manual for further details.
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