ESAB Aristo 500 User manual

Type
User manual

This manual is also suitable for

0740 800 206 101213 Valid for serial no. 033-xxx-xxxx to 044-xxx-xxxx
Aristo
®
300
Aristo
®
400
Aristo
®
500
Service manual
F0.01
- 2 -
READ THIS FIRST.................................................................................................................................. 4
INTRODUCTION ..................................................................................................................................... 6
TECHNICAL DATA................................................................................................................................. 8
WIRING DIAGRAM............................................................................................................................... 10
Component description.................................................................................................................. 10
Placement of the components....................................................................................................... 12
Diagram............................................................................................................................................ 14
DESCRIPTION OF OPERATION ......................................................................................................... 16
1 MMC unit ....................................................................................................................................... 16
1AP1 MMC control board ............................................................................................................. 16
1AP2 MMC panel.......................................................................................................................... 17
2 Mains module ............................................................................................................................... 18
2AP1 Interference suppressor board (EMC board) ...................................................................... 18
2AP2 Rectifier board..................................................................................................................... 19
2AP2 Block diagram ................................................................................................................. 19
2AP2:1 Voltage regulator ......................................................................................................... 20
2AP2:2 Pulses generator ......................................................................................................... 20
2AP2:3 Thyristors driver ........................................................................................................... 21
2AP2:4 Charging circuit............................................................................................................ 22
2AP2:5 Mains supply monitoring.............................................................................................. 22
2AP2 Component positions...................................................................................................... 23
2AP3 Power supply board ............................................................................................................ 24
2AP3 Block diagram ................................................................................................................. 24
2AP3:1 Power supply ............................................................................................................... 25
2AP3:2 +25V PWM driver ........................................................................................................ 25
2AP3:3 +25V power supply ...................................................................................................... 26
2AP3:4 +12V power supply ...................................................................................................... 27
2AP3:5 +48V PWM driver ........................................................................................................ 27
2AP3:6 +48V power supply ...................................................................................................... 28
2AP3 Component positions...................................................................................................... 29
3 Primary inductor module............................................................................................................. 30
3AP1 Harmonic suppressor board................................................................................................ 30
5 Cooling module ............................................................................................................................ 31
15 Power module................................................................................................................
............. 32
15AP1 Power board...................................................................................................................... 32
15AP1 Block diagram............................................................................................................... 32
15AP1:1 Gate drivers ............................................................................................................... 34
15AP1:2 Switching circuit......................................................................................................... 35
15AP1:3 Overvoltage and undervoltage protection ................................................................. 36
15AP1:4 Temperature protection ............................................................................................. 37
15AP1:5 Fan control................................................................................................................. 38
15AP1:6 Voltage regulator ....................................................................................................... 38
15AP1 Component positions.................................................................................................... 39
20 Control module........................................................................................................................... 40
20AP1 Control board .................................................................................................................... 40
20AP1 Block diagram............................................................................................................... 41
20AP1:1 Power supply ............................................................................................................. 42
20AP1:2 Fan control................................................................................................................. 43
20AP1:3 The CAN bus ............................................................................................................. 44
Starting sequence..................................................................................................................... 44
Communication interruptions.................................................................................................... 45
Terminating resistors ................................................................................................................ 45
20AP1:4 Temperature monitoring ............................................................................................ 46
20AP1:5 Overvoltage and undervoltage protection ................................................................. 46
20AP1:6 Rectifier board interface ............................................................................................ 47
20AP1:7 Gate pulses................................................................................................................ 47
20AP1:8 Output current sensor................................................................................................ 48
- 3 -
20AP1:9 Arc voltage feedback ................................................................................................. 49
Opencircuit voltage control..................................................................................................... 50
20AP1:10 Primary current sensor ............................................................................................ 52
20AP1:11 LED board interface................................................................................................. 52
20AP1:12 Cooling unit interface............................................................................................... 52
20AP1:13 External shutdown ................................................................................................... 53
20AP1 Component positions.................................................................................................... 54
