ESAB AristoMig U400 User manual

0740 800 166 Valid for serial no. 105--xxx--xxxx to 524--xxx--xxxx050614
AristoMig U400
AristoMig 400
AristoTig 400
AristoArc 400
Service manual

-- 2 --TOCe
Rights reserved to alter specifications without notice.
READ THIS FIRST 4.................................................................
INTRODUCTION 5...................................................................
TECHNICAL DATA 6.................................................................
AristoMig U400 6..................................................................
AristoMig 400 7...................................................................
AristoTig 400 8...................................................................
Cooling unit 8....................................................................
AristoArc 400 9...................................................................
WIRING DIAGRAMS 10...............................................................
Component description 10..........................................................
AristoMig MMC option 13...........................................................
AristoMig U400 valid for serial number 322--xxx--xxxx to 524--xxx--xxxx 14.................
AristoMig 400 valid for serial number 105--xxx--xxxx to 524--xxx--xxxx 16...................
AristoTig 400 valid for serial number 105--xxx--xxxx to 524--xxx--xxxx 18...................
AristoArc 400 valid for serial number 105--xxx--xxxx to 524--xxx--xxxx 20...................
DESCRIPTION OF OPERATION 22.....................................................
AP2 Interference suppressor board 22...............................................
1 MMC module 22..................................................................
2AP1 Interference suppressor board 23..............................................
4 Autotransformer 23...............................................................
5 Cooling unit 24...................................................................
15 The power module 25............................................................
15AP1 Power board 26.............................................................
15AP1:1 Mains rectifier bridge and charging circuit 26..................................
15AP1:2 Switching circuit 27........................................................
15AP1:3 Overvoltage and undervoltage protection 27...................................
15AP1 Component positions 28....................................................
15AP2 Gate driver board 29.........................................................
15AP2:1 Gate driver stages 29......................................................
15AP2:2 Overvoltage and undervoltage protection 29...................................
15AP2 Component positions 31....................................................
20AP1 Control board 32............................................................
20AP1:1 Power supply 32...........................................................
20AP1:2 Fan control 33.............................................................
20AP1:3 The CAN bus 33...........................................................
Terminating resistors 34....................................................
20AP1:4 Temperature monitoring 35..................................................
20AP1:5 Overvoltage and undervoltage protection 36...................................
20AP1:6 Communication with relay board 20AP2 36
....................................
20AP1:7 Gate pulses 36............................................................
20AP1:8 Current sensor 36.........................................................
20AP1:9 Arc voltage input for Universal and MIG machines 37...........................
20AP1:9 Arc voltage input for TIG and MMA machines 39...............................
20AP1 Component positions 40....................................................
20AP2 Relay board 42..............................................................
20AP2:1 Power supply 42...........................................................
20AP2:2 External shutdown 42......................................................
20AP2:3 Starting sequence 43.......................................................
20AP2:4 Power supply to the cooling unit 44..........................................
20AP2:5 Cooling water monitoring in MIG welding mode 44.............................
20AP2:5 Cooling water monitoring in TIG welding mode 46..............................
20AP2:6 TIG Gas valve 47..........................................................
20AP2:7 TIG HF starting device 47...................................................
20AP2:8 TIG Starting 47............................................................
20AP2:9 Gas flow monitor 48........................................................
20AP2 Component positions 48....................................................
20AP2 Circuit diagram 49.........................................................

-- 3 --TOCe
Rights reserved to alter specifications without notice.
REMOTE CONTROLS 50..............................................................
FAULT CODES 50....................................................................
SERVICE INSTRUCTIONS 50..........................................................
What is ESD? 50...................................................................
Service aid 51......................................................................
Exchange circuit boards 52.........................................................
Dismantling 53.....................................................................
Service traps 53....................................................................
Checking the IGBT transistors 54...................................................
Mounting components on the heat sink 55...........................................
Replacing MCB 2FU1 55............................................................
Checking the gate pulses 56........................................................
Pulses from circuit board 15AP2 to transistors 15Q1 and 15Q2 57.........................
Pulses from circuit board 20AP1 to circuit board 15AP2 58...............................
Soft starting 60....................................................................
Checking the overvoltage and undervoltage threshold values 62......................
Calibrating the current sensor signal 64.............................................
AristoMig, calibration of the arc voltage input 65.....................................
AristoTig & AristoArc, calibration of the arc voltage input 68..........................
Replacing TR1 on 15AP1 with new version of 2TC1 69................................
Electrical installation of built--in autotransformer 70..................................
INSTRUCTION MANUAL 71...........................................................
SAFETY 71........................................................................
INSTALLATION 72..................................................................
Lifting instructions 72..............................................................
Mains power supply 72.............................................................
Terminating resistor, AristoMig 73...................................................
OPERATION 73....................................................................
Connections and control devices, AristoMig U400 73.................................
Connections and control devices, AristoMig 400 74..................................
Connections and control devices, AristoArc 400 74..................................
Connections and control devices, AristoTig 400 75...................................
Turning on the power source 75....................................................
Fan control 76.....................................................................
Overheating protection 76..........................................................
Cooling unit 76....................................................................
Remote control unit 76.............................................................
MAINTENANCE 77.................................................................
Cleaning the air filter 77............................................................
Topping up the coolant 77..........................................................
SPARE PARTS 78....................................................................
NOTES 78...........................................................................

