Esab Luc 400 Aristo 400

LUC 400
Aristo 400
Welding power source
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Service manual
740 800--070 9305 -- 1

LIST OF CONTENTS Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THE INVERTER PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPONENT DESCRIPTION, LUC 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INTERCONNECTION DIAGRAM, LUC 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BLOCK DIAGRAM, CIRCUIT BOARD AP5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMPONENT POSITIONS, CIRCUIT BOARD AP5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION OF OPERATION, CIRCUIT BOARD AP5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHECKING THE GATE PULSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SWITCH UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SOFT STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CIRCUIT DIAGRAM, CIRCUIT BOARD AP9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIODE BRIDGE BOARD AP13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SETTING BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DISPLAY BOARD, AP10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MICROPROCESSOR BOARD, AP11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FAULT/ERROR MESSAGES ON THE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
REMOTE CONTROL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTRUCTION MANUAL ARISTO 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

TECHNICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SETTING BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
REMOTE CONTROL UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
EXPLANATION OF ABBREVIATIONS AND CONCEPTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Ordering numbers for components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
STATIC CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
EFFICIENCY/POWER FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Rights reserved to alter specifications without notice.
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INTRODUCTION
This service manual is intended for use by personnel with appropriate technical training, to
provide assistance with fault--tracing and maintenance.
The Aristo MED 44 wire feed unit is described in a separate service manual.
To assist in understanding operation of the machine, the instruction manual is included at the
end of the service manual.
This manual contains details of all design changes incorporated up to and including May
1993.
The edition date on the front page is followed by a one (9305 - 1), this means that the layout
has been altered, the contents are still the same as in the 9305 edition, however the spare parts
list is updated and includes all design changes up to January 1996.
Layout and presentation of the material are intended to assist in quickly locating and
correcting any faults in the machine.
Use the diagrams in the manual as starting points when tracing faults. The interconnection
diagram is accompanied by a list of the machines components in alphabetical and numerical
order.
The Aristo 400 has been designed and tested in accordance with the international EN
60 974--1 standard (IEC 974--1).
On completion of service or repair, 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.
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RATING PLATE
The rating plate is secured to the rear of the machine. The following points describe what the
various items on it mean.
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1 LUC 400 is the type designation for the Aristo 400. The first letter, L, indicates
that Aristo is a rectifier, while U indicates a universal power unit and C indicates
the design generation.
The numerals 400 indicate the maximum welding current.
2 These symbols indicate that Aristo incorporates an inverter, a transformer and a

rectifier.
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3 Indicates the voltage/current characteristic when MIG/MAG welding, over a
current range of 15 -- 400 A.
The voltages of 15 V and 34 V indicate that we comply with the international arc
voltage characteristic as specified in IEC 974--1.
X = The intermittence factor, i.e. the length of time for which welding can be
performed at the specified welding data, expressed as a percentage of a
ten--minute period.
I2 = Current at the respective intermittence factor.
U2 = Voltage in accordance with the arc voltage characteristic.
Uo = Open--circuit voltage.
4 Indicates the voltage/current characteristic for MMA welding.
5 Indicates that the unit is intended for connection to a 400 V three--phase 50 Hz or

60 Hz supply.
I1 = primary currents at maximum welding current.
6 IP21 indicates the enclosure class with respect to protection against entry of foreign
bodies and/or water.
This symbol indicates that the unit is designed for use in areas of elevated
electrical hazard.
7 The machines serial number, consisting of three groups of figures (xxx yyy zzz).
The first group (xxx) indicates the version. The numerals indicate the year and
week of approval of the design version.
The second group (yyy) indicates the year and week of the machines final testing:
e.g. 203 indicates 1992, week 3.
The final group (zzz) consists of three or four numerals and is a consecutive serial
number from 0001 to 9999.
8 Shows that ESAB complies with the international IEC 974--1 standard.
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THE INVERTER PRINCIPLE
The Aristo 400 is a transistorised power unit that operates on the inverter principle.
The 400 V 3--phase mains voltage is rectified by rectifier bridge VC1 and smoothed by
capacitor C01.
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On open circuit and with a 400 V mains supply, the voltage across C01 is 565 V. This voltage
is then switched rapidly to the primary windings (TM1 and TM2) of the main transformer.
The time interval is controlled by circuit board AP5, which provides control pulses to the
transistors in switching units A, B and C, D.
The switching pairs A and B (in one pair) and C and D (in the other) operate in anti--phase.
Each pair operates at 24 kHz, and the anti--phase connection means that the frequency on the
welding side is 48 kHz.
1. The output voltage from the upper switching pair, A and B (40% duty cycle)
2. The output voltage from the lower switching pair, C and D (40% duty cycle)
3. The output voltage from the two pairs together (80% duty cycle)
4. The current in the welding circuit
Each voltage pulse on the primary sides of transformers TM1 and TM2 produces a
corresponding voltage pulse on the secondary sides. These voltage pulses are rectified by
welding diodes V5 and V7. The welding current flows through the arc, shunt RS1 and
welding current inductors L1 and L2. The shunt provides a voltage signal proportional to the
current.
As the control pulses must lie within 39.5 -- 41.5% of a whole cycle, and as the switching
units operate in anti--phase, it might be thought that current flows for only a maximum of
83% of the cycle. However, this is not the case, as the current is maintained by inductors L1
and L2 and the freewheel diodes V6 and V8.
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COMPONENT DESCRIPTION, LUC 400
This component description refers to interconnection diagram on page 12.
AP1--AP4 Circuit board with switching units. Fault--tracing instruction are on page 35.
AP5 Main circuit board with control electronics: see the block diagram on page 14
and DESCRIPTION OF OPERATION, CIRCUIT BOARD AP5 on page 19.
AP6 Circuit board with two LEDs: LD1 (yellow) for fault indication and LD2
(green) for indication of cooling water flow.
The board also provides 22 V to indicating lamp HL1 (Mains On) from
transformer TC1. See also Fault tracing on page 28 .
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Component positions on circuit board AP6

AP7 Suppressor board. Prevents mains--borne interference.
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Circuit diagram and component positions on circuit board AP7
AP8 Interference suppression board: protects against the effect of mains--borne

voltage transients.
AP9 Interference suppression board, fitted by the connection for the remote control
units. Circuit diagram and component positions are shown on page 39.
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AP10 Display board, fitted in the welding settings control unit. See SETTING
BOX on page 47.
AP11 Circuit board in the welding settings control unit. See SETTING BOX on
page 47.
AP12 Interference suppression board, fitted by the OKC (welding current) terminals.
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Circuit diagram and component positions, circuit board AP12.