20AP2 LED board......................................................................................................................... 54
20AP2 LED board......................................................................................................................... 55
REMOTE CONTROLS.......................................................................................................................... 56
FAULT CODES ..................................................................................................................................... 56
SERVICE INSTRUCTION ..................................................................................................................... 61
What is ESD?................................................................................................................................... 61
Service aid ....................................................................................................................................... 62
Service traps.................................................................................................................................... 63
Checking the input rectifier............................................................................................................ 64
Checking the IGBT transistors ...................................................................................................... 67
Checking the output diodes........................................................................................................... 70
Mounting components on the heat sinks ..................................................................................... 73
Soft starting ..................................................................................................................................... 74
Changing wire connections prior to soft starting........................................................................... 74
Checking the gate pulses from circuit board 20AP1..................................................................... 76
Checking the gate pulses from circuit board 15AP1..................................................................... 78
Measurements .............................................................................................................................. 81
Checking temperature monitoring................................................................................................. 83
Checking the overvoltage and undervoltage threshold values..................................................... 86
Calibrating the current sensor signal ........................................................................................... 88
MIG power sources, calibration of the arc voltage feedback..................................................... 89
MMA power sources, calibration of the arc voltage feedback ................................................... 91
CONNECTION OF TERMINATING RESISTORS ................................................................................ 92
IN-SERVICE INSPECTION AND TESTING ......................................................................................... 94
General requirements ..................................................................................................................... 94
Periodic inspection and test ...................................................................................................
....... 94
After repair, inspection and test.................................................................................................... 94
Visual inspection............................................................................................................................. 95
Electrical test................................................................................................................................... 96
Functional test................................................................................................................................. 98
Test report........................................................................................................................................ 99
INSTRUCTION .................................................................................................................................... 100
SAFETY .......................................................................................................................................... 100
INSTALATION ................................................................................................................................ 100
Lifting instruction ......................................................................................................................... 100
Location ...................................................................................................................................... 100
Mains supply ............................................................................................................................... 101
OPERATION................................................................................................................................... 102
Connections and control devices................................................................................................ 102
Turning on the power source ...................................................................................................... 102
Fan control .................................................................................................................................. 103
Overheating protection ............................................................................................................... 103
TIG welding................................................................................................................................. 103
MAINTENENCE.............................................................................................................................. 104
Power unit ................................................................................................................................... 104
Welding gun and torch................................................................................................................ 105
FAULT-TRACING........................................................................................................................... 105
SPARE PARTS ................................................................................................................................... 105
- 4 -
READ THIS FIRST
Maintenance and repair work should 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 the use by technicians with electrical/electronic
training in order to help them in connection with faulttracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit
boards are divided into numbered blocks, which are described individually in more
detail in the description of operation. Component names in the wiring diagram are
listed in the component description.
Use the spare parts list as a guide to where the components are located in the
equipment.
The spare parts list is published as a separate document, see page 105.
This manual contains details of design changes that have been made up to and
including July 2010.
The manual is valid for:
Aristo 300
Aristo 300 A44
Aristo 400
Aristo 400 A44
Aristo 500
Aristo 500 A44
with serial number 033xxxxxxx and 044-xxx-xxxx
Aristo 300, Aristo 300 A44, Aristo 400, Aristo 400 A44, Aristo 500, Aristo
500 A44 is designed and tested in accordance with the international and
European standards IEC/EN 60974. On completion of service or repair
work, it is the responsibility of the person(s) performing the work to
ensure that the product still complies with the requirements of the above
standard.
- 5 -
CAUTION!
Read and understand the instruction manual before
installing or operating.
WARNING!
Many parts of the power source are at mains voltage.
- 6 -
INTRODUCTION
The Aristo 300/400/500 series is a welding power source intended for MIG/MAG
welding, as well as for welding with powder filled cored wire (FCAW-S), live TIG
welding (power source with panel A44) and for welding with coated electrodes
(MMA).
There are different variants of the Power source:
Aristo 300 - max current 300A, without cooling unit, without MMC panel
Aristo 300 A44 - max current 300A, without cooling unit, with A44 panel
Aristo 400 - max current 400A, without cooling unit, without MMC panel
Aristo 400 A44 - max current 400A, without cooling unit, with A44 panel
Aristo 500 - max current 500A, without cooling unit, without MMC panel
Aristo 500 A44 - max current 500A, without cooling unit, with A44 panel
Control panels, welding process parameters are controlled via the control panel.