Edition 050614
-- 4 --
cu20d1
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 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. All component names in the wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made from January 2001
up to and including June 2005.
The manual is valid for AristoMig U400, AristoMig 400, AristoTig 400 and AristoArc 400 with serial
no. 105--xxx--xxxx, 322--xxx--xxxx, 334--xxx--xxxx, 347--xxx--xxxx, 445--xxx--xxxx and
524--xxx--xxxx.
Note: AristoMig 400, AristoTig 400 and AristoArc 400 with serial number 050--xxx--xxxx
differ slightly from the description in this manual. For those machines there are separate
service manuals available.
AristoMig U400, AristoMig 400, AristoTig 400 and AristoArc 400 have been designed
and tested in accordance with international and European standards IEC/EN 60974--1
and EN 50199.
On completion of service or repair, the service organisation that has performed the
work must make sure that the equipment still complies with the above standards.
WARNING
Many parts of the power source are at mains voltage.

Edition 050614
-- 5 --cu20d1
INTRODUCTION
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.
Schematic diagram of the power source
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 forward converter inverter, operating at a switching frequency of 27 kHz.
IGBT transistors are used as the switching elements. All power semiconductors are built
into modules in order to ensure a robust design suitable for use in the demanding welding
environment.
20 Processor board module (controller module)
This is the controller board, 20AP1, with a microprocessor, that monitors and controls the
voltage and current. It is served by relay board 20AP2, which handles input and output
signals to/from the controller board.
Further information on the modules can be found in the component and function
descriptions.

Edition 050614
-- 6 --
cu20d1
TECHNICAL DATA
AristoMig U400
Mains voltage 400V, ±10%, 3∼50 Hz
Primary current
Imax MIG/MAG
Imax MMA
Imax TIG
36 A
38 A
29 A
No--load power demand when in the energy--saving mode,
6.5 min. after welding 60 W
Voltage/current range
MIG/MAG
MIG/MAG, M2
MMA
TIG
8--60 V / 16--400 A
8-- 42 A
16-- 400 A
4 -- 400 A
Permissible load at MIG/MAG
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 34 V
320 A / 30 V
250 A / 27 V
Permissible load at MMA
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
Permissible load at TIG
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 26 V
320 A / 23 V
250 A / 20 V
Power factor at maximum current 0.65
Efficiency at maximum current 85 %
Open--circuit voltage
MIG/MAG
MMA
TIG
55 -- 70 V
78 -- 90 V
78 -- 90 V
Operating temperature -- 1 0 t o + 4 0 ˚C
Continual A--weighted sound pressure <70 db
Dimensions, lxbxh
with cooling unit
625 x 394 x 496 mm
625 x 394 x 776 mm
Weight
with cooling unit
61 kg
81 kg
Insulation class H
Enclosure class IP 23
Application class

