ESAB Aristo 1000 - Tandem and Parallel connection Installation guide

ESAB
Brand
ESAB
Model
Aristo 1000 - Tandem and Parallel connection
Category
Car kits
Type
Installation guide
Installation manual
0740 801 030 GB 20170905
Tandem and Parallel connection
of Aristo®1000AC/DC
TABLE OF CONTENTS
0740 801 030 © ESAB AB 2017
1
SAFETY ......................................................................................................... 3
1.1 Meaning of symbols ................................................................................. 3
1.2 Safety precautions ................................................................................... 3
2
INTRODUCTION............................................................................................ 7
2.1 Technical data........................................................................................... 7
3
INSTRUCTIONS ............................................................................................ 8
3.1 Parallel connection including two Aristo 1000 AC/DC.......................... 8
3.1.1 General................................................................................................... 8
3.1.2 Connecting the emergency stop system (parallel) ................................. 9
3.1.3 Connecting the Dual CAN2 cable kit ...................................................... 10
3.1.4 Connecting the power sources............................................................... 11
3.1.5 Setting of parallel power sources ........................................................... 12
3.1.5.1 General setting of parallel power sources .......................................... 12
3.1.5.2 Setting of parallel power sources using the PAB control unit.............. 13
3.2 Tandem connection including two Aristo 1000 AC/DC......................... 14
3.2.1 General................................................................................................... 14
3.2.2 Connecting the emergency stop system (tandem)................................. 15
3.2.3 Connecting the Dual CAN2 cable kit ...................................................... 16
3.2.4 Connecting the power sources............................................................... 17
3.2.5 Setting of tandem power sources........................................................... 18
3.2.5.1 General setting of tandem power sources .......................................... 18
3.2.5.2 Setting of tandem power sources using the PAB control unit ............. 19
4
ORDERING NUMBERS................................................................................. 20
Rights reserved to alter specifications without notice.
1 SAFETY
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© ESAB AB 2017
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2 Safety precautions
CAUTION!
Installations must only be performed by ESAB trained and authorized service
technicians.
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
1 SAFETY
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4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
1 SAFETY
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MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
1 SAFETY
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© ESAB AB 2017
Aristo 1000 AC/DC is designed and tested in accordance with the international and
European standards IEC-/EN60974-1, IEC-/EN60974-10. It is the obligation of the
service unit which has carried out the service or repair work to make sure that the
product still conforms to the mentioned standard.
2 INTRODUCTION
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© ESAB AB 2017
2 INTRODUCTION
Two Aristo 1000 power sources can be connected in parallel or in tandem.
A parallel system is controlled by a PEK unit.
A tandem system is controlled by a PEK unit for each power source.
In a parallel system the total current outlet will be evenly distributed between the connected
power sources.
2.1 Technical data
For technical data, see the instruction manual of the power sources and the PEK control
unit.
3 INSTRUCTIONS
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3 INSTRUCTIONS
3.1 Parallel connection including two Aristo 1000 AC/DC
3.1.1 General
Two Aristo 1000 power sources can be connected in parallel. In a parallel connected system
one of the power sources is designated as Master and the other power source as Slave.
The total current outlet will be evenly distributed between the parallel connected power
sources.
The parallel connected system is controlled by a PEK control unit.
The parallel connected power sources communicate on an additional CAN bus (CAN2) that
is totally separated from the usual CAN bus (CAN1) which handles the communication
between power source and the PEK control unit. ACAN2 cable kit needs to be installed in
the Master/Slave power sources to make parallel welding possible. In Aristo1000 power
sources with serial number from 336-xxx-xxxx, the CAN2 cable kit is factory installed.
WARNING!
When two Aristo1000 power sources are connected in parallel, the emergency
stop systems of the power sources must be connected according to
“Connecting the emergency stop system (parallel)”, page9.
If the emergency stop systems are not connected correctly as described, the
emergency stop functionality might be disabled!
NOTE!