AP13 Diode bridge board, provides galvanic separation of primary side thermal
cutouts, ST3 and ST4, from the secondary side. See DIODE BRIDGE
BOARD AP13 on page 40
C01 Capacitor, 50 F 600 V. Buffer/smoothing capacitor.
C02 Motor start--and--run capacitor for the cooling water pump, 6 F 400 V.
C03,C04 RFI suppression capacitor, 0.1 F 250 V. For suppression of interference on
the supply to the welding data control unit.
C05,C06 Decoupling capacitor, 10 nF 1000 V.
C7 RFI suppression capacitor, 0.1 F.
C09,C10 Decoupling capacitor, 10 nF 1000 V.
C11 Capacitors, six, each 1000 F 400 V. Mounted together with L3 and R11,
when TV1 or TV2 are fitted. See also L3.
C12 RFI suppression capacitor, 22 nF 250 V.
EV1,EV2 Cooling fans for the switching units.
EV3 Cooling fan for the water cooler.
FU1 MCB, 5 A, fitted at the rear of the machine. Protects the primary sides of
transformers TC1 and TC2.
FU2 Fuse, 10 A, fitted at the rear of the machine. Protects the 42 V supply from
transformer TC2 to wire feed unit connection XP3 and control circuit board
AP5.
FU3 Fuse, 2 A, fitted at the rear of the machine. Protects the 9 V supply from
transformer TC1 to the welding data control unit.
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FU4 Fuse, 0,5 A. Fitted in the connection between E4 on circuit board AP5 and the
negative terminal of capacitor C01.
Protects the overvoltage protection circuits on circuit board AP5.
KT1 Timer relay, delays closing of contactor QF1 by about one second.
This delay is necessary to allow the smoothing capacitors to charge up via R1.
L1 Upper welding inductor. The core of this inductor has a 2 mm airgap.
L2 Lower welding inductor. The core of this inductor has no airgap.
L3 Primary inductor, fitted together with C11 and R13 when TV1 or TV2 is fitted.
When these components are fitted, three resistors (R1) must be fitted, in order
to reduce the heat produced when charging the capacitors.
With C11 and R13, L3 forms a voltage stabilisation filter. This filter is needed
in order to reduce the voltage ripple that can occur as a result of the inductance
of TV1/TV2
When operating on a supply system with unstable voltage, the mains filter may
be needed for stabilisation of the supply voltage.
C11, L3, R13 and two of the R1 resistors can be ordered as Filter Set, under
part no. 468 925--880.
M1 Motor, cooling water pump.
HL1 Indicating lamp, 28 V. It is supplied at 22 V from TC1 via circuit board AP6.
The lamp is lit when switch SA1 is on.
QF1 Main contactor, energised when switch SA1 is on.
If the contactor does not open again after having been energised, it must be
replaced, as must also resistor R1 if it is burnt out.
R1 Resistor, 10 50 W. Three of these resistors are fitted in machines in which
C11, L3 and R13 are fitted. In other machines, only the resistor that is
connected to wire 055 is fitted.
R2 Resistor, 25 k 50 W. This resistor is connected in series with the power
supply to the overvoltage protection circuitry on circuit board AP5.
R3,R4 Resistor, 10 50 W.
R5,R6 Resistor, 4.7 5 W. Forms part of the transient protection circuit across the
welding and freewheel diodes.
R7 Resistor, 40 50 W.
R8,R9 Resistors, 10 50 W.
R10,R11 Resistor, 4.7 5 W.
R12 Resistor, 40 50 W.
R13 Resistors, two, each 10 k 25 W.
Fitted together with C11 and L3 when TV1 or TV2 is fitted. See also L3.
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RS1 Shunt, gives 24 mV output signal at 100 A welding current.
SA1 Main switch.
SA2 Switch. Cooling water pump, On/Off.
ST1,ST2 Thermal cutouts, open at 100C, fitted on the heat sinks for the secondary
diodes (V5, V7). See also DIODE BRIDGE BOARD AP13 on page 40.
ST3,ST4 Thermal cutouts, open at 85C, fitted on the heat sinks for the switch units.
WARNING: the cutouts are in the 565 V circuit.
See also DIODE BRIDGE BOARD AP13 on page 40.
SF1 Water flow switch. Closes at flow rates above 0.7 litre per minute.
TA1,TA2 Current transformers.
TC1 Control power supply transformer. Supplied at 400 V through fuse FU1.
An autotransformer winding on the primary side provides 230 V to fans EV1
and EV2, as well as to the coil of contactor QF1.
Secondary voltages:
22 V to circuit boards AP5 and AP6.
9 and 15 V to circuit board AP5.
9 V from a separate winding to the welding data control unit.
TC2 Control power supply transformer. Supplied at 400 V via fuse FU1.
Secondary voltages:
230 V to pump M1 and fan EV3.
42 V via fuse FU2 to circuit board AP5 and to the wire feed unit via
interference suppressor board AP9 and connection XP3.
TM1,TM2 Main transformers.
TV1 Autotransformer for machines connected to 230 V mains power supplies.
TV2 Autotransformer for machines connected to 415 or 500 V mains power
supplies.
V1--V4 Switch units: see description on page 35.
V5,V7 Rectifier diodes for the welding current: 2 x 6 diodes. See also item 10 on
page 42.
V6,V8 Freewheel diodes: 2 x 4 diodes.
During the time interval between voltage pulses from transformers TM1 and
TM2, inductors L1 and L2 maintain the welding current through the freewheel
diodes. See also item 10 on page 42.
VC1 Mains rectifier diode bridge.
XP1 15--pole male connector.
XP2 15--pole female connector.
XP3 23--pole female connector for connection of the remote control device/wire
feed unit.
XP6,XP9 2--pole female connector.
XP7,XP8 2--pole male connector.
XS1 Welding current terminals.
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XT1--XT5 Terminal blocks for screw connections.
XT06 4--pole edge connector socket, for connection to connections E on circuit board
AP5.
XT08 5--pole edge connector socket, for connection to connections G on circuit board
AP5.
XT09 2--pole connector, for connection to connections B on circuit board AP6.
XT10 14--pole edge connector socket, for connection to connections I on circuit
board AP5.
XT11 11--pole edge connector socket, for connection to connections J on circuit
board AP5.
XT12 3--pole edge connector socket, for connection to connections K on circuit board
AP5.
XT13 9--pole edge connector socket, for connection to connections L on circuit board
AP5.
XT14 6--pole edge connector socket, for connection to connections A on circuit board
AP6.
XT15 18--pole connector, for connection to circuit board AP9.
XT17-XT22 Coaxial connectors.
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INTERCONNECTION DIAGRAM, LUC 400
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BLOCK DIAGRAM, CIRCUIT BOARD AP5
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COMPONENT POSITIONS, CIRCUIT BOARD AP5
WARNING High voltage within the shaded area.
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DESCRIPTION OF OPERATION, CIRCUIT BOARD AP5
This description refers to the block diagram on page 14 and to the component positions
diagram on page 16.
Only those parts connected to the inputs and outputs of the circuit board are described.
If a circuit board is faulty, it must be replaced in its entirety: do not attempt to repair it.
After replacing a circuit board, the machine must be soft--started: see the instructions on page
36.
The gate driver and overvoltage protection circuits are at mains voltage. A yellow warning
cover is fitted above them.
The remainder of the board is connected to the welding circuit. Pulse transformers and
optocouplers, capable of withstanding a test voltage of 4.5 kV, provide galvanic separation
between the parts.
The electronic neutral on the control board is directly connected to the mounting bolts, the
plate behind the board and the negative of the shunt.
The remote control devices have separate power supplies with their own neutral point (0VA),
connected to L2.
The contacts and connectors on the board are designated by the letters A - L. Contact A is at
the top and L at the bottom. The numbering in each contact runs from top to bottom.
DANGER
Many parts of the control circuit board (AP5) and the power units
are at mains voltage.
The metal parts of coaxial contacts A, B, C and D to the MOSFET transistors are at
mains voltage (565 V).
The plugs must not be allowed to hang freely or touch each other. This will result in
failure of the transistors.
The measurement points (test points) are indicated by Mp.... in the block diagram and the
component positions diagram.
The circuit board incorporates test points in the form of pins. The test point marked Mp0 is
connected to the electronic neutral.
Unless otherwise specified, measure test voltages relative to the electronic neutral.
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1 POWER SUPPLY
Power supply to all parts of the circuit board except blocks 3, 10, 14 and 16.
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Bridge rectifier BR2 is supplied at 9 V from transformer TC1 via connections L6 and
L7. Voltage regulator VR1 stabilises the voltage to +5 0.03 V. This voltage can be
measured at test point Mp1.
Fuse S1 (2.5 A anti--surge) prevents the foil on the circuit board or the transformer
from being destroyed in the event of a short circuit on the board.
Rectifier BR3 is supplied at 22 V from transformator TC1 via connections L8 and L9.
Fuse S2 (2.5 A anti--surge) protects the board. Voltage regulator VR2 stabilises the
voltage. Potentiometer R10 adjusts the voltage at Mp3 to +15.2 0.1 V.
The voltage at test point Mp2 is +22 1 V.
The white indicating lamp (HL1) on the front panel is supplied at 22 V AC from TC1.
VR3 is a voltage converter which, with capacitors C43 and C44, converts +15 V to
- 13.2 1.2 V. Measure at test point Mp4.
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2 ARC VOLTAGE SENSING
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An arc voltage signal is connected to:
S K1, external sensing from the filler wire via the casing of the wire feed motor,
and
S K3 internal sensing of the voltage at the positive welding current terminal.
The negative welding current terminal (which is also the electronic neutral) is the zero
point for arc voltage sensing in cases 1 and 2 below.
There are three different arc voltage sensing modes:
1. Internal sensing of the voltage at the positive terminal for MMA welding.
The board senses the voltage between the positive terminal and the electronic
neutral.
2. External sensing of the voltage on the welding wire (at positive polarity) for
MIG/MAG welding. The board measures the voltage between the wire in the wire
feed unit and the negative welding current terminal on the power source.
The voltage signal is received via the control cable from the wire feed unit and
pin E in the 23--pole connector at the rear of the machine, and to connection K1
on the circuit board
3. External sensing on the welding wire, at negative polarity for MIG/MAG hollow
wire. The board measures the voltage between the welding wire in the wire feed
unit (K1) and the positive welding current terminal on the power source (K3).
The electronic circuitry on the board automatically measures the correct arc voltage in
all three cases, without manual intervention. Check that the voltage as received at the
board is the same as the true arc voltage in each case above.
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3 REMOTE CONTROL INPUTS
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Power supply
Rectifier BR4 is supplied at 15 V from transformer TC1 via connections L4 and L5. The
supply is protected by fuse S3 (2.5 A anti--surge).
Voltage regulator VR4 stabilises the voltage to about +10 V. This is referred to as the +10VA
supply: its neutral point is 0VA.
The output voltage from VR4 is adjusted so that the maximum reference signal at J11, i.e.
+10VA, gives +5.15 0.05 V across diode D8.
Control Synergic remote control device
This remote control input has its own galvanically insulated power supply, with its own 0VA
neutral connected to L2. The input is connected to other electronic circuity via differential
inputs. The input can withstand short--circuiting of the power supply and connection to the
welding circuit without being destroyed.
The remote control reference signal for the welding voltage (MIG/MAG) is connected to L1.
The minimum reference is 0 V and the maximum reference voltage is 10.4 V.
The remote control reference signal for the wire feed speed is connected to J11. The
minimum reference is 0 V and the maximum reference voltage is 10.4 V.
This input becomes the remote control reference input for welding current in the MMA
welding mode.
Control 5 Program remote control device
This remote control input has its own galvanically insulated power supply, with its own 0VA
neutral connected to L2. It can withstand short--circuiting of the power supply and connection
to the welding circuit without being destroyed.
The remote control unit provides selection of a number of sets of welding data parameters for
remote control: see page 85 in the Instruction manual. Either 5 or 31 sets of welding data
parameters are available.
The five--program choice is used together with the Control 5 Program remote control
device.
The 31--choice selection is intended for use with mechanised welding to provide a simple
means of calling up different sets of welding parameters. The five inputs then form the
number to the welding parameter set in binary--coded form.
The table below shows the data sets selected in response to each activated input in the two
modes. i.e. 5 programs or 31 programs. In the 31--program mode, it is the sum of the selected
inputs that selects the welding parameter data set.
The activated input is connected to 0VA (= XP3, connector L) via the remote control device.
The voltage at the unactivated inputs is 10.4 V.
Contact XP3 Circuit board AP5 Control 5 Program 31 sets, binary value
Pin N Input J6 Welding data 1 1

Pin P Input J5 Welding data 2 2
Pin R Input J4 Welding data 3 4
Pin S Input J2 Welding data 4 8
Pin T Input J3 Welding data 5 16
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Increase/decrease
Increase: input I14. Activation of this input results in 0 V between I14 and L2.
Deactivation of this input results in 10.4 V between I14 and L2.
Decrease: input J1. Activation of this input results in 0 V between J1 and L2.
Deactivation of this input results in 10.4 V between J1 and L2.
4 START/STOP INPUT
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This input accepts the Start/Stop signal from the welding gun when MIG/MAG
welding.
Operating the trigger on the welding gun applies 42 V AC between I9 and I10.
5 GAS AND HF CONTROL
This function is not used in the LUC 400.
6 OPTO INTERFACE
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The opto interface consists of a transmitter, IC4, and a receiver, IC3.

The signal from the optical fibre receiver to the welding process regulator is
connected to test point Mp5.
When the welding data control unit transmits data to the control board, the signal
pulses between +1.5 V and +5 V. Changing the welding method from the control unit
is an example of such data.
The signal from the welding process regulator to the optical fibre transmitter is
connected to test point Mp6.
When the control board transmits data to the welding data control unit, the signal
pulses between +1.5 V and +5 V. Changing welding method from the control unit is
an example of such data.
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7 SHUNT VOLTAGE AMPLIFIER
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The shunt provides a signal of 24 mV at 100 A, linearly proportional to the welding

current. It is simplest to measure the voltage at a welding current of 100 A into a
resistive load in the MMA welding mode.
Measure the current using an external shunt and a digital voltmeter.
Using a digital voltmeter, measure the shunt voltage signal across resistor R107 on the
control board. Measure between the metal casing on the shunt contact and the lower
part of R107.
If the machines shunt voltage is incorrect, the fault will be in the shunt itself or in the
coaxial cable.
8 ERROR DETECTOR
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When a fault occurs, the error detector sends a blocking signal to the pulse width
modulator (15), together with an error indication signal to the error indication unit
(11).
The yellow LED on the front panel indicates that a fault/error has occurred. It is
controlled by output G1 on the control board, which is at a voltage of about +1.7 V
when the diode is lit and 0 V when it is extinguished.
Conditions that can cause a fault or error state are as follows:
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Thermal cutout
If one of the thermal cutouts has operated, it will result in the message MACHINE
ERROR: HEATSINK TEMP appearing on the control unit display.
The yellow LED on the front panel of the power source and D19 on the control panel
circuit board also light up.
When the thermal cutout contacts are closed, the voltage between connection I3 and
the electronic neutral is about 8 V. The method of operation of the thermal cutout
protection circuit is described on page 41.
Cooler On/Off
When the cooler is ON, contact SA2 is closed and the voltage at connection G3 is 0 V.
When the cooler is OFF, the voltage on G3 rises to +28 V.
Water flow monitor
The water flow monitor switch, SF1, is closed when the water flow rate exceeds 1
litre/minute. This results in a voltage of +15 V on I1, as opposed to 0 V when the
cooling water flow is less than this.
The signals from switch SA2 and water flow monitor SF1 are compared on the
control board. The green LED on the front panel of the machine indicates that
cooling water is flowing. The supply to the diode is +2 V when cooling water is
flowing, and 0 V with no flow.
If the cooler is ON, but the flow monitor switch is open, the fault message
MACHINE ERROR: NO WATER FLOW will be displayed.
The green LED on the front panel will be extinguished, and the yellow LED lit.
Diode D18 on the control board will also be lit.
Overcurrent protection
Operation of the overcurrent protection lights the yellow LED connected to G1.
See also item 9, below.
Overvoltage protection
Operation of the overvoltage protection lights the yellow LED connected to G1.
See also item 10, below.
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cny1ade1 -- 26 --
9 OVERCURRENT PROTECTION
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The two current transformers, TA1 and TA2, measure the primary current to the two
pairs of switches. Their ratio is 400:1.
The output voltages from TA1 and TA2 are connected to I5 - I7 and I6 - I8.
The combined signal can be measured at Mp14 (the upper terminal of R131).
The overcurrent protection operates at a peak voltage of 8.2 V as measured at Mp14,
which is equivalent to a welding current of 1400 A and 200 A transistor current.
The circuit also trips if the difference in the currents from the two pairs of switches
exceeds about 150 A.
Operation of the circuit results in the fault message MACHINE ERROR: HIGH
CURRENT, and the yellow LED on the front panel of the machine lights up.
Diode D20 on the control board also lights.
The circuit can be reset by momentarily turning off the machine.
The polarity of the signals is important. Make sure that the wires are correctly
connected and that the current transformers are correctly orientated.
Loading the power source with a resistive load to produce a current of 100 A at 24 V
produces a waveform at Mp14 as shown in the trace below. In order to avoid
interference, the oscilloscope must be connected to the mains through an interposing
transformer.
Waveform of current trace at Mp14 for a resistive load to

produce a current of 100 A at 24 V
cny1ade1 -- 27 --
10 OVERVOLTAGE PROTECTION
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DANGER: MAINS VOLTAGE

