ESAB Aristo 1000 AC/DC SAW User manual

Service manual

0740 800 205 GB 20161115

Valid for: serial no. 145-, 221-, 336-xxx-xxxx

Aristo® 1000 AC/DC SAW

TABLE OF CONTENTS

0740 800 205 © ESAB AB 2016

READ THIS FIRST....................................................................................

5

INTRODUCTION.......................................................................................

6

TECHNICAL DATA ...................................................................................

8

WIRING DIAGRAM...................................................................................

9

Component description ...........................................................................

9

Aristo 1000 AC/DC - Primary - Valid for serial no. 145-xxx-xxxx .........

12

Aristo 1000 AC/DC - Secondary - Valid for serial no. 145-xxx-xxxx ....

15

Aristo 1000 AC/DC - Primary - Valid for serial no. 221-xxx-xxxx .........

17

Aristo 1000 AC/DC - Secondary- Valid for serial no. 221-xxx-xxxx .....

19

Aristo 1000 AC/DC - Primary - Valid for serial no. 336-xxx-xxxx .........

21

Aristo 1000 AC/DC - Secondary- Valid for serial no. 336-xxx-xxxx .....

23

Aristo 1000 component positions...........................................................

25

DESCRIPTION OF OPERATION..............................................................

26

Aristo 1000 internal voltage map ............................................................

26

1 MMC module ..........................................................................................

26

2 Mains Module.........................................................................................

27

Power On sequence, internal mode ....................................................... 27

Power On sequence, external mode ...................................................... 29

Emergency stop ..................................................................................... 30

Abnormal function .................................................................................. 33

2AP1 Internal power supply board ......................................................... 35

2AP1:1 Auxiliary supply +24 V_M & Fault indication.............................. 35

2AP1:2 Auxiliary supply +24 V ............................................................... 36

2AP1:3 Start Fan.................................................................................... 36

2AP1:4 Soft start & activation of the main contactor .............................. 37

2AP1:5 External stop.............................................................................. 37

2AP1 Component positions.................................................................... 38

2AP2 Power on board ............................................................................ 39

2AP3 EMC filter...................................................................................... 40

15 Power module......................................................................................

41

15AP1 Power Board............................................................................... 41

15AP1:1 Switching Circuit ...................................................................... 42

15AP1:2 Over-/ under-voltage monitoring.............................................. 43

15AP1:3 Current sensor......................................................................... 44

15AP1:4 Temp monitoring ...................................................................... 45

15AP2 Power board ............................................................................... 45

15AP2:1 Switching Circuit ...................................................................... 46

15AP2:2 Over-/ under-voltage monitoring.............................................. 47

15AP2:3 Current sensor......................................................................... 47

15AP2:4 Temp monitoring ...................................................................... 48

15AP1, 15AP2 Component positions ..................................................... 49

15AP3 Filter board ................................................................................. 50

15AP4 Filter board ................................................................................. 51

15AP3, 15AP4 Component positions ..................................................... 52

15AP5 Secondary rectifier board ........................................................... 53

15AP6 Secondary rectifier board ........................................................... 54

15AP5, 15AP6 Component positions ..................................................... 55

TABLE OF CONTENTS

0740 800 205 © ESAB AB 2016

15AP7 Soft start board ........................................................................... 56

15AP7:1 Soft start circuit........................................................................ 56

15AP7:2 Power supply for over-/ under-voltage monitoring................... 56

15AP7 Component positions.................................................................. 57

18AP1 AC control board ..........................................................................

58

18AP1:1 Output voltage monitoring ....................................................... 58

18AP1:2 Auxiliary switch commutation .................................................. 59

18AP1:3 Reset ....................................................................................... 60

18AP1:4 Fault......................................................................................... 60

18AP1:5 Temp monitoring ...................................................................... 61

18AP1:6 +24V ........................................................................................ 62

18AP1:7 Commutation switch gate control ............................................ 62

18AP1:8 Capacitor voltage monitoring................................................... 63

18AP1:9 Current block ........................................................................... 63

18AP1 Component positions.................................................................. 64

20AP1 Control board................................................................................