Parallel power sources have to be configured according to the sub-sections
below and used as parallel if they are connected. If only one of the parallel pair
is to be used for some reason, the other power source has to be physically
disconnected from the welding circuit. Otherwise the power source may get
damaged.
3 INSTRUCTIONS
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© ESAB AB 2017
3.1.2 Connecting the emergency stop system (parallel)
Emergency stop connections in a parallel connected system
Do not remove any jumper on the master power source XT1terminal!
Remove the following jumpers on the slave power source XT1 terminal:
•
Slave power source: Jumper 285
1)
•
Slave power source: Jumper 286
2)
1)
Jumper 285 is the connection between XT1:3 and XT1:5 in the original wiring design.
2)
Jumper 286 is the connection between XT1:4 and XT1:6 in the original wiring design.
3 INSTRUCTIONS
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© ESAB AB 2017
3.1.3 Connecting the Dual CAN2 cable kit
NOTE!
In Aristo1000 power sources with serial number from 336-xxx-xxxx, the Dual
CAN2 cable kit is factory installed.
Aristo 1000 with Dual CAN2 cable kit
20AP1 – Aristo 1000 control board
CAN1:1 – Cable for communication with PEK control unit
CAN1:2 – Cable for communication with service tool
CAN2:1 – Cable for communication between Master/Slave power sources
CAN2:2 – Cable for communication between Master/Slave power sources
3 INSTRUCTIONS
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© ESAB AB 2017
3.1.4 Connecting the power sources
Parallel connected system containing two Aristo 1000 power sources
XS4
XS5
XS6
XS7
A
B
– Connection (CAN1) for control unit PEK
– Connection (CAN1) for service tool
– Connection (CAN2) between Master/Slave power sources (identical to XS7)
– Connection (CAN2) between Master/Slave power sources (identical to XS6)
– Interconnection cable (to be connected to either of XS6 or XS7)
– Interconnection cable to be connected to red banana sockets (arc voltage
monitoring) on the Master and Slave power sources
3 INSTRUCTIONS
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© ESAB AB 2017
3.1.5 Setting of parallel power sources
Setting of the power sources for parallel connection can be performed in two different ways,
one "general" procedure and one procedure using the PAB control unit (assumed the power
sources are equipped with PAB).
3.1.5.1 General setting of parallel power sources
1. Turn the welding power sources and the PEK unit off.
Configuring the Master power source
2.
3.
4.
Connect the PEK unit to the Master power source.
Turn the welding power sources on (the PEK unit will now be automatically turned on).
Press the MENU button on the PEK unit.
5. Make the following choices on the PEK display:
a.
b.
c.
d.
e.
Choose CONFIGURATION.
Choose MACHINE CONFIGURATION.
Choose PARALLEL POWERSOURCES.
Set PARALLEL POWERSOURCES to ON.
Set parallel couple ID. First parallel couple is set to1, next parallel couple is set
to2etc.
f. Choose Connect with slave and press Enter. A message "Connect" appears.
Press Enter again.
When the Master and Slave power sources are connected, the text "Connected" is
presented.
6. Turn the welding power sources and the PEK unit off.
Checking the settings
7. Turn the welding power sources on (the PEK unit will now be automatically turned on).
8. Check that the Parallel settings/connections are correct as follows:
a. set the REGULATION TYPE(on the PEK) toCA.
b. set the CURRENT(on the PEK) to more than 1000A. If the Parallel
settings/connections are incorrect, thePEK will not accept a value larger than
1000A.
3 INSTRUCTIONS
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© ESAB AB 2017
3.1.5.2 Setting of parallel power sources using the PAB control unit
1. Turn the welding power sources and the PAB unit off.
Configuring the power sources using PAB
2. Connect the PAB unit to the Master power source.
3. Turn the welding power sources on.
4. Perform the following settings on the PAB:
a.
b.
Set parallel on via Profibus asynchronous interface parameter 78 = 1.