The overvoltage protection circuit takes its power from smoothing capacitor C01 via
R2, which is a high--resistance 50 W resistor. The supply, at about 10 V, is connected
to terminals E3 and E4.
The circuit senses the voltage across the capacitor, between connections E1 and E4. If
the voltage exceeds 660 V, the gate pulses are blocked and the yellow LED on the
front panel lights up. The message MACHINE ERROR: HIGH VOLTAGE appears
on the control unit display, and diode D21 on the control board is also lit.
The circuit resets automatically when the voltage falls below 660 V.
11 ERROR INDICATION
The error indication circuit provides indication of the cause of faults by lighting one
of LEDs D19 - D21 and sending an appropriate error message to the control unit for
display there via block 12.
LED Error message Fault
D18 MACHINE ERROR: NO WATER FLOW No cooling water although the pump is on
D19 MACHINE ERROR: HEATSINK TEMP Excess temperature: see description on page 41
D20 MACHINE ERROR: HIGH CURRENT Too high primary current through the transistors
D21 MACHINE ERROR: HIGH VOLTAGE Too high voltage across C01
Positions of the diodes on the control board
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12 WELDING PROCESS CONTROL
The processor senses the set welding data parameters and the arc voltage. It also
calculates a setpoint value for the current and supplies it to the current control
amplifier (13).
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For use when MIG/MAG--welding, it also supplies a wire feed speed reference
signal to the wire feed unit.
The speed reference is connected to J9 and must be +3.92 V at a wire feed speed of
10 metres per minute. The maximum reference voltage is 8.6 volt, which represents
a speed of 22 metres per minute. The relationship is linear.
Arc voltage feed back
Voltage ref. Power pack

MIG/MAG Process--
regulator + (fast response
- current amplifier)
Current ref.
Current
feed back
Principle for control of the process regulator
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13 CURRENT CONTROL AMPLIFIER
The current setpoint value signal to the amplifier can be measured at test point Mp9.
Measure the value of the signal for MMA welding and with an ARC FORCE setting
of 0.
In order to be able to adjust the ARC FORCE setting, it is necessary first to change
to non--synergic control mode, i.e. allowing independent adjustment of arc voltage and
welding current. See the Instruction manual under the heading Settings without
synergic functions on page 80.
The machine must be loaded so that the arc voltage is in the range 15 - 40 V.
The reference voltage at test point Mp9 must be 0.92 V at 100 A. The reference is linear
in relation to the current.
The reference signal voltage is determined by the welding process data control unit
and the welding process regulator.
14 OPEN--CIRCUIT VOLTAGE CONTROL

If the open--circuit voltage is too low or too high, it is important to check if the
circuit board senses the correct voltage.
Measure the voltage between K3 on circuit board AP5 and the electronic neutral
with a digital voltmeter, see the block diagram on page 14. If the voltage, measured
at K3, is the same as the open--circuit voltage at the welding current terminals for
MMA welding, and the open--circuit voltage still is too low or too high, the circuit
board (AP5) must be replaced.
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15 PULSE WIDTH MODULATOR
The pulse width modulator controls the time during which the transistors in the
power unit conduct.
S Mp10 Input signal to the pulse width modulator.

The control range is from +1.8 V (minimum pulse time) to +4.5 V (maximum
pulse time).
The control signal is supplied by the current control amplifier (13).
As measured at test point Mp10, the signal from the current control amplifier
is - 0.3 V for minimum current and and +7 V for maximum output current.
Example:
If the reference signal to the current control amplifier is greater than the signal
from the shunt, the amplifier produces maximum output voltage (+7 V).
If the reference signal to the amplifier is less than the voltage signal from the
current shunt, the amplifier produces minimum output voltage (--0.3 V).
At constant load (100A/24V), the signal at Mp10 is about +2.8 V.
S Mp11 The arc voltage signal for controlling the open--circuit voltage for
MMA welding.
If the open--circuit voltage exceeds 58 V, the pulse width modulator is blocked.
An arc voltage of 58 V gives a voltage of 2.5 V at test pont Mp11, which is the
switching level for the pulse width modulator (blocking over +2.5 V).
When current flows in the welding circuit, the voltage at Mp11 is pulled below
+1 V by the welding process regulator, so that the arc voltage can rise.
The circuit reverts to open--circuit voltage control as soon as the welding cur-
rent is interrupted.
The open--circuit control circuit is also engaged during MIG/MAG welding
from the instant of pressing the welding gun trigger switch until the arc strikes.
When the trigger switch is released, the open--circuit voltage control circuit is
disengaged.
S Mp12 Blocking signal from the process regulator to the pulse width modulator.
When the welding process regulator ramps down the welding current to zero,
the pulse width modulator is blocked by Mp12 being pulled down to 0 V.
In the MIG/MAG welding mode, the blocking is activated when the trigger
switch on the welding gun is not pressed. When the trigger switch is pressed,
the voltage at Mp12 is +3.4 V.
S Mp13 The blocking signal from the error detector circuits to the pulse width
modulator.
The switching level is +2.5 V. Normally, the voltage at Mp13 is +3.3 V.
However, if the error detector circuits (block 8) detect a fault, Mp13 is pulled
down to below +1.5 V and the pulse width modulator is blocked.
Faults are indicated by individual red LEDs on the control board: see block 11.
They are also indicated by a non--specific yellow LED on the front of the
power source and by an error message on the control unit display panel.
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16 TRANSISTOR GATE DRIVERS
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The four gate circuits are identical: the following description, relating to one of
them, is therefore applicable to all of them.
The pulse from connection 3 on transformer TR1 passes D44, D45 and connection
A1 to the gate of the power transistors, with the return circuit via D47 and C114.
Capacitor C114 is charged to about 4.0 V by the gate pulse.
The peak pulse voltage is about +15 V. When the pulse goes negative, transistor
Q19 starts to conduct and supplies base current to transistor Q20, which pulls down
the gate voltage to --4 V.
Fuses S4 - S7 are not fitted: instead, they are replaced by links. The signal is
protected by fuses on circuit boards AP1 - AP4.
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CHECKING THE GATE PULSES
DANGER
The four gate circuits are at mains potential.
The metal bodies of the coaxial plugs are live.
Check the gate pulses from the control board with an oscilloscope.
S Turn off the machine.
S In order to avoid connecting mains voltage to the oscilloscope, remove gate connections
A, B, C and D from the control board (AP5) and insulate them from each other.
S NOTE, the overvoltage protection circuit on the control board and the switch units are
still at mains potential.
Measuring the control pulses with a separate gate load
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S To measure the gate pulses, you will need a separate, dummy load connected to a BNC
plug. This load consists of a 33 nF capacitor and a 4.7 W resistor, connected in
series.
Connect the probe to the gate (A1) and the earth to the source (A2). Connect the gate
load to circuit board AP5 via the BNC contact.
Connecting the oscilloscope to the gate load
S When you have made the connections, turn on the mains power supply. Select the MMA
welding mode and a current setting on the control unit sufficient to display control pulses
on the oscilloscope screen.
S Check that the pulses are within the range 39.5 -- 41.5% of the cycle time, and that the
total cycle time is within the range of 40.8 - 42.6 microseconds. Measure the pulse and
cycle times at a level of +5 V.
S Transfer the gate load as necessary and measure the pulses between A1- A2, B1 - B2,
C1 - C2 and D1 - D2.
S If any of the control pulses is outside the above limits, replace control board AP5.
If any of the pulses displays a long sloping decay time, the board is faulty and must be
replaced.
Control pulses as measured across separate gate load
cny1ade1 -- 34 --
SWITCH UNITS
The switch units consist of four heat sinks, each with twelve power transistors and a circuit
board (AP1 - AP4).
The transistors control the welding current. Maximum current is supplied when the
transistors are conducting for 39.5 - 41.5% of the cycle time.
MOS TESTER
A MOS tester is needed in order to test the switch units.
This is a special instrument, and can be ordered only from ESABs Service Department in
Lax. Its order number is 468 469--001.
The following instructions describe how to use the MOS tester to test the switch units.
Connection:
S Disconnect the power source from the mains.

S Disconnect wires 024, 025 and 026 from capacitor C01, and keep them separate from
each other. Note that there are two sets of wires marked 024, 025 and 026.
S Disconnect gate leads A, B, C and D from AP5.
S Connect the wire having the BNC connector to the corresponding connector on the MOS
tester.
S Connect the clip on the black wire to the heat sink (the drain). It is important that you
connect the wire to the correct switch unit, as otherwise you will obtain a fault reading.
Testing:
S Press the TEST pushbutton.

S If everything is operating correctly, the red and green LEDs will flash alternately, at a
rate of about once a second. Note that the red LED never goes quite out, but the change
in intensity must be clear.
S If the transistor board is short--circuited, the red LED will be continuously lit. The green
LED may also continue to flash, or also be continuously lit.
S If the transistor board is open--circuited, the green LED will be continuously lit.
Check that there is good electrical contact between the black wire and the heat sink.
S If you have identified a switch unit as faulty, remove it from the machine and test it once
more before replacing it. See on page 43 for instructions on removal and replacement.
cny1ade1 -- 35 --
IMPORTANT
Even if only one switch unit is faulty, both
units in the same pair must be replaced.
Check the gate pulses from AP5 before operating the new
switch units. See instructions on page 33.
After repair, the machine must be soft--started.
SOFT STARTING
After replacing the control board and/or the switch units, it is important to soft--start the
machine. If any fault is still present, you will be able to detect it when soft starting.
S Disconnect and insulate wires 019 and 020 from capacitor C01. See the circuit diagram
on page 12.
S Disconnect connector C and D from circuit board AP13. See the circuit diagram and
component positions diagram on page 40. Connect a jumper between 1 and 2 at con-
nector D so that wire 074 is connected to wire 017.
S Connect a suitable power supply, having a current limit of 0.5 A, across capacitor C01.
Connect the positive line to wire 031 or to the copper busbar between the switch units.
Connection point for positive supply from the power unit
S Adjust the power supply to a maximum of 40 V, with 0.5 A current limit.

