ESAB Aristotig 405 AC/DC Service Manual Download Page 1

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0458 165 002

9910

DTG 405

Aristotig 405 AC/DC

Welding rectifier

Service manual

Summary of Contents for Aristotig 405 AC/DC

Page 1: ...0458 165 002 9910 DTG 405 Aristotig 405 AC DC Welding rectifier Service manual...

Page 2: ...25 A1 7 PRIMARY MOSFET DRIVER 25 A1 8 MAINS SWITCH MONITORING 26 A2 COMPONENT POSITIONS 27 A2 DESCRIPTION OF OPERATION 28 GENERAL FUNCTION 28 DOWN SLOPE RAMP FUNCTION 28 SIGNAL DESCRIPTION X4 29 A4 A...

Page 3: ...VERLOAD 47 ERROR CODE 5 COOLING WATER FAULT GENERAL ERROR INTERRUPT OVERVOLTAGE TRIP 47 8 TESTING WITH TESTER IT01 47 GENERAL DESCRIPTION 47 TEST PROCEDURE WITH IT01 49 9 TESTING OF A4 A5 A9 A10 A11 A...

Page 4: ...VERHEATING PROTECTION 69 5 CONTROL PANEL 69 5 1 Error codes 71 5 2 Instruction types selection 2 72 5 3 Welding current selection switch 22 72 5 4 Remote control 73 6 ELECTRODE WELDING MMA 74 6 1 Sett...

Page 5: ...n the operation description All important component names in the connection dia gram are listed in the component description This manual contains details of all designs that have been made up to and i...

Page 6: ...unctions the valid safety instructions the welds 2 The operator must ensure that no unauthorized persons are situated in the working area while switching on the device that all persons near the ignite...

Page 7: ...hing 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 sui...

Page 8: ...nergy The primary switching frequency is about 66 kHz pulse width modulation PWM The frequency of the welding current while AC welding is controlled from 50 Hz to 200 Hz by the AC converter The AC con...

Page 9: ...9 NOTES...

Page 10: ...10 CONNECTION DIAGRAM DTG 405...

Page 11: ...11...

Page 12: ...A2 Designed to ensure and manage the advanced operating parameters and mode control It comprises A2 1 input for remote control A2 1 sequencer control A2 1 current value and current slope control A2 1...

Page 13: ...ontrol Potential separation secondary MOSFET drivers for A9 A13 A10 A14 Arc current and arc voltage monitoring A9 A13 A10 A14 Secondary power MOSFET modules full bridge AC converter containing Interco...

Page 14: ...transformer 2000 1 T3 High frequency inverter main transformer T4 Mains supply transformer supply A2 A6 230V AC fans pump 42V AC solenoid valve main contactor HF ignition device X Connectors X1 Mains...

Page 15: ...15 NOTES...

Page 16: ...16 BLOCK DIAGRAM DTG 405 405a pcx...

Page 17: ...17 Warning Some parts of this circuit are connected to mains voltage potential 405b pcx...

Page 18: ...UZ UZ is in the range from 510 V to 620 V When the unit is loaded the link voltage decreases somewhat and it becomes wavy Primary switches A4 A5 A11 A12 switch the DC voltage at approx 66 kHz produci...

Page 19: ...anel A2 The current actual value is re ported to A8 via the transformer shunt T2 see section A8 1 The output voltage is tapped at the inverter A9 A13 A10 A14 see section A8 2 These references and actu...

Page 20: ...errupts energy flow from the mains to the outputs of the power supply This status can only be cancelled by turning the unit OFF and back ON again This complies with the stipulation for Safe Failure de...

Page 21: ...s LED3 amber Comes on when the mains switch contacts 13 14 on Q1 are open A1 DESCRIPTION OF OPERATION The description refers to the BLOCK DIAGRAM DTG 405 and to A1 COMPONENT POSITIONS Only those items...

Page 22: ...a delay of about 1 second the main contactor K1 is closed via a switching stage 4 At the same time the drive circuits for the inverter are enabled see section A1 5 and section A1 7 A1 2 SUPPLY INVERT...

Page 23: ...even if Error Code 2 is not displayed NOTE If an excessive mains voltage 500 V AC occurs starting with a link voltage UZ of about 730 V DC the supply of A1 and A8 attempts to protect itself by perfor...

Page 24: ...n some cases without any hard ware fault e g HF starting directly on the machine frame etc But usually a primary overcurrent trip is only initiated by a hardware fault e g fault on A5 A12 A4 A11 AP10...

Page 25: ...ircuit and its parts are connected to mains voltage potential The Figure only shows the Low side the High side is controlled in a similar way The PWM clock signal is sent from A8 to A1 A1 causes poten...