See the separate instruction and service manuals for a detailed description of the
panels.
Design structure of the power source
The power source is transistorcontrolled, operating on the inverter principle. It
consists of a number of function modules, as shown in the schematic diagram below.
Each module has a module number, which is always included as the first part of the
name/identification of components in the module.
The modules have the following main functions:
1 MMC module
The control panel and welding data unit, which control the machine functions.
2 Mains module
Mains interference suppressor, mains switch, control power transformer, contactor.
15 Power module
This module is a full-bridge converter inverter, operating at a switching frequency of
27 kHz. IGBT transistors are used as the switching elements.
20 Processor board module (controller module)
This is the controller board, 20AP1, with a microprocessor, that monitors and controls
the voltage and current.
5 Cooling unit module
The cooling unite control board which controls cooling unit functions.
Further information on the modules can be found in the component and function
descriptions.
- 7 -
+
-
15L1
M
L1
L2
L3
15EV1
Fan
M
15EV2
Fan
M
5EV1
Fan
M
5M1
Pump
2QF1
Main switch
XS 1
XS 2
3 x 380V-440V AC
PE
Cooling unit option MMC panel
Mounted only in power
source wit h MMC panel:
Arist o 300 A44
Arist o 400 A44
Arist o 500 A44
2AP1
EMC
board
2AP2
Rectifier
board
15TM1
Main
transformer
15D1-15D4
Output
rectifier
15AP2
Current
sensor
20AP1
Control
board
2AP3
Power
supply
board
5AP1
Coolling
unit
board
XS 3
Control
connector
1AP1
MMC
control
board
1AP2
MMC
panel
20AP2
LED
board
15AP1
Power
board
3L1
3AP1
Harmonic
suppressor
board
Block diagram of the power source
F2.01
- 8 -
TECHNICAL DATA
Aristo 300 Aristo 400 Aristo 500
Mains voltage
380-440V +/-10%, 3~50/60Hz
Mains supply S
SC min
From serial number 033-xxx-xxxx
3.0 MVA 4.0 MVA 5.0 MVA
From serial number 044-xxx-xxxx
3.8 MVA 6.0 MVA 8.4 MVA
Mains supply Z
max
From serial number 044-xxx-xxxx
- - 0.22
Primary current
I
max
MMA mains voltage 380V 18A 26A 35A
I
max
MMA mains voltage 400V 17A 25A 34A
I
max
MMA mains voltage 440V 16A 23A 31A
No-load Power
40W
Setting range
MIG/MAG 8 – 48V 8 – 48V 8 – 48V
MMA 16 – 300A 16 – 400A 16 – 500A
TIG (if applicable) 4 – 300A 4 – 400A 4 – 500A
Permissible load at MIG/MAG
60% duty cycle - - 500A / 39.0V
80% duty cycle - 400A / 34,0V 400A / 34,0V
100% duty cycle 300A /29.0V 300A / 29.0V 300A / 29.0V
Permissible load at MMA
60% duty cycle - - 500A / 40.0V
80% duty cycle - 400A / 36.0V 400A / 36.0V
100% duty cycle 300A / 32.0V 300A / 32.0V 300A / 32.0V
Permissible load at TIG
60% duty cycle - - 500A / 30.0V
80% duty cycle - 400A / 26.0V 400A / 26.0V
100% duty cycle 300A / 22.0V 300A / 22.0V 300A / 22.0V
Power factor
at maximum current
0.91
0.92
0.93
Efficiency
at maximum current
87%
88%
89%
Open-circuit voltage
VRD function deactivated
1)
55V
VRD function activated
1)
<35V
Operating temperature
-10 to +40 ºC
Transportation temperature
-20 to +55 ºC
Constant sound pressure at no-
load
<70 db (A)
Dimension l×w×h
610 × 250 × 445 mm
Weight
40 kg
Insulation class
H
Enclosure class
IP23
Application class
1) The VRD function is explained in the instruction manual for the control panel.