S Energise the other parts of the machine from the normal mains power supply.
S WARNING, several parts in the machine are at mains potential.
S Select MMA welding mode and 20 A or higher current setting from the control unit.
S Check that the power supply unit is not being overloaded, and reduce the voltage.
cny1ade1 -- 36 --
S Measure the secondary voltage from main transformers TM1 and TM2 on an oscillo-
scope. Connect the probe to the junction of R5 and TM1 when measuring the signal from
TM1, and to the junction of R10 and TM2 when measuring the signal from TM2.
See the circuit diagram on page 13.
Connect the earth connection to the terminal connected to inductor L1.
Connecting the oscilloscope when measuring

the secondary voltage from TM1/TM2
cny1ade1 -- 37 --
S If the waveform from the transformers is similar to that shown in the diagram below, the
machine is almost certainly healthy and can be connected to the normal mains voltage
supply.
Secondary voltage from TM1 (TM2) with a 40 V supply across C01
S Turn off the power supply, disconnect the temporary power supply unit and reconnect
wires 019 and 020.
S Connect a load resistor (RC 500), a shunt and an instrument for measuring welding
current and voltage.
S Start the machine on no load (open circuit). Select MMA welding mode, Arc Force = 0
and 10 A welding current from the control unit.
S Check that the no--load voltage is 55 -- 65 V, (normal value 58 V).
S Connect the load.
S Increase the current setting and check that the actual current is the same as the set value.
S Load the machine fully in accordance with the arc characteristic, 400 A - 36 V.
S Make a test weld as a final check.
cny1ade1 -- 38 --
CIRCUIT DIAGRAM, CIRCUIT BOARD AP9
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Circuit diagram, suppressor board AP9
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Component positions, suppressor board AP9
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DIODE BRIDGE BOARD AP13
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Circuit diagram, diode bridge board AP13
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Component positions, diode bridge board AP13
cny1ade1 -- 40 --
DESCRIPTION OF OPERATION, DIODE BRIDGE BOARD AP13
This circuit board has two functions: suppression of line interference to the three--phase
bridge and galvanic insulation of the thermal overload cutouts on the switch units from the
welding circuit.
DANGER
Most of this board is at mains potential.
The three--phase bridge is protected against line interference by capacitors C1 - C6 and

varistors R11 - R13. These components protect the bridge against supply voltage transients
and HF interference.
Resistors R1 - R4 are discharge resistors for the capacitors.
POWER SUPPLY
The board is supplied at +565 V from rectifier VC1, via fuse F1 on the board. Resistor R2,
which is mounted on the copper busbar in the control area, controls the current through diode
D1 in the power supply circuit. D1 is a zener diode with a 56 V zener voltage.
THE THERMAL OVERLOAD CUTOUTS CIRCUIT

Optocoupler IC1 controls transistor Q1, which is connected in series with the thermal
overload cutout switches (ST1 and ST2) on the secondary diodes.
When IC1 conducts, transistor Q1 is turned on, and the voltage drop across it falls to about
2.5 V.
The gate pulses to the switch units are blocked when the voltage at connection I3 on circuit
board AP5 is less than 1.9 V.
The voltage between connection I3 on AP5 and the electronic neutral is 8 V when Q1
conducts, and 0.4 V when it is turned off.
Optocoupler IC1 is controlled by the two series--connected thermal overload cutout switches
on the switch unit heat sinks and by an auxiliary contact on contactor QF1. The purpose of
this contact is to block the gate pulses when contactor QF1 drops off.
If either of the thermal cutout switches has operated, or if the contactor has not closed, the
error message MACHINE ERROR: HEATSINK TEMP. is displayed on the welding
settings control unit.
The message is cleared when the contactor closes.
cny1ade1 -- 41 --
FAULT TRACING
If the mains fuse blows when the unit is turned on, check the following points:
1. Check that too small a mains fuse has not been fitted.
A 35 A anti--surge fuse must be fitted for a 400 V mains supply. See the instructions,
under the heading Installation, for details of fuse ratings for other supply voltages.
2. Check that contactor QF1 is in good condition and capable of carrying the current.
3. Check that resistor R1 on contactor QF1 has not burnt out. Its value must be 10 .
If mains voltage transformers TV1 or TV2 are fitted, there will be three resistors.
The resistance of each must be 10
4. Measure all diodes in mains rectifier bridge VC1, using the Diode position of a digital
multimeter.
5. Check the mains rectifier smoothing filter on AP13 for burnt--out components.
6. Check transient overvoltage protection board AP8 for burnt--out components or leads.
7. Check that capacitor C01 is not short--circuited.

Remove the capacitor and measure it with an insulation tester (Megger). Check that it can
be charged to 600 V.
8. Check all the switch units using the MOS tester. See SWITCH UNITS on page 35.
9. Check the control pulses: see the description of the gate pulses on page 33.
10. Check the welding and freewheel diodes V5, V6, V7 and V8 using a DMM.
Disconnect the welding cables and measure between the welding current terminals.
The anodes of the diodes are connected to the negative terminal. A discharge resistor of
2.2 k (R1 on circuit board AP12) is fitted between the welding current terminals, and
can interfere with measurement in some cases.
11. The machine is now ready for soft starting: see on page 36.
cny1ade1 -- 42 --
DISASSEMBLY
REMOVAL OF THE UPPER SWITCH UNITS
S Remove the side panels, the top cover and the rear panel from the machine. Take care
that the centre plate does not drop out.
S Remove the nipple on the water tank so that the rear panel can be slid backwards a little
way.
S Remove rectifier bridge VC1.
S Remove the insulation sheet so that the copper busbar can be removed from beside the
lower heat sink.
S Remove the screws from the supports (a) closest to the fans and bend back the insulating
sheet so that the fan panel is not in the notch of the insulating sheet, see the picture
below.
S Pull the switch units and the fan panel apart to allow the supports to be removed.
Remove the bolt that passes through the upper current transformer TA1.
S Remove the copper busbar from the main transformer from the switch unit and bend it
backwards. Undo the nut and disconnect the cables and the copper busbar underneath the
main transformer from the switch unit.
The switch units must be replaced only in pairs.
Replace the lower pair in the same way as the upper pair.
Fit the new units in the reverse order.
WARNING !
Do not replace individual transistors.
If you do, there is a risk of further transistor failure.
cny1aae1 -- 43 --
REMOVING THE RECTIFIER AND FREEWHEEL DIODES
S Remove the side panels, cover and front panel and lift out the air grille.
S Remove circuit board AP12, the bolts from the machine units and the circuit board plate.
S Remove the front supports and bend the insulating sheet out of the way so that the front
panel can be removed.
S Remove the bolts (a) shown below. Remove the insulating panel so that the copper bar
from the side of the lower switch unit can be removed.
S Remove the insulation sheet from the other side and bend it outwards slightly.
Remove the nut from the bolt that passes through the current transformer.
S Remove the copper bar between the main transformer and the switch unit and bend it
backwards. Remove the nut and disconnect the cables and the lower copper bar on the
main transformer from the switch unit. Remove the supports by separating the main
transformer and the switch units.
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S Lift the main transformer so that the diodes are accessible, as shown in the picture below.
S Use a DMM to find which row of diodes is faulty, but do not allow the copper busbars to
contact each other.
S Remove the anode connections of the diodes from the copper busbar.
S Measure the diodes, one at a time.
S Carefully remove the faulty diodes from the heat sink.
S When fitting the diodes, do not tighten them harder than 2.0 - 2.5 Nm.
S Replace the lower diodes in the same way.
S Take care when reassembling the unit so that a short circuit is not formed between the
shunt and chassis and/or between the copper busbar from the freewheel diodes and the
bottom plate.
cny1aae1 -- 45 --
cny1ade2 -- 46 --
SETTING BOX
The welding settings control unit contains two circuit boards: a keyboard/display board and a
microprocessor board. The microprocessor board has its own microprocessor and associated
memory capacity, in the same way as has the main AP5 control circuit board.
Communication between the power source and the welding settings control unit is through a
5 m long bidirectional optical fibre cable. This cable also contains two ordinary copper
conductors for power supply to the unit.
The 9 V AC power supply comes from a separate winding on control transformer TC1, and is
protected by means of fuse FU3 in the power source.
The welding settings control unit contains functions for setting, measuring and storing the
required welding parameters. The unit also displays fault/error messages.
The welding parameters can be set manually and individually, or by synergic control.
100 sets of values can be stored. When the machine is turned off, a lithium battery maintains
the power supply to the memory.
The display, which incorporates a HOLD function, can display welding current or voltage.
The Operators Instructions contain a description of use of the unit.
Construction of the welding settings control unit.
cny1ade2 -- 47 --
DISPLAY BOARD, AP10
CIRCUIT DIAGRAM, DISPLAY BOARD
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COMPONENT POSITIONS, DISPLAY BOARD
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MICROPROCESSOR BOARD, AP11
CIRCUIT DIAGRAM, AP11
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Inputs and outputs to/from the microprocessor board
cny1ade2 -- 50 --
COMPONENT POSITIONS, AP11
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DESCRIPTION OF OPERATION, MICROPROCESSOR BOARD

A Connector A links the display board to the microprocessor board by means of
a ribbon cable.
B Connections B1 and B2 provide a 9 V AC supply to the board. This supply is
protected by fuse FU3 in the main power source.
BA1--BA2 Battery for back--up power supply to memory chip IC6. Only one battery is
fitted: the empty position is intended for use when changing the battery.
See the description on page 53.
BR1 Rectifier bridge BR1 rectifies the supply, which is then stabilised to +5 V
5% by voltage regulator VR1.
BY2--BY3 Links BY2 and BY3 must not be fitted.
IC5 EPROM containing the software for the unit.
IC6 RAM, battery--backed memory with capacity for 100 welding data programs.
IC8 Optical fibre receiver for signals from the power source.
IC9 Transmitter for optical fibre signals to the power source.
Mp7 Test point Mp7, which is connected to pin 1 of IC2, enables the signal from
the optical fibre receiver to the processor in the unit to be measured.
When the power source transmits information to the welding settings control
unit (e.g. when changing the welding method at the power source), the signal
pulses between +1.5 V and +5 V.
cny1ade2 -- 51 --
Mp8 Test point Mp8, which is connected to pin 8 of IC2, enables the signal from
the welding settings control unit microprocessor to the optical fibre transmitter
to be monitored.
When the welding settings control unit transmits information to the power
source (e.g. when changing the welding method at the control unit), the signal
pulses between 0 V and +3.8 V.
In the event of failure of the optical fibre communication link, the following
fault messages may appear after turning the machine on:
S WAITING FOR MACHINE IDENT.