65

20AP1:1 Power supply ........................................................................... 66

20AP1:2 CAN 1 ...................................................................................... 68

20AP1:3 CAN 2 ...................................................................................... 69

20AP1:4 Connection to the Internal power supply board ....................... 69

20AP1:5 Over-/under voltage monitoring ............................................... 70

20AP1:6 Idle voltage .............................................................................. 70

20AP1:7 Secondary current ................................................................... 71

20AP1:8 Temp monitoring power module .............................................. 72

20AP1:9 Secondary voltage................................................................... 73

20AP1:10 Primary gate drives................................................................ 74

20AP1:11 Primary current ...................................................................... 76

20AP1:12 Temp monitoring: power board .............................................. 77

20AP1:13 Temp monitoring: primary heatsink and main transformer .... 78

20AP1:14 Output voltage monitoring AC unit......................................... 79

20AP1:15 Current block AC unit ............................................................ 80

20AP1:16 Reset signal AC unit .............................................................. 80

20AP1:17 Fault signal AC unit ............................................................... 80

20AP1:18 Temp monitoring AC unit ....................................................... 81

20AP1:19 +24V AC unit ......................................................................... 81

20AP1:20 Commutation switch gate control AC unit.............................. 81

20AP1:21 Capacitor voltage monitoring AC unit .................................... 82

20AP1:22 Arc voltage monitoring........................................................... 82

20AP1:23 Processor and miscellaneous circuits ................................... 83

20AP1 Component positions.................................................................. 85

FAULT CODES .........................................................................................

86

Fault log.....................................................................................................

86

Fault code description .............................................................................

86

SERVICE INSTRUCTIONS.......................................................................

94

What is ESD? ............................................................................................

94

Service aid ................................................................................................

94

Special tools .............................................................................................

95

Cleaning the heatsinks ............................................................................

96

Mounting components on the heat sink.................................................

96

Checking the primary rectifier bridge ....................................................

98

TABLE OF CONTENTS

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Checking the AC module .........................................................................

99

Checking the rectifier diodes on the Secondary rectifier boards........

101

Checking the primary IGBT transistor modules on the Power

boards........................................................................................................ 103

Soft start with no DC bus.........................................................................

105

Soft start box tests...................................................................................

105

Service modes DWC / DWC2................................................................. 105

Checking the primary IGBTs gate pulses ............................................... 106

Checking the DC bus and the primary IGBTs......................................... 109

Checking the DC welding output ............................................................ 112

Checking the AC welding output ............................................................ 113

Checking the positive Commutating capacitors ..................................... 115

Checking the negative Commutating capacitors .................................... 116

Updating attribute memory......................................................................

119

Updating attribute memory after software upgrade ................................ 119

Updating attribute memory after replacing Control board 20AP1........... 119

IN-SERVICE INSPECTION AND TESTING..............................................

121

General requirements ..............................................................................

121

Periodic inspection and test....................................................................

121

After repair, inspection and test .............................................................

121

Visual inspection ......................................................................................

121

Electrical test ............................................................................................

122

Functional test ..........................................................................................

126

TEST REPORT .........................................................................................

128

SPARE PARTS .........................................................................................

129

Rights reserved to alter specifications without notice.

READ THIS FIRST

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READ THIS FIRST

Maintenance and repair work must 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 use by technicians with electrical/electronic training for

help 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 the "SPARE PARTS" chapter

in this manual.

This manual contains details of design changes that have been made up to and including

December 2012.

The manual is valid for: Aristo 1000 AC/DC

The power source Aristo 1000 AC/DC is designed and tested in accordance with

international and European standards IEC-/EN 60974-1 and IEC-/EN 60974-10. 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 standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

INTRODUCTION

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INTRODUCTION

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. 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 Aristo 1000 power source does not include an MMC module. The MMC module used in

an Aristo 1000 system is located in an external control unit (for example PEK), and is

described in the service manual for the external control unit.

2 Mains module

Mains interference suppressor, mains switch, contactors, auxiliary transformer, power supply.

15 Power module

Soft start circuits, primary rectifier, primary power boards, main transformers, secondary

rectifiers.

18 AC module

Comprises all AC functions including AC power modules.