S
- 9 -
Mains supply, S
sc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12
Mains supply, Z
max
Maximum permissible line impedance of the network in accordance with
IEC 61000-3-11.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can
weld at a certain load without overloading. The duty cycle is valid for 40° C.
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 designed for indoor
and outdoor use.
Application class
The symbol indicates that the power source is designed for the use in areas with
increased electrical hazard.
S
- 10 -
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 indicate 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,
connection (plug/socket) XS1 XS99 (S = sleeve), XP1 XP99 (P = pin) etc.
Circuit boards within each module have names such as 20AP1 20AP99.
20 = module association, 169
AP = circuit board
1 = individual identification number, 099
Transistors within particular modules have identification numbers such as 15Q1
15Q99.
15 = module association, 169
Q = transistor
1 = individual identification number, 099
Component description
Component Description
1
MMC module. Wire numbers 100199. See description on
page 16.
1AP1
MMC Control Board
1AP2
MMC Panel
2
Mains module. Wire numbers 200299.
2AP1
EMC suppressor board. See diagram on page 18.
2AP2
Rectifier board
2AP3
Power supply board
2L1, 2L2
Ferrite rings
2QF1
Mains switch.
3
Primary inductor module. Wire numbers 300399.
3AP1
Harmonic suppressor board (from serial no. 044-xxx-xxxx)
3L1
Primary inductor.
5
Water cooling module. Wire numbers 500599. The power
supply to the cooling water pump and fan is controlled by the
machine software. See the description on page 30.
5EV1
Fan, 24 V DC.
- 11 -
5M1
Pump, 24 V DC.
5XP1
Cooling unit plug connector (pin)
15
Power module. Wire numbers 15001699. See the schematic
diagram and description on page 32.
15AP1
Power board.
15AP2
Current sensor. See the description of 20AP1:8 on page 48.
15D1, 15D2,
15D3, 15D4,
Output rectifier diode modules. Each module consists of two
diodes.
See page 73 for assembly instructions for the diode modules.
15EV1, 15EV2
Fans, 24 V DC. See the description of 20AP1:2 on page 43.
15L1
Inductor.
15L2, 15L3,
15L4, 15L5,
2 + 2 ferrite rings. Reduce transient voltages.
15C1, 15C2
Smoothing capacitors
15C3, 15C4,
15C5
Interference capacitors
15Q1, 15Q2
IGBT transistors. See the description of 15AP1:2 on page 35
and the installation instructions on page 73.
15R1, 15R2
Power resistors
15R3, 15R4
Varistors
15ST1
Temperature sensor, mounted on the heat sink for the output
diode modules. See the description of 15AP1:4 on page 37.
15ST2
Temperature sensor, mounted on the heat sink for the IGBT
modules. See the description of 15AP1:4 on page 37.
15ST3
Temperature sensor, mounted on the main transformer. See
the description of 15AP1:4 on page 37.
15TM1
Main transformer.
20
Control module. Wire numbers 20002099. See the
description on page 40.
20AP1
Control circuit board
20AP2
LED board
L1
Ferrite ring
XS1, XS2
Output outlets terminals
XS3
Control socket connector (sleeve)
XS4
Cooling unit socket connector (sleeve)
CAUTION !
STATIC ELECTRICITY can damage circuit boards and
electronic components.
Observe precautions for handling electrostaticsensitive
devices.
Use
p
ro
p
er static
p
roof ba
g
s and boxes.
- 12 -
Placement of the components
2AP3
1AP2
2AP2
20
A
P1
F4.01
F4.02
- 13 -
- 14 -
Diagram
Aristo 300, Aristo 300 A44
Aristo 400, Aristo 400 A44
Aristo 500, Aristo 500 A44
F4.03
CN1.4
CN1.1
CN1.2
CN1.3
CN2.3
CN2.4
CN2.1
CN2.2
CN2.5
CN4.2
CN4.1
CN3.3
CN3.4
CN3.1
CN3.2
CN3.5
CN5.3
CN5.4
CN5.1
CN5.2
2AP3
Power supply board
L1
L2
L3
L11
L22
L33
2AP1
EMC board
CN2
CN3
CN4
CN5
CN6
CN7.2
CN7.1
CN7.3
CN7.4
CN1.1 - CN1.14
2AP2
Rectifier board
2QF1
Main swi tch
3 x 380V-440V AC
L1
L2
L3
Chassis
PE
7231
7234
0V_FE
+48V_FE
0V_FE
+48V_FE
0V_CAN
+12V_CAN
0V
+25V
0V
+25V
E_WAR.