S COMM. ERROR: TIME OUT.
R4 Potentiometer for adjusting the display contrast.
TR1 DC/AC converter, producing a power supply of about 100 V AC from the
+5 V DC supply. This supply is used to power the background illumination of
the display.
Transistor Q1 turns off the lighting about 10 minutes after the unit was last
used.
MEMORY PROBLEMS
If you suspect that the memory has become corrupted, all programmed data should be erased.
The data should also be erased when changing software.
Erasure of the welding data memory:

S Press the four keys SEL, SET, MEA, and MEM simultaneously until the display shows:
S ( RAM XX = YYY)
SET RAM = ZZZ
S Press the ARROW DOWN key
until the display shows:

SHOW VERSION
( RESET WD--RAM )
(In the lower line, the abbreviation WD means Weld Data.)
S Press the NEXT key. This erases all the stored welding data. All other preset values re-
turn to their default values.
The default value for display language, for example, is English.
S The display shows the message NV--RAM INITIALIZED, as acknowledgement that the
memory has been erased. The unit then defaults to the welding method selection state.
cny1ade2 -- 52 --
BATTERY REPLACEMENT
Construction of the weldings settings control unit
S Remove the clip (1) from the case.
S Unscrew the right--hand end (8).
S Disconnect the yellow--green earth wire from the casing.
S Slide out circuit boards 6 and 7 and fold them apart so that the battery is accessible.
S When replacing the battery, all programmed data will be lost unless the 3 V power supply
is maintained all the time. To avoid this, solder the new battery into position, in the un-
used space, before removing the old battery.
S The lithium battery can be expected to have a life of about five years of normal oper-
ation.
The battery is a BR 2325 -- 1HC battery.
cny1ade2 -- 53 --
FAULT/ERROR MESSAGES ON THE DISPLAY
In general, fault/error messages remain displayed until a key is pressed on the unit, or until
the main welding power source is turned off and restarted.
1. Faults in the power electronic circuits of the machine

a. MACHINE ERROR: HIGH VOLTAGE
Too high a voltage after rectifier V01. This fault can be due to too high mains
voltage or excessive inductance in the mains power supply to the machine.
Check that the voltage at terminal XT2 is 3 x 400 V.
b. MACHINE ERROR: HIGH CURRENT

Too high a primary current to switching units A and B or C and D, or unbalanced
distribution between the two sets of switches.
A spurious fault message can be displayed if main switch SA1 is turned on and off
very quickly. This is not a fault.
See on page 27 for a description of overcurrent fault protection.
c. MACHINE ERROR: HEATSINK TEMP

This indicates excessive temperature of the switching units. It can be caused by such
effects as overloading, a faulty cooling fan, faults in the thermal cutout switches or
in contactor QF1.
The thermal overload cutouts are described on page 41.
d. MACHINE ERROR: NO WATER FLOW

Failure of cooling water supply to the welding gun. This fault message is disabled if
the cooling water pump is turned off when an air--cooled welding gun is in use.
cny1ade2 -- 54 --
2. Memory errors/faults
The machine automatically performs a self--test of all memory cells on power--up.
If any of the cells is found to be faulty, one of the following fault/error messages will be
displayed. These messages are displayed only immediately after power--up.
It may be possible to use the machine despite the fault/error message. However, be care-
ful when using it, as welding performance may be affected, despite the fact the machine
appears to be operating normally.
a. RAM ERROR IN POWER SOURCE
Check that each memory position can be written to and read from. If this message
appears, it indicates that a memory cell in the machines read/write memory is defec-
tive.
Replace circuit board AP5.
b. RAM ERROR IN CONTROL UNIT

appears, it indicates that a memory cell in the control units read/write memory is
defective.
Replace the microprocessor circuit board in the welding settings control unit.
c. ROM ERROR IN POWER SOURCE

Program memory is tested using a check sum. If this message appears, it indicates
that a memory cell in the machines EPROM program memory is defective.
Replace circuit board AP5.
d. ROM ERROR IN CONTROL UNIT

Program memory is tested using a check sum. If this message appears, it indicates
that a memory cell in the control units EPROM program memory is defective.
Replace program memory chip IC5 in the control unit.
e. CONTROL UNIT WELD DATA ERROR

This message results from a random check of the contents of the welding data mem-
ory. A check figure is stored in a memory position: if it is not correctly read, the
fault message will be displayed.
The commonest cause of this fault is failure of the battery in the control unit.
Deal with this by replacing the battery: see the instructions on page 53.
cny1ade2 -- 55 --
f. EXT. RAM ERROR IN CONTROL UNIT
appears, it indicates that a memory cell in the memory chip (IC6) in the control unit
is defective.
Replace the microprocessor circuit board in the control unit.
3. Communication faults/errors
These fault/error messages relate to the serial communications link between the power
source and the control unit. They can occur as a result of random events. In such cases,
deal with them by turning the machine off and then on again.
If these faults occur more frequently, there is probably an underlying reason, which needs
to be found.
a. COMM. ERROR: RECEIVE CH. SUM

An incorrect sum has been detected five times in succession when transmitting from
the power source to the control unit.
Check that the ends of the optical fibres are correctly aligned with the receivers/
transmitters.
b. COMM. ERROR: TRANSM. CH. SUM

An incorrect sum has been detected five times in succession when transmitting from
the control unit to the power source.
Check that the ends of the optical fibres are correctly aligned with the receivers/
transmitters.
c. COMM. ERROR: TIME OUT

The control unit has sent a message/instruction to the power source, but has not re-
ceived acknowledgement.
Check that the optical fibre contacts are correctly connected at each end. Check too,
that the fibres have not moved relative to their housings so that a gap of some tenths
of a millimetre has occurred between the end of the fibre and the transmitter/re-
ceiver.
If the optical fibre cable appears to be fault--free, but communication is still not
working, check the +5 V voltage on circuit board AP5 on the power source.
For further informati on on possible location of the fault, use an oscilloscope to
measure the voltages at test points Mp5 -- Mp8.
cny1ade2 -- 56 --
d. POWER SOURCE TIME OUT
The power source has sent a message/instruction to the control unit, but has not re-
ceived acknowledgement.
Check the optical fibre as described above.
e. COMM. ERROR: RECEIVE BUFFER

The control unit has not processed incoming messages sufficiently quickly, with the
result that the receiver buffer has become full.
f. COMM. ERROR: SEND BUFFER

The machine has not succeeded in receiving messages from the control unit at the
same rate as which they have been transmitted, with the result that the transmitter
buffer has become full.
This fault message can occur if the machine is provoked by uninterruptedly chang-
ing between the end positions on the five--way control unit.
g. WAITING FOR MACHINE IDENT

The control unit is waiting for the first message from the power source.
This message opens communication between the power source and the control unit.
This message always appears briefly when the machine is powered up.
If, however, the message persists:
S Check that the optical fibre contacts are correctly connected at each end.
S Check that the control power supply transformer and its connections are healthy
by measuring the +5 V voltage at test point Mp1 on circuit board AP5.
cny1ade2 -- 57 --
REMOTE CONTROL DEVICES
The following four pages show the Aristo Control Synergic and Aristo Control 5--Program
remote control devices. The instructions for the remote control devices explain how they are
intended to be used. Here we list only the spare part numbers for some of the components in
them.
ARISTO CONTROL SYNERGIC TORCH 466 515 -- 880
Quantity Name Order number

2 Potentiometer, 2.5 k 2 W 191 870 - 112
cny1ade2 -- 58 --
ARISTO CONTROL SYNERGIC BOX 466 801 -- 880

2 Potentiometer 2.5 k 2 W 191 870 - 212
cny1ade2 -- 59 --
ARISTO CONTROL 5--PROGRAM TORCH 466 515 - 881

1 Selector switch, 5--position 193 703 - 001
1 Selector switch, 2--position, spring return 193 703 -- 002
cny1ade2 -- 60 --
ARISTO CONTROL 5--PROGRAM BOX 466 801 - 881

1 Selector switch, 5--position 192 722 - 004
1 Selector switch 147 866 - 004
cny1ade2 -- 61 --
ORDERING SPARE PARTS
Order spare parts through your nearest ESAB representative. Give details of the machine type
(e.g. LUC 400), machine serial number, names of the spare parts and their numbers.
This information simplifies dealing with your order and ensures that the correct parts will be
supplied.
cny1ade2 -- 62 --
INSTRUCTION MANUAL ARISTO 400
cny1ap00
A400e -- 63 --
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS HAZARD DATA.
ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS -- Can injure eyes and burn skin.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE OPERATING MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
A400e -- 64 --
TECHNICAL DESCRIPTION
ARISTO 400 is a transistor--controlled welding power source of universal type, built in
modules to facilitate erection. handling and accessibility at the work place.
It is programmable. adapted for co--operation with a welding robot and can be controlled by
way of a PC system.
ARISTO 400 is programmed and controlled directly from the work place by way of small
portable cable--connected boxes.
With ARISTO 400 the following arc welding methods can be applied:
MMA Welding with coated electrodes
MIG/MAG Semi--automatic welding
CAC Carbon arc gouging
ARISTO 400 is a machine of inverter type. which means that the mains voltage first is
rectified and then converted back to alternating current of very high frequency. After this
occurs the transformation to welding current.
The size of the transformer depends on the frequency: the higher the frequency, the smaller
the transformer needed to obtain a given power. The same is applicable to the inductor.
Rectifier Inverter Transformer Rectifier
Control system
In other words. welding machines of inverter type are considerably smaller and lighter than
conventional machines supplying the same power.
The inverter principle makes it possible to control every sequence of the welding process by
means of electronics. which results in better welding properties.
The ARISTO 400 microcomputer is of type Siemens 80535. It is programmed to provide

good starting properties for each one of the welding methods. When the desired values have
been set. the microcomputer supervises the welding procedure and provides for the right
static and dynamic properties.
A400e -- 65 --
ARISTO 400 is a flexible system composed of the following units that can be built together
in accordance with your needs:
Power source, containing:
S Power module with power units and control electronics.

Here the incoming mains voltage is transformed to high--frequency alternating voltage
that is then transformed to welding voltage.
The following controls can be found on the front panel:
S Main switch and ON/OFF switch for the cooling unit. Light--emitting diodes indicate
the operating position of the switches.
S Welding current terminals. (+) and (--).
S Grommet for the setting box cable.
On the rear panel is:
S Grommet for the mains cable.
S Connection for feed unit. (or remote control unit for MMA).
S 2 fuses (glass tube).
S 1 circuit breaker.
The cooling unit contains:
S Quick--couplings for cooling water.
S Inlet for water filling with deaeration.
S Setting box for welding methods and parameters, measuring and storing.
S Module for water--cooling of the welding gun.

The module is to be built into the same casing as the power module and consists of the
following main components:
S Tank for 1.5 -- 1.7 l cooling medium.
S Pump of turbine type, energized by a direct--coupled induction motor. The motor is
to be connected to a 220 V single--phase terminal on a control transformer in the
power module and it is provided with a starting capacitor. The pump is started with a
rotary switch on the front panel. A green light--emitting diode goes on.
S Flow--guard which breaks the current supply to the pump if the cooling water flow is
lower than 0.7 l/min. The green light--emitting diode, which indicates operation
status, goes out and the yellow one goes on.
S Cooler of copper tubes and cooling flanges of aluminium.
S Fan for forced air--cooling.
Working principle:
The pump sucks the cooled water from the tank and forces it out into the welding
gun cooling system which is connected to the unit by means of quick--couplings.
After return, the heated water first passes the flow--guard, then the cooler before it
goes back to the tank. (See picture.)
A400e -- 66 --
FLOW CHART FOR COOLING MODULE
DEAEREATION FILLING
TANK
COOLER
PUMP
FLOW GUARD
QUICK--COUPLINGS
S Mains adaptation module

To be built into the casing of the power module. Connected manually for the right mains
voltage.
Water cooling and mains adaptation are normally built in before delivery. (Can also be
delivered separately.)
S Feed unit
for MIG/MAG welding, MED 44 ARISTO. Can be mounted on the power unit or be
hung up separately. See special instruction manual, ordering number 154 138--031.
S Remote control unit
To be connected to the feed unit (MIG/MAG welding) or to the power source
(MMA welding).
S CONTROL 5 PROGRAM.
For shifting between 5 preprogrammed sets of parameters.
Possible to change voltage in MIG/MAG position.
S CONTROL SYNERGIC.
With stepless setting of:
Wire feed speed and voltage for MIG/MAG welding
Welding current for MMA welding.
A400e -- 67 --
TECHNICAL DATA:
Enclosure type IP 21 AF
Temperature class F (155C)
Mains connection 3--phase
Mains voltage 400 V
Mains frequency 50/60 Hz
Primary current 26 A
Mains fuses 35 A
The machine is independent of

phase sequence.
Mains adaptation module, variant 1 50/60 Hz

(---881)
881) 230 V
400 V
Mains adaptation module, variant 2 50 Hz
(--882) 400 V
415 V
500 V
Mains voltage compensation:

+/--10% resulting in +/--0.2% variation
in welding data
Permissible load
at 100% duty cycle 400 A
36 V
Open--circuit voltage 65 V
No--load power < 350 W without cooling unit

< 500 W with cooling unit
Power factor 400 A 0.96
Efficiency 400 A 0.83
Weight - 880 400 V 72 kg with cooling unit

--881 230--400 V 104 kg with cooling unit
--882 415/500--400 V 92 kg with cooling unit
A400e -- 68 --
For MIG/MAG welding
Current range 30 - 400 A
Arc voltage (mean value) 10 - 46 V
Wire feed speed 0 - 22 m/min
For MMA welding and CAC (carbon arc gouging)

Current range 8 - 400 A
Arc voltage (mean value) 20 - 40 V
Cooling module
Mains voltage 230 V
Mains frequency 50/60 Hz
Power 130 W
Cooling capacity 1.5 kW
Fluid volume 1.5 - 1.7 l
A400e -- 69 --
SETTING BOX
*
ARISTO 400 is programmed for welding by way of a portable box. connected to the machine
with a 5 m cable.
The setting box has four main areas of application. represented by the keys SEL, SET, MEA
and MEM. The other keys are used for the selection of settings after activation of one of the
main keys.
SEL (select) for description of methods and materials.

