ESAB Aristo 500 User manual

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

Open−circuit 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 fault−tracing 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 033−xxx−xxxx 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 transistor−controlled, 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, 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

1

MMC module. Wire numbers 100−199. See description on

page 16.

1AP1

MMC Control Board

1AP2

MMC Panel

2

Mains module. Wire numbers 200−299.

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 300−399.

3AP1

Harmonic suppressor board (from serial no. 044-xxx-xxxx)

3L1

Primary inductor.

5

Water cooling module. Wire numbers 500−599. 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 1500−1699. 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 2000−2099. 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 electrostatic−sensitive

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

0VDC

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

0V

Y

12 3

switch

Fan+

Fan-

Fan+

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

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

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

t°

15ST2

t°

15ST1

15L4

15L5

Red

Blue

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

t°

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

Red

Blac k

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.

ESAB Aristo 500 User manual

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ESAB Aristo 500 User manual

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