7232
7233
201
201
0VDC
202
202
7203
7204
7205
7212
7211
7222
7221
0V
+25V
0V
+25V
E_WAR.
1
2
5
6
7
8
9
4
3
XS4
7222
7221
Chassis
7201
7202
221
222
223
211
212
213
7241
7242
7246
7244
7245
2XS4
2XS5
2XS6
2XS1
2XS2
2XS7
2XS3
2L1
2L2
7220
+
-
Voltage regulator
Pulses generator
Thyristors driver
Charging circuit
Mains supply monitoring
0VDC
VDC
1
2
3
5
4
1
2
4
5
VDC
6
3
Power supply
+25V
PWM
driver
+48V
PWM
driver
+12V power supply
+48V
power
su
pp
l
y
+25V
power
supply
5 Cooling unit
CN1
CN3
CN2
CN4
3AP1
Red
Blue
Harmoni c
suppressor board
3L1
Primary inductor
Red
Green
Blue
Yellow
- 15 -
F4.04
CN10
CN9
CN11
CN12
CN4.1
CN4.2
CN5.1
CN5.2
CN2.1
CN2.3
CN3.1
CN3.3
CN2.2
CN3.2
CN1.1 - CN1.20
CN21
CN22
CN20. 1
CN20. 2
CN18. 1
CN18. 2
CN19. 2
CN19. 1
CN17. 2
CN17. 1
CN6.1
CN6.2
CN8.2
CN8.1
CN8.3
CN8.4
15AP1
Power board
X1
X3
X4
X2
20AP2
LED board
2
1
3
4
15AP2
15C1
15C2
4
5
6
7
1
3
2
15Q2
4
5
6
7
1
3
2
15Q1
15L1
15R2
15C4
15C5
15C3
Chassis
1577
1578
1576
1575
1573
1574
1572
1571
1572
1571
1501
1502
1503
1504
H4
H5
H1
H2
S1
S2
S3
S4
W2
W5
L1
L2
X1
X3
K2
K3
K1
K4
K5
K6
K7
K8
K9
K10
WP5
WP4
WP3
WP2
WP1
K12
K11
L4
L3
H3
WP6
X2
K13
K14
K15
K16
K17
K18
K20
K19
W3
W1
W4
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
CAN_C2
CAN_C3
CAN_C1
CAN_C4
ST2
ST1
CAN_C5
CAN_D2
CAN_D3
CAN_D1
CAN_D4
CAN_D5
T1
T2
T3
T4
J2
J1
20AP1
Control board
IGBT Heatsink
Power on/offOvertemp
7251
7253
White
Blue
0V
+25V
Pump
ELP
Flow guard
Over/Under
Gate drivers
M
+
-
15EV1
M
+
-
15AV2
Contactor
Mains s upply
0V
+25V
Warning
+12VCAN
0VCAN
+24V
+24V
0V
0V
Y
12 3
switch
Fan+
Fan-
Fan-
Fan-
Fan+
Fan+
0V
0V
DRV1+
DRV1-
DRV1+
DRV1-
15TM1
Main transformer
15D1
15D2
15D4
15D3
15L2
15L3
7241
7242
1506
1508
1506
+12V_CAN
0V_CAN
CANL
CANH
1508
+24V
+24V
0V
0V
7211
7212
15R1
2011
2012
2013
2014
Dio de Heats ink
U1 - U34
CAN_A6
CAN_A9
CAN_A2
CAN_A7
1AP1
MMC Control Board
U1 - U34
1AP2
MMC Panel
MMC panel
CANL
CANH
+12V_CAN
0V_CAN
0V
+25V
7251
7253
F
E
C
D
H
J
K
B
A
L
M
XS3
XS1
XS2
+Ub
-Ub
AVS+
AVS-
+15V
-15V
signal
0V
1511
1512
1513
1514
1501
1502
1503
1504
ASV+
ASV-
CANH
CANL
+12V CAN
0V CAN
Shield CAN
+48V FE
+48V FE
0V FE
0V FE
7210
Red
Black
Shield
7246
7244
7245
2011
2012
2013
2014
7200
7240
7231
7234
7232
7233
7203
7204
7205
7201
7202
7220
7230
1573
1574
1577
1578
1576
1575
20XS1
20XS2
20XS3
20XS4
20XS5
20XP1 20XP2 20XS6
20XS9
20XS10
15XS3
20XS7
20XS8
1XP1
1XS1 1XS2
15XS1 15XS2 15XS4 15XS5
15XS10
15XS9
15XS8
15XS7
15XS10
Chassis
Thermal protection
15ST2
15ST1
15L4
15L5
Red
Blue
0V
0V
temp
Power
A44
Mounted only in power
source with MMC panel:
A
risto 300 A44
A
risto 400 A44
A
risto 500 A44
+
-
15R3
15R4
Main transformer
15XS11
15ST3
C1
0V_CAN
Wh i t e