SET (set) for setting of welding data.
MEA (measure) for measuring of real welding data. which also can be adjusted.
MEM (memory) for storing. call--back and deletion of above settings.
The memory can hold 100 complete sets of welding data.
SEL: Shows alternatives within a number of different levels. which are shown on the
display in a certain order. First come the welding methods. The alternatives are
called with the key NEXT. With the desired alternative on the display. the selection
is done by going over to the following level, using the key with the arrow pointing
diagonally downwards.
Depending on the selected welding method, the levels will appear in the following
order:
MIG/MAG MMA (and CAC)*

2 Arc type Electrode quality
3 Electrode quality Electrode diameter
4 Shielding gas
5 Electrode diameter
* CAC (carbon arc gouging) is found under Electrode quality.
A400e -- 70 --
For available alternatives, see table on page 73.
SET. After completed selection. the following welding parameters can be set:
MIG/MAG: Wire feed speed voltage
MMA: Welding current
The values are presented on the display on two horizontally parallel lines and can be adjusted
by way of the four large arrow keys.
SYNERGIC FUNCTIONS
Based on the settings made, the computer caiculates a number of further welding parameters
to control the power source.
The following is valid for the voltage in MIG/MAG mode:
The computer caiculates a suitable value with regard to the settings made under SEL and
the selected wire feed speed.
When adjusting the voltage. other values will not be affected. It simply involves an
adjustment of the preprogrammed relation between current and voltage. The adjustment
concerns only the one program.
Voltage U
Adjusted curve
Preprogrammed curve
Wire feed speed Wfs
A400e -- 71 --
The SEL key functions.
A400e -- 72 --
TABLE OF SYNERGIC DATA IN THE SETTING BOX
WELDING ARC ELECTRODE SHIELDING ELECTRODE
METHOD TYPE QUALITY GAS DIAMETER
Al Si Ar 1.0 1.2
Ar50He 1.0 1.2
Al Mg Ar 1.0 1.2
Ss Ar2O2 0.8 1.0 1.2
Ar2CO2 0.8 1.0 1.2
Ar3OHe1O2 0.8 1.0 1.2
Ar32He3,2CO21H 0.8 1.0 1.2
Ar3CO2IH2 0.8 1.0 1.2
Fe Ar16CO2 0.8 1.0 1.2
Ar2CO2 0.8 1.0 1.2
Ar8CO2 0.8 1.0 1.2
Ar20CO2 0.8 1.0 1.2
Ar5CO2502 0.8 1.0 1.2
Ar2O2 0.8 1.0 1.2
MCW Fe Ar5CO2 1.2
MCW Ss Ar2CO2 1.2
Ar20CO2 1.2
FCW Ss Ar8CO2 1.2
Ar20CO2 1.2
PULSE BFCW Fe Ar5CO2 1.2
MIG/MAG Al Si Ar 1.0 1.2

Ar50He 1.0 1.2
DIP/SPRAY Al Mg Ar 1.0 1.2
Ss Ar2O2 0.8 1.0 1.2
Ar30He1O2 0.8 1.0 1.2
Ar2CO2 0.8 1.0 1.2
Ar3CO21H2 0.8 1.0 1.2
Ar32He3,2CO21H 0.8 1.0 1.2
Fe Ar16CO2 0.8 1.0 1.2
CO2 0.8 1.0 1.2
Ar20CO2 0.8 1.0 1.2
Ar23CO2 0.8 1.0 1.2
Ar15CO25O2 0.8 1.0 1.2
Ar5CO25O2 0.8 1.0 1.2
Ar8CO2 0.8 1.0 1.2
MCW Fe Ar20CO2 1.2
BFCW Fe Ar20CO2 1.2
Selfshield 1.2
FCW Ss Ar20CO2 1.2
RFCW Fe Ar20CO2 1.2
MCW Ss Ar20CO2 1.2
Ar2CO2 1.2
Carbon Arc Air 4.0 5.0 6.0 8.0

MMA Cellulose 2.5 3.25
Rutile 1.6 2.5 3.25 4 5 6 7
Basic 1.6 2.5 3.25 4 5 6 7
* When welding aluminium using an Ar/He-- gas mixture, which has another mixture correlation, the voltage should be adjusted.
With a high helium content the arc voltage is increased and with a low helium content the arc voltage is decreased.
* Due to the limitations of the display window certain gas combinations cannot be displayed correctly.
Ar 15%CO2 5%O2 is shown as ArCO2O2
Ar 5%CO2 5%O2 is shown as ArO2CO2
A400e -- 73 --
SEL. Selection of welding method
Example:
(This is to show the principle of the selection of welding method. The pictures vary in
accordance with the program of the computer.)
For MIG welding with 1 mm stainless electrode, pulsed arc and a shielding gas of 69% argon,
30% helium and 1 % carbon dioxide, proceed as follows:
Press
The following picture turns up. The actual alternative

[MMA]
is indicated within brackets. Press NEXT for other
alternatives, see below.
[MIG/MAG]
Now go to the next level of selections Press
[DIP/SPR] Fe
Brackets indicates short and spray arc.
CO2 1.2 mm
Press
The right type of arc has now been selected, and the [PULSE] Fe
computer suggests a new type of shielding gas. Ar20CO2 1.2 mm
Change the other settings accordingly. Proceed as follows:
A400e -- 74 --
PULSE [Fe] PULSE [Ss]
Ar20CO2 1.2 mm Ar20CO2 1.2 mm
PULSE Ss PULSE Ss
[Ar20CO2] 1.2 mm [ArHeCO2] 1.2 mm
PULSE Ss PULSE Ss
ArHeCO2 [1.2 mm] ArHeCO2 [1.0 mm]
The selection of welding method, gas and electrode is now finished. Go to SET
SET. Setting of welding data.
Example:
The picture indicates one # VOLT = 23 V

Press value for the voltage and one
for the wire feed speed (Wfs). * Wfs = 0.0 m/min
The wire feed speed value, Wfs=, remains from the previous setting. Based on the Wfs
value and the selections made under SEL, the computer calculates the voltage.
Adjust the Wfs value with the keys

*
The computer calculates a new voltage value. If
desired, the voltage can be adjusted without the Wfs
being affected.
This is done with the decrease/increase keys for

voltage
Measuring of real data is ordered with the MEA key.
A400e -- 75 --
Short arc/spray arc (KB/SPRAY)
Voltage
= Length of arc.
A higher voltage gives a longer arc and hotter welding.
Wire feed (Wfs)
Corresponds to the joint and material thickness.
Dynamic (Dyn)
Inductance. Higher dynamic gives hotter welding and a need for increased voltage.
Short pulsing (PULSE)

The machine is current controlled by short pulsing. (Thats to say that the machine holds the
current constant with the pulses independent of changes in cable length, stick--out or other
changes in resistance).
In addition there is an arc length regulating function which aims to hold a constant arc length.
Also at non--synergic settings of the parameters the arc length regulator will maintain the arc
length. (Thats to say, maintain the melt--off rate).
After completing the setting of the parameters for a work piece the set voltage and the
measured voltage should not fluctuate more than 1 volt from each other.
With changes in stick--out the power source will change the pulse frequency and adjust the
background current to maintain a constant arc length.
The following two parameters are always adjustable at short pulsing:

Voltage
Decides the length of the arc. Higher voltage = longer arc.
Wire feed (Wfs)
Corresponds to joint and material thickness.
At independent setting (synergic) the following parameters are adjustable:

Pulse amplitude (lp)
The top of the current pulse cuts off a drop from the end of the wire and transports it to the
weld pool.
The pulse amplitude is dependent on the selection of wire type, wire diameter, and type of gas
used.
The amplitude should be held as low as possible. If it is too high the pressure from the arc
will be too high which can cause problems with thinner plate; too low amplitude will either
cause a short--circuit or large hanging drops on the tip of the electrode.
Pulse time (Tp)
The width of the current pulse. An increase of Tp results in a frequency reduction.
A400e -- 76 --
Type of regulator (REG. TYPE)
Using the regulator type you can select which welding characteristics the machine should
have. There are five options, one for mixed gas and one for each of the wire dimensions
when CO2 welding.
Final pulse (FIN. PUL.)
The amplitude of the finishing pulse as a percentage of the nominal value. The nominal value
is calculated by taking the wire speed and the average current into consideration and lies in
the interval 400--700 A. The percentage can be set between 10--120%.
Background current (lb)
The size of the current in between the pulses. A higher lb gives hotter welding. A low lb
gives rise to the risk of the arc being extinguished.
The background current acts as pre--heating of the electrode.
Frequency (FREQ)
The number of pulses per second. An increased wire feed needs a higher frequency.
Slope--time
Inclination of the pulse rise and fall. A lower number gives a steeper inclination and results in
a higher sound level and a harder arc.
Arc length-- (Ka and Ki) regulator--factors
Decides to what degree the power source shall react when the welder tries to change the arc
length.
Standard values Ka approx. 40 %
Ki = 0%
Fin. pul. Amplitude modification of the final pulse.
MMA
Current
Welding current.
Arc--force
High arc--force gives a higher current with short circuiting and a harder arc.
A too high setting gives a risk of spatter.
Start display
ARISTO 400
VER 1.XX 89XXXX
Number of program version Date of the latest modification of

in the setting box the
synergic functions
A400e -- 77 --
MEA. Measuring of welding data.
Example:
Press before welding, while welding or after finished welding.
The average value of the arc voltage is measured continuously during the welding process.
After completing the weld the measurement value taken 2--3 seconds before finishing is
displayed.
The set value can be changed even when the setting
box shows the measurement value by using the # VOLT AGE = 23 V
*
increase/decrease buttons. CURRENT = 150 A
With short puising the setting box indicates the average
value of the arc voltage during the pulses.
MEM. Store handling.

Example:
Data can be stored [STO], recalled [RCL] or deleted [DEL]. The memory can take up to 100
sets of welding parameters. For storing, the parameter set is given a registration number.
The computer chooses the lowest free number available, but it is also possible to choose any
optional number not occupied.
The brackets are moved to the intended function with the adjoining
keys in the direction STO--RCL--DEL or DEL--RCL--STO.
Store:
[STO 12] RCL...