Edition 050614
-- 7 --
cu20d1
AristoMig 400
AristoMig 400
not reconnectable
AristoMig 400
reconnectable
Mains voltage 400V, ±10%, 3∼50 Hz 208/230/400/460/475/500/
575 V, ±10%, 3∼50/60 Hz
Primary current
Imax (MIG/MAG)
Imax (MMA)
36 A
38 A
61/54/36/28/28/25/19 A
65/57/38/30/30/26/20 A
No--load power demand when in the
energy--saving mode, 6.5 min. after wel-
ding
60 W 235 W
Voltage/current range
(MIG/MAG)
(MIG/MAG, M2)
(MMA)
8--60 V / 16--400 A
8-- 42 A
16-- 400 A
8--60 V / 16--400 A
8-- 42 A
16 -- 400 A
Permissible load at (MIG/MAG)
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 34 V
320 A / 30 V
250 A / 27 V
400 A / 34 V
320 A / 30 V
250 A / 27 V
Permissible load at (MMA)
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
400 A / 36 V
320 A / 33 V
250 A / 30 V
Power factor at maximum current 0.65 0.65
Efficiency at maximum current 85 % 85 %
Open--circuit voltage
(MIG/MAG)
(MMA)
55 -- 70 V
78 -- 90 V
55 -- 70 V
78 -- 90 V
Operating temperature --10 till +40˚C--10 till +40˚C
Dimensions, lxbxh
with cooling unit
625 x 394 x 496 mm
625 x 394 x 776 mm
625 x 394 x 776 mm
625 x 394 x 1056 mm
Continual A--weighted sound pressure <70 db <70 db
Weight
with cooling unit
57 kg
77 kg
114 kg
134 kg
Insulation class H H
Enclosure class IP 23 IP 23
Application class

Edition 050614
-- 8 --
cu20d1
AristoTig 400
AristoTig 400
not reconnectable
AristoTig 400
reconnectable
Mains voltage 400V, ±10%, 3∼50 Hz 208/230/400/460/475/500/575 V,
±10%, 3∼50/60 Hz
Primary current
Imax (TIG)
Imax (MMA)
29 A
38 A
50/44/29/23/23/20/15 A
65/57/38/30/30/20/20 A
No--load power in the energy--saving
mode, 6.5 min. after welding 60 W 235 W
Voltage/current range
(TIG)
(MMA)
8--60 V / 4--400 A
16 -- 400 A
8--60 V / 4--400 A
16 -- 400 A
Permissible load at TIG
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 26 V
320 A / 23 V
250 A / 20 V
400 A / 26 V
320 A / 23 V
250 A / 20 V
Permissible load at MMA
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
400 A / 36 V
320 A / 33 V
250 A / 30 V
Power factor at maximum current 0.65 0.65
Efficiency at maximum current 85 % 85 %
Open--circuit voltage 78 -- 90 V 78 -- 90 V
Operating temperature range -- 1 0 t o + 4 0 ˚C-- 1 0 t o + 4 0 ˚C
Dimensions, lxbxh
with cooling unit
625 x 394 x 496
625 x 394 x 776
625 x 394 x 776
625 x 394 x 1056
Continual A--weighted sound pres-
sure <70 db <70 db
Weight
with cooling unit
59 kg
79 kg
116 kg
136 kg
Insulation class H H
Enclosure class IP 23 IP 23
Application class
Cooling unit
Cooling power 2500 W at 40˚C temp. difference and flow1.5l/min
Coolant 50 % water / 50% glycol
Coolant quantity 5.5 l
Maximum water flow 2.0 l/min

Edition 050614
-- 9 --
cu20d1
AristoArc 400
Mains voltage 400 V, ±10%, 3∼50 Hz
Primary current Imax 38 A
No--load power in energy--saving mode 6.5 min. after
welding 50 W
Setting range 16 A -- 400 A
Maximum permissible load at
35% duty cycle
60 % duty cycle
100 % duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
Power factor at maximum current 0.65
Efficiency at maximum current 85%
Open--circuit voltage 78 -- 90 V
Temperature range --10 till + 40˚C
Dimensions, l x b x h 625 x 294 x 492 mm
Continual A--weighted sound pressure <70 db
Weight 45 kg
Insulation class H
Enclosure class IP 23
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
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 use in areas with increased
electrical hazard.

Edition 050614
-- 1 0 --
cu20d1
WIRING DIAGRAMS
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 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,
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
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
SObserve precautions for handling electrostatic--
sensitive devices.
SUse proper static--proof bags and boxes.
ESD
Component description
Component Description
AP1 Connection board for communication with the wire feed unit and remote
control device.
AP2 Interference suppressor board. See diagram on Page 22.
AP3 CAN bus distribution board. Accessory, included in the MMC kit for
AristoMig, see page 13.
C3 Capacitor, 100 nF 250 V.
C4 Capacitor, 100 nF 250 V.
D1 LED, orange, for overtemperature indication.
HL1 Indicating lamp, white. Indicates Power On
XP.. Plug connectors.