Set parallel couple id for by setting via Profibus asynchronous interface parameter
118. Set the first parallel pair to 1 and the next parallel pair to 2 and so on if
available. Note that when setting up parallel connection, only the power sources that
are to be connected, parallel Master and Slave should have power on and be active
on the can bus.
c. Connect the Master and Slave power sources, by setting via Profibus asynchronous
interface parameter 119.
d. For synchronized AC welding, set parameter 52 = 1 on the Master power source.
5. Turn the welding power sources off.
Checking the settings
6. Turn the welding power sources on (the PAB unit will now be automatically turned on).
7. Check that the Parallel settings/connections are correct as follows:
a. Set the REGULATION TYPEtoCA, using the PAB control unit.
b. Set the CURRENTto more than 1000A. If the Parallel settings/connections are
incorrect, thePAB will not accept a value larger than 1000A.
3 INSTRUCTIONS
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© ESAB AB 2017
3.2 Tandem connection including two Aristo 1000 AC/DC
3.2.1 General
Two Aristo 1000 power sources can be connected in a tandem system. In a tandem system
one of the power sources is designated as Head and the other power source as Tail.
The tandem connected power sources are controlled by a PEK control unit each.
The tandem connected power sources communicate on an additional CAN bus (CAN2) that
is totally separated from the usual CAN bus (CAN1) which handles the communication
between power source and the PEK control unit. ACAN2 cable kit needs to be installed in
the Head/Tail power sources to make tandem welding possible. In Aristo1000 power
sources with serial number from 336-xxx-xxxx, the CAN2 cable kit is factory installed.
WARNING!
When two Aristo1000 power sources are connected in tandem, the emergency
stop systems of the power sources must be connected according to
“Connecting the emergency stop system (tandem)”, page15.
If the emergency stop systems are not connected correctly as described, the
emergency stop functionality might be disabled!
3 INSTRUCTIONS
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© ESAB AB 2017
3.2.2 Connecting the emergency stop system (tandem)
Emergency stop connections in a tandem connected system
Remove the following jumpers on the XT1 terminals:
•
Head power source: Jumper 286
2)
•
Tail power source: Jumper 285
1)
•
Tail power source: Jumper 286
2)
1)
Jumper 285 is the connection between XT1:3 and XT1:5 in the original wiring design.
2)
Jumper 286 is the connection between XT1:4 and XT1:6 in the original wiring design.
3 INSTRUCTIONS
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© ESAB AB 2017
3.2.3 Connecting the Dual CAN2 cable kit
NOTE!
In Aristo1000 power sources with serial number from 336-xxx-xxxx, the Dual
CAN2 cable kit is factory installed.
Aristo 1000 with Dual CAN2 cable kit
20AP1 – Aristo 1000 control board
CAN1:1 – Cable for communication with PEK control unit
CAN1:2 – Cable for communication with service tool
CAN2:1 – Cable for communication between Head/Tail power sources
CAN2:2 – Cable for communication between Head/Tail power sources
3 INSTRUCTIONS
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© ESAB AB 2017
3.2.4 Connecting the power sources
Tandem connected system containing two Aristo 1000 power sources
XS4
XS5
XS6
XS7
A
– Connection (CAN1) for control unit PEK
– Connection (CAN1) for service tool
– Connection (CAN2) between Head/Tail power sources (identical to XS7)
– Connection (CAN2) between Head/Tail power sources (identical to XS6)
– Interconnection cable (to be connected to either of XS6 or XS7)
3 INSTRUCTIONS
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© ESAB AB 2017
3.2.5 Setting of tandem power sources
Setting of the power sources for tandem connection can be performed in two different ways,
one "general" procedure and one procedure using the PAB control unit (assumed the power
sources are equipped with PAB).