Blue
Red
Black
Shi eld
White
Blue
Red
Black
Shield
+12V_CAN
0V_CAN
CANL
CANH
0V_CAN
Wh i t e
Blue
Black
Red
Shi eld
L1
Wh i t e
Black
Wh i t e
Black
Wh i t e
Black
Wh i t e
Black
Blac k
Blac k
Red
Red
Blac k
Blac k
Red
Red
Fan control
Switching circuit
1521
1522
1523
1524
15XS6
vol tage
Power suppl y
Fan control
CAN b us
Rectifier board interface
Output current sensor
Arc vol tage feedback
1521
1522
1523
1524
20XS11
0V
5
3
4
1
2
1
6 2 5
7
4
10
12
11
3
8
9
Vol tage
regul ator
6
13
protection
Connection to
wi re f ee d un i t
Cabl e 7200 i s mounted onl y i n
power source wi th MMC uni t
Connect or
chas si s
Cooling unit
interface
External
shutdown
LED board
interface
Over
Primary
current
sensor
Temp
moni t
DRV2+
DRV2-
DRV2+
DRV2-
Gate
driver
Over/under
voltage
protection
- 16 -
DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other
components in the power source. It is divided into sections, numbered to correspond
to the circuit board numbers and divisions into function blocks.
1 MMC unit
The MMC unit can either be fitted to the wire feed unit and/or the power source.
The MMC unit consists of an operator’s control panel and a welding data board with
a welding data unit. The welding data unit is the central unit in the system. In addition
to storing and issuing welding data, it also exercises overall control of the system as
a whole.
1AP1 MMC control board
The welding data board has a machine ID, a hardware ID, a unit type and a unit
number. To read them you need the ESAT service kit, see page 62.
The machine ID determines which type of control panel the board is intended for.
The hardware ID shows the design and type of circuit board.
The unit type and unit number are used for identification on the CAN bus.
The identification numbers of this board are:
Machine ID 31
Hardware ID 4
Unit type 0
Unit number 1
If power source with control panel A44 (unit number = 1) is connected to a wire
feeder with control panel MA44 (unit number = 0). The MA44 welding data board will
then control the system.
Note! The welding data board in the A44 control panel does not have a terminating
resistor.
Read more about the CAN bus on page 44.
- 17 -
1AP2 MMC panel
A44 is a MMC unit with welding data board.
MMC unit A44
The MMC unit is described in separate instruction and service manuals.
F5.1.01
- 18 -
2 Mains module
The mains module filter the input mains power (2AP1), convert 3phase 400 V AC to
DC voltage (2AP2) and delivery +25VDC to the control electronic and +48VDC to the
control connection (2AP3).
2AP1 Interference suppressor board (EMC board)
This circuit board reduces mainsborne interference to/from the power source.
