Welding power source
740 800--070
9305 -- 1
LUC 400
Aristo 400
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Service manual
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LIST OF CONTENTS Page
INTRODUCTION 3...................................................................
RATING PLATE 4....................................................................
THE INVERTER PRINCIPLE 6........................................................
COMPONENT DESCRIPTION, LUC 400 7..............................................
INTERCONNECTION DIAGRAM, LUC 400 12............................................
BLOCK DIAGRAM, CIRCUIT BOARD AP5 14............................................
COMPONENT POSITIONS, CIRCUIT BOARD AP5 16....................................
DESCRIPTION OF OPERATION, CIRCUIT BOARD AP5 19...............................
CHECKING THE GATE PULSES 33.....................................................
SWITCH UNITS 35....................................................................
SOFT STARTING 36..................................................................
CIRCUIT DIAGRAM, CIRCUIT BOARD AP9 39..........................................
DIODE BRIDGE BOARD AP13 40......................................................
F AULT TRACING 42..................................................................
DISASSEMBLY 43....................................................................
SETTI NG BOX 47....................................................................
DISPLAY BOARD, AP10 48............................................................
MICROPROCESSOR BOARD, AP11 50.................................................
BATTERY REPLACEMENT 53.........................................................
FAULT/ERROR MESSAGES ON THE DISPLAY 54.......................................
REMOTE CONTROL DEVICES 58......................................................
ORDERING SPARE PARTS 62.........................................................
INSTRUCTION MANUAL ARISTO 400 63...............................................
TECHNICAL DESCRIPTION 65........................................................
SETTI NG BOX 70....................................................................
REMOTE CONTROL UNIT. 82..........................................................
ERROR MESSAGES 86...............................................................
EXPLANATION OF ABBREVIATIONS AND CONCEPTS 89................................
INSTALLATION 91....................................................................
OPERATION 92......................................................................
MAINTENANCE 93...................................................................
Ordering numbers for components 93....................................................
STATIC CHARACTERISTICS 95........................................................
EFFICIENCY/POWER FACTOR 96.....................................................
SPARE PARTS LIST 99................................................................
Rights reserved to alter specifications without notice.
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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 t he 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 i n the 9305 edition, however the spare part s
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 machine’s 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 i s 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.
2 These symbols indicate that Aristo incorporates an inverter, a transformer and a
rectifier.
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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.
I
2
= Current at the respective intermittence factor.
U
2
= Voltage in accordance with the arc voltage characteristic.
U
o
= Open--circuit voltage.
4 Indicates the voltage/current characteristic for MMA welding.
5 Indicates that the unit is intended for connection to a 400 V three--phase 50 Hz or
60 Hz supply.
I
1
= primary currents at maximum welding current.
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 machine’s 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 machine’s 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 t ransistorised power unit that oper ates 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 t ogether (80% duty cycle)
4. The current in the welding circuit
Each voltage pulse on the primary sides of transformers TM1 and T M2 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 curr ent flows for only a maximum of
83% of the cycle. However, this i s 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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Component positions on circuit board AP6
AP7 Suppressor board. Prevents mains--borne interference.
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Circuit diagram and component positions on circuit board AP7
AP8 Interference suppression board: pr otects against the effect of mains--borne
voltage transients.
AP9 Interference suppression board, fitted by the connection for the remote control
units. Circuit diagram and component positions are shown on page 39.
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AP10 Display board, f itted 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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Circuit diagram and component positions, circuit board AP12.
AP13 Diode bridge board, provides galvanic separation of primary side thermal
cutouts, ST3 and ST4, from the secondary side. See “DIODE BRIDGE
BOARD AP13” on page 40
C01 Capacitor, 50 ←F 600 V. Buffer/smoothing capacitor.
C02 Motor start--and -- run capacitor for the cooling water pump, 6 ←F 400 V.
C03,C04 RFI suppression capacitor, 0.1 ←F 250 V. For suppression of interference o n
the supply to the welding data control unit.
C05,C06 Decoupling capacitor, 10 nF 1000 V.
C7 RFI suppression capacitor, 0.1 ←F.
C09,C10 Decoupling capacitor, 10 nF 1000 V.
C11 Capacitors, six, each 1000 ←F 400 V. Mounted together with L3 and R11,
when T V1 or TV2 are fitted. See also L3.
C12 RFI suppression capacitor, 22 nF 250 V.
EV1,EV2 Cooling fans for the switching units.
EV3 Cooling fan for the water cooler.
FU1 MCB, 5 A, fitted at the rear of the machine. Protects the primary sides of
transformers TC1 and TC2.
FU2 Fuse, 10 A, fitted at the rear of the machine. Protects t he 42 V supply fro m
transformer TC2 to wire feed unit connection XP3 and control circuit board
AP5.
FU3 Fuse, 2 A, fitted at the rear of the machine. Protects the 9 V supply from
transformer TC1 to the welding data control unit.
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FU4 Fuse, 0,5 A. Fitted in the connection between E4 on cir cuit 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 char ging 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, 10τ 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 kτ 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 τ 50 W.
R5,R6 Resistor, 4.7 τ 5 W. Forms part of the transient protection circuit across the
welding and freewheel diodes.
R7 Resistor, 40 Ω 50 W.
R8,R9 Resistors, 10 Ω 50 W.
R10,R11 Resistor, 4.7 τ 5W.
R12 Resistor, 40 τ 50 W.
R13 Resistors, two, each 10 kτ 25 W.
Fitted together with C11 and L3 when TV1 or T V2 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 100˚C, 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 85˚C, 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 f eed 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 Rectifierdiodesfortheweldingcurrent: 2x6diodes.Seealsoitem10on
page 42.
V6,V8 Freewheeldiodes:2x4diodes.
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 r ectifier diode bridge.
XP1 15--pole male connector.
XP2 15--pole female connector.
XP3 23--pole female connector for connection of t he 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
WARNING High v oltage within the shaded area.
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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 par ts.
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 t he 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 diagr am.
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 ±1V.
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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