Page 26: ...stem the position of the mains switch Q1 is eval uated via a contact on 13 14 The unit does not start unless the contact is closed Then a fault indication amber LED comes on is displayed on the front...

Page 27: ...27 A2 COMPONENT POSITIONS a2 1b pcx a2 2b pcx...

Page 28: ...ON The potentiometer provided on the front panel for adjusting the downslope ramp governs the dy namics of current change i e the number of amperes per unit of time the current changes during the down...

Page 29: ...V Start Stop of power stage 11 A2 0 10 V AC welding current frequency 12 A2 0 10 V AC welding current balance 13 A2 15 V DC mode AC mode high active for AC 14 A2 15 V Positive polarity for DC in MMA...

Page 30: ...30 A4 A11 COMPONENT POSITIONS Warning The circuit and its parts are connected to mains voltage potential...

Page 31: ...H MULTIMETER Disconnect Molex control lead X11 X12 on A1 Use the multimeter to measure the ohmic resist ance between pins 1 and 2 of X11 and X12 If the MOSFETs are OK the reading should be ap prox 500...

Page 32: ...ocedure of TEST PROCEDURE WITH IT01 CHECKING WITH OSCILLOSCOPE Turn off the machine Disconnect the cables used to transfer driver signals to modules A5 A12 and A4 A11 Connect the GND of the oscillosco...

Page 33: ...TION A6 1 SUPPLY A2 A6 Transformer T4 supplies AC voltages to X2 When rectified they are stabilised in voltage regula tors 21 22 23 and transferred to A2 via X5 The power supply to A2 and A6 is indepe...

Page 34: ...ergised so the start er detects the necessity of HF pulses via the weld voltage on A1 A2 On discontinuation of the arc the starter generates a starting pulse of the polarity desired A6 3 ARC VOLTAGE S...

Page 35: ...2 to A2 The supply voltage to X3 is 230 V a transformer and 27 are used to provide a potential isolated aux iliary voltage supply to RE2 A6 6 MONITORING THE COOLING CIRCUIT A pressure switch F11 monit...

Page 36: ...on the board All functions are controlled by a PLD programmable logic device on the board The power supply to A8 comes from A1 See section A1 2 Front panel A2 provides the following default values for...

Page 37: ...ter clock control signals for A1 Control signals for A9 A13 and A10 A14 A8 3 Status feedback signals to A2 A8 1 SECONDARY CURRENT MONITORING T2 is a floating DC current transformer The current signal...

Page 38: ...be tapped on the control A8 for other purposes e g for additional displays A8 3 SECONDARY MOSFET DRIVER The control signals for the secondary inverter are generated on A8 and transferred to the drive...

Page 39: ...supply for driver stages line 2 7 A1 15 V 15 V supply for control A8 8 A1 15 V 15 V supply for control A8 9 A8 15 V Pulse width modulation for inverter 10 GND GND Logic and supply ground 11 GND GND N...

Page 40: ...40 A9 A13 COMPONENT POSITIONS A10 A14 COMPONENT POSITIONS...

Page 41: ...ppression Filter Warning The circuit and its parts are connected to mains voltage potential T2 COMPONENT POSITIONS The trimmer on T2 defines the factory setting for the offset signal of the transforme...

Page 42: ...AULT CURRENTS After completing every repair check the electrical safety of the machine Refer to VDE 0100 and EN 60974 1 should be kept with the machine This manual will not deal with any extracts from...

Page 43: ...y switches A4 A5 A11 A12 Single phase design for 0 250 V 0 4 A is sufficient for this test For systems operating on 3 phase AC only the voltage must range up to 400 V A control trans former equipped w...

Page 44: ...slightly biased Time pattern starting current changeover to second current by second Torch button remote regulator functions ramp setting etc A ballast resistor can be used to simulate a load similar...

Page 45: ...and AC current An os cilloscope should be used to check the correct welding process as well as waveform in case of AC current The current can be measured via a suitable shunt or a transformer shunt 6...

Page 46: ...itch A5 A12 or A4 A11 defective Defect in secondary rectifier AP10 AP11 or its protective circuit Transformer shunt T2 defective or cable connection to inverter control board defective Defect in curre...

Page 47: ...ntact Failure of supply to A1 and A8 refer to A1 1 A1 2 Overvoltage trip of A1 because of excessive output voltage refer to A1 6 and Instructions for Fault Tracing and Repair 13 unit switches off afte...

Page 48: ...the electronic modules A1 and A8 which may suffer damage if there are defects in the power section The other functions of the con trol boards cannot be tested Self test of IT01 1 Connect 6 way ribbon...