20 Processor board module (controller module)

This is the control board, 20AP1, with a microprocessor and two DSPs (Digital Signal

Processor), that monitor and control the arc voltage and welding current.

Working principle

The Aristo 1000 power source is built on two parallel power blocks. Each power block

contains a primary inverter, a transformer and a secondary rectifier.

The primary inverter is a 4-transistor IGBT fullbridge with Zero Voltage Transition (ZVT). The

primary inverter frequency is 30kHz. Each primary inverter has its own capacitor bank on the

DC bus.

The primary inverter output is connected to a transformer with a 7:1 turns ratio.

The transformer output is connected to a secondary rectifier which contains four diode

modules. Two of the diode modules conduct at positive polarity at the welding output, and the

other two conduct at negative polarity.

The power blocks are controlled by a control board including a microprocessor and two

DSPs (Digital Signal Processor).

The output of the power blocks is connected to a secondary inverter giving DC or AC

(10-100Hz) current and voltage at the welding output.

The secondary inverter is controlled by an AC control board.

The input voltage range from the mains is 380±10% VAC to 575±10% VAC at rated load. The

primary rectifier creates the DC bus voltage by rectifying the input AC voltage. The Aristo

1000 power source is rated 1000A, 44VDC continuous load at the output. At weld stop a

hazard reducing device cuts the output voltage to 0V within 300ms.

INTRODUCTION

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Principle diagram of the Aristo 1000

TECHNICAL DATA

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TECHNICAL DATA

Aristo 1000

Mains voltage 380-575V, ±10%, 3~ 50/60Hz

Mains supply S

sc

min 19.2MVA

Primary current I

max

84A

Setting range 14–50V / 0–1000A

Permissible load 100% duty cycle 1000A / 44V

Power factor at maximum current 0.92

Efficiency at maximum current 82%

Open-circuit voltage U

0

max 126V

Apparent power at maximum current 55.3kVA

Active power at maximum current 49.5kW

No-load power 170W

Operating temperature -10 to +40°C (+14 to +104°F)

Transportation temperature -20 to +55°C (-4 to +131°F)

Dimensions l×w×h 865×610×1320mm (34x24x52in.)

Weight 330kg (727lbs)

Insulation class H

Enclosure class IP23

Application class

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.

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 intended for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

Mains supply, S

sc min

Minimum short circuit power on the network in accordance with IEC 61000-3-12.

NOTE!

The power source can be connected for generator power. For more information,

contact authorised ESAB service personnel.

WIRING DIAGRAM

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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 diagram show 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, connectors

XS1 - XS99 (S = socket), XP1 - XP99 (P = plug), XT1 - XT99 (T = terminal).

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

2 Mains module. Wire numbers 200-399.

2AP1 Internal power supply board.

2AP2 Power on board.

2AP3 EMC filter, interference suppressor.

2BR1 Rectifier bridge, 3 phase 42 V ---> DC.

2BR2 Rectifier bridge, 3 phase 38 V ---> DC.

2D1 LED, Power on, white.

2D2 LED, Fault indication, yellow.

2EV1 Fan, internal air circulation.

2EV2 Fan, cooling of cabinet.

2EV3 Fan, internal air circulation.

2FU1 Delay-action fuse, MCB 10 A

2FU2 Delay-action fuse, 10 A (glass-tube fuse 6.3 x 32 mm)

2FU3 Delay-action fuse, 10 A (glass-tube fuse 6.3 x 32 mm)

2FU4 Delay-action fuse, 10 A (glass-tube fuse 6.3 x 32 mm)

2FU5 Delay-action fuse, 1 A (glass-tube fuse 5 x 20 mm)

2FU6 Delay-action fuse, 16 A (glass-tube fuse 6.3 x 32 mm)

2FU7 Delay-action fuse, 16 A (glass-tube fuse 6.3 x 32 mm)

2FU8 Delay-action fuse, 16 A (glass-tube fuse 6.3 x 32 mm)

WIRING DIAGRAM

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2FU9 Delay-action fuse, 3.15 A (glass-tube fuse 5 x 20 mm)

2FU10 Delay-action fuse, 3.15 A (glass-tube fuse 5 x 20 mm)

2KM1 Main contactor. See “2AP1:4 Soft start & activation of the main

contactor”, page37.