Press Picture.
DEL 27/100
The brackets are already in store position, STO, and the figure 12 is the number that will be
given to the data to be stored. A higher registration number can be chosen with the arrow
keys in the lower key row.
*
In the memory handling these keys are used for selection of
registration numbers:
To the right at the bottom, the figure 27/1 00 indicates that 27 out
of the 100 spaces are occupied.
Storing is ordered with [Exec]
Memory 0.
If welding data are stored in memory 0 they will automatically be recalled when the power
source is switched on. If no welding data are stored in memory 0, the data last used will
automatically be recalled.
A400e -- 78 --
Recall:
When recalling e.g. data set no. 35, activate the memory function and move the brackets to
RCL.
[STO 12] RCL... STO [RCL1]

DEL 27/100 DEL 27/100
Press till 35 appears

* and execute with
The setting box confirms operations and then returns to show the same picture.
Delete:
To delete a data set, proceed as follows (if the memory function is not already activated):
[STO 12] RCL STO [RCL1]

DEL 27/100 DEL 27/100
STO 12 RCL
[DEL1] 27/100
The brackets have now moved to DEL.
Call the desired registration number with

*
Execute the deletion with
A400e -- 79 --
Settings without synergy functions
ARISTO 400 can be disconnected from the synergy functions, e.g. when welding with
electrodes or gas mixtures which are not specified in the setting box. This means, however,
that a great number of parameters will have to be manually set at their right values in relation
to one another.
Disconnection:
After SET, press the adjoining keys at the
same time for a couple of seconds
SYNERGIC
When this picture appears: press
CHANGE: [NEXT]
Now the synergy function is disconnected.

Note that the parameter values last used remain until adjusted.
The parameters concerned are:
S For MIG/MAG welding with short--pulsed arc:

Voltage
Background current
Frequency
Strengthening factors for the arc length regulator of the power source (Ki, Ka)
Pulse amplitude
Pulse time
Slope time for the pulse
S For MIG/MAG with KB/SPR arc:

Voltage
Dynamics
Type of regulator
Final pulse
S For MMA
Arc--Force
A400e -- 80 --
Return to synergy functions
Return to synergy functions can be executed in two different ways.
Alternativ 1.
After SET, press the adjoining keys at the

same time for a couple of seconds.
When this picture comes NON-SYNERGIC Press

up
CHANGE: [NEXT]
Alternativ 2.
Press and then
Return to synergy functions can also be made by connecting a remote control unit.
Connect the unit and press
A400e -- 81 --
REM--REMOTE CONTROL UNIT.
Two types of remote control units are available for ARISTO 400.
1. A 5--program unit -- ARISTO CONTROL 5--PROGRAM.

For shifting between 5 different programs with adjustable voltage.
Store the required welding data in the welding data numbers 1--5, if this has not already
been done. Synergic and nonsynergic can be combined.
Connect the unit to the wire feed mechanism and press
The display shows U= I=

REM WELD DATA 1
U and I indicate measured (real) values for voltage and current. REM WELD DATA 1
indicates the number of the actual program.
Shifting between the programs 1--5 in the setting box and adjustment of the voltage can
now be done with the resp. knobs on the remote control unit.
2. Current and voltage device -- ARISTO CONTROL STANDARD.

For setting of voltage (U) and wire feed speed (Wfs) for MIG/MAG welding and voltage
(U) and current (Current) for MMA welding.
Connect the remote control unit to the wire feed mechanism, if used, otherwise directly
to the power source.
Select method with Press
Set the desired values with the remote control unit. The result can be read off on the set-
ting box.
The display shows for MIG/MAG: For MMA
U= I= U= I=
Wfs = CURRENT = A
This remote control unit cannot be used at non--synergic setting.
NOTE! When remote condition is ordered by pressing the REM key, the other key
functions of the setting box will be blocked.
A400e -- 82 --
3. Codelock
Settings can be locked in the remote control mode so that the operator cannot change
other parameters other than those that are accessible via the remote control unit. To leave
the remote control mode requires the operator to state a four number code. To install the
code: refer to basic values.
Example: Assume that the setting unit is in the SET mode.
Example:
When you are in the remote control mode and press
to leave the remote control mode
LOCK CODE =
The displays shows
1234
Now the correct code number can be set by using the increase/decrease buttons in the
same manner as described under basic values.
When the correct code number has been set, press

then you will leave the remote control mode.
If the code is incorrect no changes are made.
NOTE! When you switch on the machine it will go into the remote control mode, if it was in
this mode when the machine was switched on.
A400e -- 83 --
BASIC VALUES
When being in mode of method selection and when pressing SEL and SET for two seconds
you enter a mode where permanent selections can be made. These selections are usually made
when the machine is new however, they can also be made at any other suitable time.
The selections available are:
1. Language
2. Lock function or no lock function. If the lock function is selected the code can be set by
using the increase/decrease buttons. By using the increase or decrease number sign one of
the four number positions is pointed out. Using the increase/decrease asterisk changes the
value of the selected number.
3. 5 or 31 welding data sets accessible through the remote inlets.
Example
LANGUAGE
Press and for 2 seconds
The display can then [ENGLISH]

indicate NO HF-DEVICE
You can change language by pressing
Available languages: English, German, Finish, Swedish, French
CODELOCK Press
[NO CODELOCK]
The display can then indicate
5 REM DATA
A400e -- 84 --
If you wish to use the codelock press
[LOCK CODE=1234]
The display can then indicate
5 REM DATA
By using
*
and
you can set another number value.
NUMBER OF WELDING DATA AT REMOTE CONTROL

Choice between 5 or 31 welding data sets which can be reached through remote inlets.
Press
31- selections are intended to be utilized when, for example, you want to call different
welding data easily while using mechanized welding.
The five inputs on the 23 pole contact (on the wire feed or at the rear of the machine) forms
the welding data number into binary code. The five contacts are:
one number (20) contact N four numbers (22) contact R sixteen numbers (24) contact T
two numbers (21) contact P eight numbers (23) contact S Common contact L
If, for example, you want the welding data number 10 you add contact S and contact P with
contact L.
FINISHING
Press one of
or
to go over to normal use.
A400e -- 85 --
ERROR MESSAGES
Generally the error message remains on the screen until any key on the setting box is pressed,
or the machine is switched off and on again.
1. Error in the electronic circuits of the power supply

1.1 MACHINE ERROR: HIGH VOLTAGE
1.2 MACHINE ERROR: HIGH CURRENT
1.3 MACHINE ERROR: HEAT SINK TEMP.
1.4 MACHINE ERROR: NO WATER FLOW
2. Storage error
2.1 RAM ERROR IN POWER SOURCE
2.2 RAM ERROR IN CONTROL UNIT
2.3 ROM ERROR IN POWER SOURCE
2.4 ROM ERROR IN CONTROL UNIT
2.5 WELD DATA ERROR IN CONTROL UNIT
3. Communication error
3.1 COMM. ERROR: RECEIVE CH. SUM
3.2 COMM. ERROR: TRANSM. CH. SUM
3.3 COMM. ERROR: TIMEOUT
3.4 POWER SOURCE TIMEOUT
3.5 COMM. ERROR: RECIVE BUFFER
3.6 COMM. ERROR: SEND BUFFER
3.7 WAITING FOR MACHINE IDENT
1. Error in the electronic circuits of the power supply

1.1 MACHINE ERROR: HIGH VOLTAGE
Too high voltage in the machine after the rectifier, which might be due to
overtension on the mains or high inductance in the voltage supply cables.
1.2 MACHINE ERROR: HIGH CURRENT

Too high primary current to the transistor switch circuits or irregular current
distribution between the two transistor packets. The limit values correspond to about
1400 A secondary current or 300 A difference in current between the two packets.
The error might be due to defective components or to faulty connections in the
electronic circuits of the power supply.
A400e -- 86 --
1.3 MACHINE ERROR: HEAT SINK TEMP
Too high temperature in the diode heatsinks, which may be caused by overload,
defective cooling fan or other defective component.
1.4 MACHINE ERROR: NO WATER FLOW

No water supply to the welding gun. May be due to silted--up hoses, defective pump
for the cooling water or lack of cooling water. If the pump has been switched off
(e.g. when using an air--cooled welding gun) this error message will be blocked.
2. Storage error
Each time the machine is switched on and voltage is supplied, all the storage cells are
tested. The program storage is tested by means of a checking sum. If any storage
cell is defective, one of the following four messages comes up on the screen. Thus
they can only appear directly after switching on the machine. The machine can be in
working order despite the error message. Caution must be used, however, as the
welding result might be affected even though the machine seems to behave perfectly.
2.1 RAM ERROR IN POWER SOURCE

Defective storage cell in the read/write storage of the machine.
2.2 RAM ERROR IN CONTROL UNIT

Defective storage cell in the read/write storage of the setting box. This storage
contains, among other things, stored welding data.
2.3 ROM ERROR IN POWER SOURCE

Defective storage cell in the program storage of the machine.
2.4 ROM ERROR IN CONTROL UNIT

Defective storage cell in the program storage of the setting box.
2.5 WELD DATA ERROR IN CONTROL UNIT

3 V battery in the setting box is used up.
A400e -- 87 --
3. Communication error
All these error messages have got something to do with the series communication
between the machine and the setting box. The error messages may appear only
occasionally. Reset by switching the machine off and on. When the messages appear
more frequently, the equipment must be seen to.
3.1 COMM. ERROR: RECEIVE CH. SUM

The wrong checking sum has been detected 5 times in a row during transmission
from the machine to the setting box.
3.2 COMM. ERROR: TRANSM. CH. SUM

The wrong checking sum has been detected 5 times in a row during transmission
from the setting box to the machine.
3.3 COMM. ERROR: TIMEOUT

The setting box has sent a message to the machine, the receipt of which has not been
acknowledged by the machine.
3.4 POWER SOURCE TIMEOUT

The power source has sent a message to the setting box, but no message acknow
edgement has been received.
3.5 COMM. ERROR: RECEIVE BUFFER

The setting box has failed to handle incoming messages at the pace they come in, and
therefore the receiving buffer storage has been filled.
3.6 COMM. ERROR: SEND BUFFER

The machine has failed to receive incoming messages from the setting box at the
pace new messages are added to the sending buffer storage of the setting box, and
therefore the sending buffer storage has been filled.
3.7 WAITING FOR MACHINE IDENT

The setting box awaits the first message from the power source.
A400e -- 88 --
EXPLANATION OF ABBREVIATIONS AND CONCEPTS
SEL SELECT DATA
MMA Hand welding
MIG/MAG Semi--automatic welding
Basic Basic electrode
Rutile Rutile electrode
Cellul. Cellulose electrode
Carbon.Arc/Air Carbon arc gouging
Dip/Spr Short--arc/Spray--arc
Pulse Short--pulse welding
Fe Non--alloy steel OK 12.51
Ss Stainless steel OK 16.32
AI Si Aluminium, AlSi OK 18.04
AI Mg AlMg OK 18.15
MCW Fe Metal cored wire, iron OK 14.00, OK 14.03
MCW Ss Metal cored wire, stainless OK 15.30
FCWf Ss Flux cored wire, stainless OK 14.30
Ar 100% argon
Ar CO2 H2 96% Argon, 3% carbon dioxide, 1 % hydrogen
Ar 2 O2 98% argon, 2% oxygen
Ar 2 CO2 98% argon, 2% carbon dioxide
Ar 20 CO2 80% argon, 20% carbon dioxide
Ar CO2 O2 90% argon, 5% carbon dioxide, 5% oxygen
CO2 100% carbon dioxide
Ar He O2 69% argon, 30% helium, 1 % oxygen
Noxalic 63% argon, 33% helium, 3% carbon dioxide, 1 % hydrogen
B FCW Fe Basic Flux cored wire, OK 15.00
R FCW Fe Rutile Flux cored wire, OK 15.15, OK 15.18
FIN. PUL Modified final pulse
A400e -- 89 --
SET Setting of welding data
MIG/MAG
Voltage Set voltage (8--50 V MIG/MAG, 10--50 V Pulse)
Wfs Set wire feed speed (0--22 m/min)
SYNERGIC The computer calculates welding data
NON SYNERGIC Manual setting of welding data
lp Pulse amplitude (100--640 A)
Tp Pulse time (Max 1.75--25.5 ms)
lb Background current (12--300 A)
Freq Pulse frequency (max 20--332 Hz)
Slope time Flank inclination of the pulse (1 - 9)
Ka Arc length regulation factor, short time (10--100%)
Ki Arc length regulation factor, longer time (0--1 00%)
Dyn Dynamic (stepless inductance) for MIG/MAG (0--100%)
REG.TYPE. Different process regulator characteristics, e.g. for CO2 or gas

mixtures.
FIN. PUL. The amplitude of the finishing pulse as a percentage of the

nominal value.
MMA
Arc force Arc pressure for MMA (1 - 100 %)
MEA= MEASURE Measuring of welding data