Page 49: ...nnect the Molex cable from the tester to X12 on A1 Set the mode selector switch on A2 to 2 Cycle Lift Arc Turn on the welding unit The primary switch red LED l must come on no drive 11 Set mode select...

Page 50: ...than 100 On all power boards A4 A5 A9 A10 A11 A12 A13 A14 1 k pro tective resistors are installed in parallel with the control inputs When power modules are connected in parallel the resistance decrea...

Page 51: ...nd smooth Apply a thin film of heat conducting paste Check the gate series resistors Check contacts between board and ISOTOP modules as well as the connections to the cable harness Check the RC elemen...

Page 52: ...es are generated at the output Nevertheless if a safety trip occurs the inverter power supply is switched off within about 0 2 sec onds after the inverter starts Error code 5 is then shown on the disp...

Page 53: ...an elec trolytic capacitor will not cause internal arc over until a voltage of about 100 V is applied To ensure reliable testing the power supply should be capable of supplying an adequately high vol...

Page 54: ...efective When welding with AC and if the HF is inadequately stabilised change over of the trigger inputs to output voltage after starting an arc will not function properly see section A6 2 Possible ca...

Page 55: ...oling connections of a water cooled torch should be connected so that the pump is not overloaded 22 RENEWAL OF CONTROL BOARDS We advise you only to install control boards which have been factory adjus...

Page 56: ...ill 103 Unlock switch 105 at rear and remove front grill Slacken 2 M6 screws 6 Current terminal 1 pole Disconnect cable from 108 108 and 112 7 HF unit A7 Disconnect all cables 8 Rectifier bridge A3 Di...

Page 57: ...57 209 201 212 203 204 205 206 207 208 D04 0301 1 214 215 216 218 217 219 220 110 221 222 213 202...

Page 58: ...ous modes of operation They can be used for comparison with output currents when car rying out service work 1 FOUR STROKE LIFT ARC DC 2 FOUR STROKE HF IGNITION DC a I1 10 Imax 40 A b slope1 20 c I2 10...

Page 59: ...ON AC a Positive pole time a b I1 20 Imax 80 A c slope1 20 d I2 120 A e slope2 10 f I3 10 I2 12 A 50 Hz 40 a Positive pole time a b I1 20 Imax 80 A c slope1 20 d I2 50 A e slope2 10 f I3 10 I2 5 A 50...

Page 60: ...HF IGNITION DC a I1 10 Imax 40 A b slope1 20 c I2 100 A d slope2 50 e I3 10 I2 10 A i lift arc ignition p pressing torch button a I1 10 Imax 40 A b slope1 20 c I2 100 A d slope2 50 e I3 10 I2 1 0A p...

Page 61: ...61 6 TWO STROKE HF IGNITION AC 7 WAVEFORM AC1 SQUARE WAVE a I1 20 Imax 80 A b slope1 20 c I2 120 A d slope2 10 e I3 10 I2 10 A 2hfac pcx ac1 pcx...

Page 62: ...62 8 WAVEFORM AC2 SMOOTH WAVE ac2 pcx...

Page 63: ...tor L1 etc 2 COMMISSIONING OF DTG405 POWER SECTION 1 Test for electrical safety 2 Disconnect water pump Jumper the water pressure switch input X9 1 to X9 2 Disconnect the fan 3 Measure the resistances...

Page 64: ...circuit when current flows for about 2 seconds while the output voltage is less than approx 8 V Do not forget After starting the hot test remove the short circuit jumper from J1 15 Set the load resis...

Page 65: ...remote regulator to socket X5 and test 26 Thermal trip at 0 05 load resistance and maximum current Mode 4 Cycle AC1 TIG with HF frequency 50 Hz balance 40 Remove the short circuit jumper once the tes...

Page 66: ...A2 1 5 The gas lead time can be adjusted by means of trimmer 3 refer to component mounting dia gram of A2 1 The gas lead time is factory set to 200 ms 6 The starter turn off lag can be altered by mea...

Page 67: ...67 LOAD CHARACTERISTICS NOTES 0 10 20 30 40 50 60 70 80 90 0 50 100 150 200 250 300 350 400 A V TIG MMA DTG 405...

Page 68: ...current during the TIG and electrode welding can be adjusted using the remote reg ulator With the remote regulator any current between 3 A and the preset welding current I2 of the unit can be selecte...

Page 69: ...the power source in order to prevent unintentional arc ignition when switching it on again An unintentionally ignited arc may damage the electrode holder the workpiece or the equipment 5 CONTROL PANEL...

Page 70: ...age to the electrode During pulsed operation When activating the button gas test the display 10 switches to the I4 value 16 Display error code Display of possible error messages 17 LED fault LED flash...