3.2.5.1 General setting of tandem power sources
1. Turn the welding power sources and the PEK units off.
2. Connect the PEK units to the Head/Tail power sources.
3. Turn the welding power sources on (the PEK units will now be automatically turned on).
Configuring the Head power source
4. Press the MENU button on the Head PEK unit.
5. Make the following choices on the PEK display:
a.Choose CONFIGURATION.
b.Choose MACHINE CONFIGURATION.
c.Choose TANDEM.
d.Set TANDEM to ON.
e.Set WELDING HEAD to HEAD.
f. Set TRAVEL CONTROL to ON (if travel control by the Head power source is
required).
g. Set SYNCHRONISED WELDSTART to: 
–ON(ifautomaticTailstartisrequired). 
–OFF(ifmanualTailstartisrequired).
Configuring the Tail power source
6.
7.
Press the MENU button on the Tail PEK unit.
Make the following choices on the PEK display:
a.Choose CONFIGURATION.
b.Choose MACHINE CONFIGURATION.
c.Choose TANDEM.
d.Set TANDEM to ON.
e.Set WELDING HEAD to TAIL.
f. Set TRAVEL CONTROL to OFF (if travel control by the Head power source is
required).
g. Set SYNCHRONISED WELDSTART to: 
–ON(ifautomaticTailstartisrequired). 
–OFF(ifmanualTailstartisrequired).
h. Set WELD HEAD OFFSET to a desired value.
8. Turn the welding power sources and the PEK units off.
3 INSTRUCTIONS
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© ESAB AB 2017
Checking the settings
9.
10.
11.
Turn the welding power sources on (the PEK units will now be automatically turned on).
Press the MENU button on the Head PEK unit.
Make the following choices on the PEK display:
a.Choose CONFIGURATION.
b.Choose MACHINE CONFIGURATION.
c.Choose SYSTEM INFORMATION.
d. Check that the Head and Tail power sources are displayed.
CAUTION!
One, and only one, of the power sources (the head or one of the tails) has to be
defined with TRAVEL CONTROL set to 'ON' even if the travel is not under the
control of any of our systems.
If the travel is not under our control then the power source that has the TRAVEL
CONTROL set to 'ON' has to have EXT. AXIS activated.
This is done by first activating a soft button with this function and then selecting it
in the measurement pane. After that is done, the soft button can be deactivated
to prevent the operator pressing this by mistake and that way produce errors.
3.2.5.2 Setting of tandem power sources using the PAB control unit
1. Turn the welding power sources on.
2. Perform the following settings using the PAB control unit:
a. Set tandem on, in the I/Omap area, command 2LSB(byte 2) bit0.
b. Set tandem role to Head or Tail via Profibus asynchronous interface parameter 76,
0=head, 1=tail.
c. For synchronized AC welding, set parameter 79=1. Phase shift in tail can be set in
I/Omap area byte 26 and27.
d. For synchronized weld start from Head, set via Profibus asynchronous interface
parameter 47=1 in all units. Also set Head distance in parameter48.
e. If the travel motion should be controlled by ESAB motor cards, set parameter 77=1
on the motor card owner and 77=0 on all other PABs.
CAUTION!
One, and only one, of the power sources (the head or one of the tails) has to be
defined with TRAVEL CONTROL set to 'ON' even if the travel is not under the
control of any of our systems.
If the travel is not under our control then the power source that has the TRAVEL
CONTROL set to 'ON' has to have EXT. AXIS activated.
This is done by first activating a soft button with this function and then selecting it
in the measurement pane. After that is done, the soft button can be deactivated
to prevent the operator pressing this by mistake and that way produce errors.
4 ORDERING NUMBERS
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© ESAB AB 2017
4 ORDERING NUMBERS
Ordering no. Denomination Type Note
0463 201 882 Dual CAN2 kit Aristo1000 For parallel/tandem
connection
0463 282 880 Interconnection cable Aristo1000 For parallel/tandem
connection
0740 800 205 Service manual Aristo1000AC/DC
0462 985 001 Instruction manual Aristo1000AC/DC
Technical documentation is available on the Internet at: www.esab.com
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ESAB Aristo 1000 - Tandem and Parallel connection Installation guide

ESAB
Brand
ESAB
Model
Aristo 1000 - Tandem and Parallel connection
Category
Car kits
Type
Installation guide
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