C5 C6C4
R9R8
R1
C3C2C1
L1
L2
L3
L1
C8C7 C9
L11
L22
L33
R4R5
R6
2AP1
EMC Board
Varistor Board
N3
N1
N2
N6
N4
N5
R7 R2
R3
Circuit diagram, 2AP1
Components position, 2AP1
Parts R4, R5 and R6 are varistors that clip the voltage peaks exceeding about
1100Vpk. The varistors do not conduct when the voltage is below 575V AC RMS, this
corresponds to a peak voltage of 810 V. Varistors are assembled on separated PCB
(Varistor Board).
F5.2.01
F5.2.02
- 19 -
2AP2 Rectifier board
The rectifier board carries the mains rectifier and input power three phase monitoring
circuit. Also it ensures soft-start for dc-link (15AP1) and provides rectified voltage for
Power supply board (2AP3).
2AP2 Block diagram
CN1.2
CN1.1
CN1.4
CN1.3
CN1.5
CN1.12
CN1.11
CN1.14
CN1.13
CN3
CN2
CN4
CN7.1
CN7.4
CN1.9
0V
24V
15V
CN11.3 CN11.2 CN11.1
CN11.5
CN11.4
CN9.3
CN9.2
CN9.1
CN9.4
LED1
CN14
CN15
CN16
CN12
CN13
PG_0V
PG_0V
0V
2AP2
32
1
5
4
Rectifier board
CN1.4
2AP3
CN1.1
2XS32XS1
201
202
2L1
2QF1
Main switch
221
222
223
L1
L2
L3
3 x 380V-440V AC
PE
211
212
213
2XS2
B2
B1
B4
B3
B12
B11
B14
B13
20XS9
7220
20AP1
Control board
Ribbon cable
B5
B9
Mains supply
monitoring
Pul ses
generator
Thyristor
driver
Char g i ng
circuit
Voltage
regulator
2AP1
EMC board
CN6
CN5
Red
Bl ue
CN11
15AP1
Power board
C1
R41
CN12
C2
R42
Primary
inductor
Power
supply
board
Red
Bl ue
3L1
3AP1
Harmoni c
suppressor
board
CN1 CN2
CN3 CN4
Blue Red
GreenYellow
Input rectifier bard 2AP2 contains a number of functional systems such as:
Thyristor power rectifier system – Provide voltage to power DC-link
Mains supply monitoring - Controls the presence of three phases on power input
Charging circuit – This module slow charging capacitors on DC-link and providing
power to the power supply 2AP3.
Voltage regulator system is responsible for providing power supply to the pulse
generator module.
F5.2.03
- 20 -
2AP2:1 Voltage regulator
D1
D2
R12
R11
R10
R9
C8
+15V
C5
0V0V 0V 0V 0V
CN1.2
CN1.1
CN1.4
CN1.3
C7
C4
CN9. 1
+24V
CN1.12
CN1.11
CN1.14
CN1.13
0V
CN9. 4
2XS2
2AP2
B2
B1
B4
B3
B12
B11
B14
B13
20XS9
7220
20AP1
0V
+24V
Control board
Rectifier board
Ribbon cable
Voltage regulator stabilize +15V which is used to supply circuit IC1 in 2AP2:2 Pulses
generator.
2AP2:2 Pulses generator
VCC
7
OUT
6
CMPEN
1
VFB
2
RT/CT
4
ISEN
3
VREF
8
GND
5
IC1
+24V
T1
R1
R2
R3
R4
R7
R6
R5
R8
LED1C6
C2
Q1
C1
C3
0V
0V0V
0V0V0V
0V0V0V
0V
0V
D4
D5
D6
D7
0V
Q2
+15V
+15V
CN1.5
CN11. 4
CN11.5
CN9. 2
PG_0V
2AP2
2XS2
B5
20XS9
20AP1
Control board
D2
Q42
Q31
R194
R118
0V
+24V
+5V
Processor
7220
Ribbon cable
Rectifier board
3
Thyristor
driver
The block of pulse generator, contained a IC1 which generated a square wave
formed in packages of pulses with constant amplitude and frequency. This signal
controls the transistor Q2. Transistor switching current flowing through impulse
transformer T1. Signal from transformer T1 provide impulses to control thyristor
driver.
The work of generator ( work / stop ) is controlled by the external signal from control
board connected to the gate of the transistor Q1.
F5.2.04
F5.2.05
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ESAB Aristo 500 User manual

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