Page 71: ...t no craters are caused Error Possible cause Action 1 Primary overcurrent Fault in power supply Call service 2 Primary undervoltage Faulty power supply Faulty fuses Check power supply Generator is und...

Page 72: ...nt 1 Soft Hot Start starts to flow when pressing the torch button The main current I2 is activated Up Slope active by releasing the torch button The down ramp is started by pressing and maintaining th...

Page 73: ...ted remote control is connected to control the set value of the welding current The device changes automatically to two stroke mode and disconnects the slope functions Using the foot operated remote c...

Page 74: ...h 2 to electrode welding Light emitting diode 6 indicates that voltage is applied to the welding current sockets E and I 3 Set the desired welding current type with welding current selection switch 22...

Page 75: ...current socket after manipulation of the torch button 4 Set the desired welding current type and ignition method using the welding current selection switch 22 5 Set Soft Hot Start function ignition cu...

Page 76: ...fter the pre flow time has expired at a current level determinated by the soft hot start ignition current control Step 2 Releasing the torch button causes the current to increase to the welding curren...

Page 77: ...ant on the set welding current I2 6 Set final current I3 using the potentiometer 30 7 Set gas post flow time using the potentiometer 18 0 2 30 s 7 1 3 TIG TWO STROKE WELDING Step 1 By pressing the tor...

Page 78: ...The range of times which can be set using this switch is from 0 002 to 0 1s corresponding to a frequency range of 250 to 5 Hz Normal pulse The arc pulses between the two current values set by the pote...

Page 79: ...uency is progressively adjustable from 50 up to 200 Hz A higher AC frequency results in a more concentrated and a more stable arc It is suitable for lower currents and for welding thin plates Using th...

Page 80: ...ough the ventilating grill to the rear Leave the housing closed Never blow the compressed air through the grill on the rear of the unit A ventilating fan is located there that would be brought to such...

Page 81: ...81 NOTES...

Page 82: ...8 2 0458 165 065 Current terminal 1 pole X3 X7 109 1 0538 500 902 2 pole panel socket X5 110 1 0457 377 039 Gas connection nipple 111 1 0458 165 055 Remote regulator socket Burndy complete X4 112 1 04...

Page 83: ...oler 212 1 0458 165 024 Hose clip 9 8 12 3 213 1 0458 165 064 Fan 300mm M1 214 2 0458 165 005 Spacer M20 215 2 0192 859 026 washer 36 21x3 216 1 0458 165 066 power unit 217 19 0458 165 004 Nut M6 spez...

Page 84: ...4 1 0366 481 004 Seal 82 46 305 1 0469 689 002 Cover watertank 306 1 0469 689 001 Water tank 307 1 0458 165 059 Cable set DTG 405 308 1 0458 165 056 Flat cable 26 conductor 800mm 309 1 0457 377 071 In...

Page 85: ...10k 300 403 1 0458 165 077 Potentiometer 10k 300 403 1 0458 165 077 Potentiometer 10k 300 403 1 0458 165 077 Potentiometer 10k 300 403 1 0458 165 077 Potentiometer 10k 300 403 1 0458 165 077 Potentiom...

Page 86: ...86 D04 0304 1 D04 0305 0 501 502 503 502 502 504 505 506 507 508 509 510 511 512 513 515 516 505 517...

Page 87: ...m 512 1 0458 165 060 Insulating foil 513 1 0458 165 032 Control ACST1 ESD A6 515 1 0458 165 061 Solenoid valve 42V Y1 516 1150mm 0458 165 021 Gas hose black 5x1 5 517 4 0458 165 070 Spacer screw Item...

Page 88: ...8 165 040 Modul WPH MI ESD A9 A13 706 2 0458 165 037 Modul GPD PL ESD A5 A12 707 4 0458 165 082 Rectifiermodul B23 P10 708 6 0458 165 080 Mosfetmodul N 900V 26A 709 6 0458 165 083 Rectifiermodul B200...

Page 89: ...0458 165 091 HF choke L2 803 1 0458 165 097 Main transformer T3 804 1 0458 165 098 Main choke L1 805 1 0458 165 089 Rectifier bridge A3 806 1 0458 165 100 E Assembly 4x 1500yF 385V kpl set C1 C2 C3 C4...

Page 90: ...ter IT01 1 0458 165 099 Central connection with cable set 1 E458 165 042 Control ACST1 for exchange ESD 904 1 E458 165 043 Control ACI 30 for exchange ESD 1 E458 165 044 Control GWL DTG 405 for exchan...

Page 91: ...page...

Page 92: ...LAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 333 4...

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ESAB Aristotig 405 AC/DC, Service Manual

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Summary of Contents for Aristotig 405 AC/DC

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