2KM2 Start contactor. See “2AP2 Power on board”, page39.

2KM3 Power on contactor. See “2AP1:1 Auxiliary supply +24 V_M & Fault

indication”, page35.

2L1 Primary inductor.

2L2-2L6 Ferrite cores.

2L9-2L10 Ferrite cores.

2L11-2L13 Ferrite cores.

2R1, 2R2 Discharge resistors, 1 MΩ 0.25W

2S1A, 2S1B Start enable switch.

2S2 Stop switch.

2S3 Start switch.

2TC1 Auxiliary transformer.

Secondary voltages:

11 V, (9 V ~ 14 V).

21 V, (17 V ~ 26 V).

38 V, 3 phase, (30 V ~ 47 V).

42 V, 3 phase, (33 V ~ 52 V).

15 Power module. wire numbers 1500 - 1699.

15AP1 Power board. See “15AP1:1 Switching Circuit”, page42.

15AP2 Power board. See “15AP2:1 Switching Circuit”, page46.

15AP3 Filter board. See “15AP3 Filter board”, page50.

15AP4 Filter board. See “15AP4 Filter board”, page51.

15AP5 Secondary rectifier board, with rectifier modules. See “15AP5 Secondary

rectifier board”, page53.

15AP6 Secondary rectifier board, with rectifier modules. See “15AP6 Secondary

rectifier board”, page54.

15AP7 Soft Start board, fitted to the primary rectifier. See “15AP7 Soft start

board”, page56.

15BR1 Primary rectifier.

15C1-15C4 Capacitors, 2700μF

15C5-15C8 Capacitors, 2700μF

15CS1 Current sensor, upper power block.

15CS2 Current sensor, lower power block.

15EV1 Upper fan, power module.

WIRING DIAGRAM

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15EV2 Lower fan, power module.

15L1 Inductor, upper power block.

15L2 Inductor, lower power block.

15L3-15L10 Ferrite cores.

15R5, 15R6 NTC resistors fitted on the heatsinks of the secondary rectifiers.

15ST1, 15ST2 Temperature switches mounted on the heatsinks of the primary inverters.

15ST3, 15ST5 Temperature switches mounted in the windings of the main transformers.

15ST7, 15ST9 Temperature switches mounted on the heatsinks of the secondary

rectifiers.

15ST8, 15ST10 Temperature switches mounted in the windings of the secondary

inductors.

15TM1 Main transformer, upper power block.

15TM2 Main transformer, lower power block.

18 AC module. Wire numbers 1800-1999.

18AP1 AC control board. See “18AP1 AC control board”, page58.

18C1-18C4 Capacitors, 260μF

18C5 Capacitor, 5.6nF

18EV1 Fan, AC module

18L1 Inductor, commutation circuit.

18PM1-18PM5 Commutation switch modules.

18PM6-18PM7 Auxiliary switch modules.

18PM8-18PM9 Freewheel diode modules (only for serial no. 221-xxx-xxxx).

18R1, 18R2 Discharge resistors 1500 ohm 50 W.

20AP1 Control board. See “20AP1 Control board”, page65.

20C1-20C3 Capacitors, 0.1μF

20L1 Ferrite core.

20FU1 Delay-action fuse, 3.15 A (ceramic-tube fuse 5 x 20 mm)

XP.. Plug (pin).

XS.. Socket (sleeve).

XT.. Terminal block.

For position of circuit boards and other components of the power source see “Aristo 1000

component positions”, page25.

WIRING DIAGRAM

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CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

Aristo 1000 AC/DC - Primary - Valid for serial no. 145-xxx-xxxx



WIRING DIAGRAM

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WIRING DIAGRAM

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WIRING DIAGRAM

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Aristo 1000 AC/DC - Secondary - Valid for serial no. 145-xxx-xxxx



WIRING DIAGRAM

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WIRING DIAGRAM

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Aristo 1000 AC/DC - Primary - Valid for serial no. 221-xxx-xxxx



WIRING DIAGRAM

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WIRING DIAGRAM

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Aristo 1000 AC/DC - Secondary- Valid for serial no. 221-xxx-xxxx



WIRING DIAGRAM

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