Edition 050614
-- 1 1 --
cu20d1
Component Description
XS.. Socket connectors.
XT.. Terminal blocks.
1 MMC module. Wire numbers 100--199. See description on Page 22.
2 Mains module. Wire numbers 200--299.
2AP1 EMC suppressor board. See diagram on Page 23.
2FU1 MCB, 5 A. Replaced by a 4 A slow blow (anti--surge) fuse,
from serial no. 347--351--xxxx. See also Page 55.
2FU2 Fuse, 6.3 A, slow blow (anti--surge).
2FU3 Fuse, 3.15 A, slow blow (anti--surge).
2FU4 Fuse, slow blow (anti--surge), different rating depending on machine type.
AristoMig U400 and AristoMig 400: 8 A.
AristoTig 400: 0.5 A
2FU5 Fuse, 2 A, slow blow (anti--surge).
2KM1 Main contactor. See 20AP2:3 on Page 43.
2QF1 Mains switch. See 20AP2:3 on Page 43.
2TC1 Control power transformer. New winding added from serial no.
524--xxx--xxxx, see page 69.
2TC2 Control power transformer. If the mains voltage exceeds 427 V, the link on
terminal 2XT2 must be moved from the 400 V terminal to the 428 V
terminal.
3 Primary inductor module. Wire numbers 300--399.
3L1 Primary inductor.
4 Autotransformer module. Wire numbers 400--499.
Se the diagram and connection notes on Page 23.
4EV1 Fan, 24 V DC. See 20AP1:2 on Page 33.
4TM1 Autotransformer.
5 Water cooling module. Wire numbers 500--599.
The wiring diagram for the cooling module is on Page 24.
The power supply to the cooling water pump and fan is controlled by the
machine software. See the description of the 20AP2:5 on Page 44.
10 TIG module. Wire numbers 1000--1199.
10AP1 HF starting device. See the description of 20AP2:7 on Page 47.
10C1 Interference suppression capacitor, 47 nF 250V.
10TV1 HF transformer.

Edition 050614
-- 1 2 --
cu20d1
Component Description
10YV1 Gas valve. See the description of 20AP2:6 on Page 47.
15 Power module. Wire numbers 1500--1699. See the schematic diagram
and description on Page 25.
15AP1 Power board.
15AP2 Driver board.
15AP3 Current sensor. See the description of 20AP1:8 on Page 36.
15BR1 Rectifier bridge. See the description of 15AP1:1 on Page 26 and the
assembly instructions on Page 55.
15D1, 15D2 Rectifier and freewheel diode modules. Each module consists of two
diodes.
15D1 rectifies the welding current. During the time interval between two
voltage pulses from transformer 15TM1, the freewheel diodes 15D2
maintain the welding current from inductor 15L3.
See Page 55 for assembly instructions for the diode modules.
15EV1, 15EV2 Fans, 24 V DC. See the description of 20AP1:2 on Page 33.
15L1, 15L2 2 + 2 ferrite rings. Reduce transient voltages produced when the diode
modules 15D1 and 15D2 turn off.
15L3 Inductor.
15Q1, 15Q2 IGBT transistors. See the description of 15AP1:2 on Page 27 and the
installation instructions on Page 55.
15ST1 Thermal overload cutout, in the winding of main transformer TM1. See the
description of 20AP1:4 on Page 35.
15ST2 Thermal overload cutout, mounted on the heat sink for the IGBT modules.
See the description of 20AP1:4 on Page 35 and the installation
instructions on Page 55.
15TM1 Main transformer.
20AP1 Controller circuit board.
20AP2 Relay board.

Edition 050614
-- 1 3 --
cu20d1
AristoMig MMC option
CAN bus distribution board AP3 connected to AristoMig
The AristoMig is normally delivered without MMC module. If the accessory ’MMC kit’ is
used, the MMC module can be moved from the wire feed unit to the power source.

Edition 050614
AristoMig U400 valid for serial number 322--xxx--xxxx to 524--xxx--xxxx
-- 1 4 --
cu20d1

Edition 050614
-- 1 5 --cu20d1

Edition 050614
AristoMig 400 valid for serial number 105--xxx--xxxx to 524--xxx--xxxx
-- 1 6 --
cu20d1

Edition 050614
-- 1 7 --cu20d1

Edition 050614
AristoTig 400 valid for serial number 105--xxx--xxxx to 524--xxx--xxxx
-- 1 8 --
cu20d1

Edition 050614
-- 1 9 --cu20d1

Edition 050614
AristoArc 400 valid for serial number 105--xxx--xxxx to 524--xxx--xxxx
-- 2 0 --
cu20d1