Current A Real welding current (ampere)
Voltage V Real arc voltage (volt)
MEM = MEMORY Storage handling

STO Store welding data/program
RCL Recali welding data/program
DEL Delete welding data/program
19/100 19 out of 100 programs are used
REM = REMOTE Connection and disconnection of remote control unit

(5--program unit) ARISTO CONTROL 5--PROGRAM
U=V Real arc voltage
I=A Real welding current
REM WELD DATA Set welding data, number
Adjusting equipment for ARISTO CONTROL SYNERGY
current and voltage
U=V Real arc voltage
I=A Real welding current
Wfs = m/min Set wire feed speed for MIG/MAG
Current = A Set wire feed speed for MMA
A400e -- 90 --
INSTALLATION
1. Place the machine so that there is nothing to prevent the cooling air from passing
through it.
2. Connection should be made to 3--phase terminals. Phase sequence is unimportant.
3. Recommendations: Mains voltage Cable area Fuse size
50 Hz 230V 10 mm2 50 A
400 6 20
415 6 20
500 6 20
4. Dismount the right side panel.
Check the connection of the mains adaptation unit.
A400e -- 91 --
OPERATION
1. Set the starting switch to position 1. The indicating lamp goes on to show that mains
voltage is supplied.
2. Connect the return cable between the workpiece and the machine terminal. Make sure
that good contact is obtained!
3. Select welding mode on the setting box.
4. Set welding data by means of the setting box. Press the keys in accordance with the fol-
lowing until the desired data appear on the display:
a. Select welding mode with and
b. For MIG/MAG: and

select pulsed arc, short arc or spray arc with
c. Select electrode quality with and
d. Select electrode diameter with and
e. Set the wire feed speed (Wfs). The voltage that is dependent
on the wire feed speed will change automatically. When the
value of the voltage is adjusted the wire feed speed will not be
affected.
f. For check--up of real welding current after finished welding
To change the values press the up or down keys
g. If welding data are stored in Memory 0 they will automatically be recalled when
the power source is switched on. If no data are stored in Memory 0 the data last
used will automatically be recalled.
See also the chapter SETTING BOX.
If operating disturbances in the form of overheating in the power circuit, over--current,
over--voltage or a stop in the water flow occur, this is then indicated by the machine
stopping and the yellow signal lamp coming on and an actual message being displayed
on the min. setting box.
A400e -- 92 --
MAINTENANCE
ARISTO 400 is to be cleaned regularly with dry compressed air at reduced pressure.
No further maintenance is needed.
Ordering numbers for components

S Power source with setting box and built--in cooling unit
400 V 50 Hz 469 120--880
230/400 V 50 Hz 469 120--881
400/415/500 V 50 Hz 469 120--882
S Carriage
Chassis 369 580--880
TROLLEY SEMI 369 580--884
TROLLEY MAXI 369 580--885
TROLLEY MAXI 2 BOTTLES 369 580--886
S Remote control unit

CONTROL 5 PROGRAM BOX 466 801--881
CONTROL SYNERGIC BOX 466 801--880
CONTROL 5 PROGRAM TORCH 466 515--881
CONTROL SYNERGIC TORCH 466 515--880
For MIG/MAG
S Wire feed unit MED 44 ARISTO 369 341--880
Turning device for mounting of the feed unit on the power source 156 681--880
S Torch with cable bundle PSF 500 3 m 366 400--884

PSF 500 4,5 m 366 400--885
PSF 501 W 3 m 366 800--884
PSF 501 W 4,5 m 366 800--885
S Counterbalancing arm for torch with cable bundle 156 682 880
S Mast for torch with cable bundle 156 746--880
For MMA
S Welding accessories 160 302--883
A400e -- 93 --
A400e -- 94 --
STATIC CHARACTERISTICS
U2 = STANDARDIZED LOAD VOLTAGE
A400e -- 95 --
EFFICIENCY/POWER FACTOR
A400e -- 96 --
DIMENSION DRAWING
A400e -- 97 --
A400e -- 98 --
SPARE PARTS LIST LUC 400
Edition 9601
cny1ap00
Ordering numbers for LUC 400 welding rectifiers

Ordering no. Denomination Notes
469 120--880 LUC 400 400 V 3~ 50 Hz
469 120--881 LUC 400 230/400 V 3~50 Hz
469 120--882 LUC 400 400/415/500 V 3~50 Hz
Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover. Kindly indicate type of unit, serial number,
denominations and ordering numbers according to the spare parts list.
Reservdelar bestlls genom nrmaste ESAB--representant, se sista sidan. Vid bestllning var vnlig uppge typ och tillverkningsnummer samt
benmningar och bestllningsnummer enligt reservdelsfrteckningen.
Die Ersatzteile knnen bei der nchsten ESAB--Vertretung bestellt werden, siehe letzte Seite. Bitte geben Sie Typenbezeichnung und
Herstellungsnummer sowie Bezeichnungen und Bestellnummern laut Ersatzteilverzeichnis an.
Au dos de la brochure, vous trouverez ladresse du reprsentant ESAB le plus proche. Prire de lui adresser votre commande, aprs avoir pris le
soin de mentionner le type et le numro de srie de lunit ainsi que le numro de commande et la dsignation conformment la liste de pices
dtaches.
cny1se1 -- 99 --
Spare parts list -- Reservdelsfrteckning -- Ersatzteilverzeichnis -- Liste de pices dtaches
C = component designation in the circuit diagram
Item
Qty Ordering no. Denomination Remarks C
no.
Welding rectifier
101 2 368 557--002 Handle
102 1 467 200--001 Front panel
103 1 469 113--001 Side panel, left
104 1 368 560--001 Cover
105 1 456 222--880 Rear panel From machine no. 550 . . .
1 368 563--880 Rear panel Before machine no. 550 . . .
106 1 469 114--001 Side panel, right
107 4 319 455--002 Foot
108 2 366 296--002 Knob
109 2 366 295--005 Switch SA1
110 1 486 108--880 PC board, LED AP6
111 1 193 669--006 Connector XT14
112 1 193 586--101 Circuit breaker 5A FU1
113 1 466 484--001 Fuse holder
114 1 567 9001--16 Quick--blow fuse 10 A FU2

1 567 9001--11 Quick--blow fuse 2A FU3
116 1 193 759--001 Indicating lamp HL1
117 1 193 260--150 Connector XT9
118 14 192 562--103 Cage nut low M5

26 192 562--104 Cage nut high M5
2 192 562--105 Cage nut low M6
8 192 562--106 Cage nut high M6
cny1se1 -- 100 --
cny1se1 -- 101 --
Item
no.
Power module
201 1 192 579--538 Resistor R2
202 1 481 948--880 PC--board AP13
204 1 193 045--002 Connection block XT4
205 1 369 325--880 Transient protection C03, C04
207 6 192 903--505 Capacitor Only when item 237 is fitted C11
208 1 481 764--886 Control board AP5
209 1 193 661--110 Capacitor C01
210 1 193 769--001 Rectifier bridge VC1
212 2 320 729--001 Current transformer TA1, TA2
213 1 366 589--001 Insulation
214 1 162 532--001 Bushing
215 1 481 413--880 PC board Lightning protection AP8
217 1 468 943--001 Control transformer TC2
218 1 162 781--002 Connection block
219 1 469 950--880 Cable inlet From machine no. 550 . . .
1 191 309--110 Clip D= 22
Before machine no. 550 . . .
1 191 309--107 Clip D= 16
Before machine no. 550 . . .
220 1 467 753--001 Auto--transformer 230/400 V 50Hz TV 1
1 369 245--001 Auto--transformer 400/415/500 V 50Hz TV2
221 1 192 784--016 Sleeve plug XP2
222 1 192 784--015 Pin plug XP1
223 1 193 669--004 Connector 4--pole
224 1 193 260--151 Connector 3--pole XT12
1 193 260--153 Connector 5--pole XT8
225 1 369 124--181 Cover for XT12
1 369 124--183 Cover for XT8
1 369 124--187 Cover for XT13
1 369 124--189 Cover for XT11
1 369 124--192 Cover for XT10
227 1 466 517--880 Fuse holder
228 1 5679 001--23 Fuse 0.5 A FU4
229 1 466 837--880 Capacitor C7
231 1 481 158--880 Suppressor board Before machine no. 550 . . . AP7
(mains connection)
232 1 162 781--002 Connection block Before machine no. 550 . . . XT2
233 1 193 502--103 Contactor QF1
234 1 193 502--104 Time relay KT1
235 2 192 579--136 Resistor Only when item 237 is fitted R13
236 2 192 579--315 Resistor Only when item 237 is fitted R1b, R1c
237 1 193 758--001 lnductor When item 220 is fitted or option L3
1 468 925--880 Filter kit Contains: C11, L3, R1b and R1c
238 1 486 360-880 Suppressor board (EMC) From machine no. 550 . . . AP7
cny1se1 -- 102 --
223
237
221
224 201
222
225
cny1se1 -- 103 --
Item
no.
Power module
301 1 369 228--001 Insulating plate
306 1 368 827--880 lnductor, upper Ll
307 2 368 824--880 Main transformer TM1, TM2
308 2 Switching unit (See item no. 350) V1, V3
309 1 192 753--003 Connection block XT5
310 2 320 655--001 Thermal cutout ST1, ST2
311 2 Switching unit (See item no. 350) V2, V4
312 20 320 759--003 Diode V5, V6,
V7, V8
313 1 368 827--881 lnductor, lower L2
314 1 481 606--880 Suppressor board AP12
315 2 160 362--881 Welding current terminal OKC XS1
316 1 368 830--880 Shunt RS1
317 12 466 658--001 Support
318 2 368 260--880 Rectifier unit Items 310 and 312 are included
319 1 369 327--148 Shunt cable
320 4 369 335 880 RC--filter
321 1 192 579--221 Resistor R7, R12
SPARE PARTS SET
Item no. Orderingno. Denomination Remarks
350 468 515-889 Set of switch units Contains items 308 and 311, one of each.
cny1se1 -- 104 --
cny1se1 -- 105 --
Item
no.
Power module
401 2 318 731--001 Fan EV1, EV2
402 1 193 318--006 Control transformer TC1
403 1 192 579--315 Resistor R1a
405 1 481 457--880 Suppressor board AP9
406 1 369 124--196 Cover
407 1 193 260--166 Connector 18 pol. XT15
cny1se1 -- 106 --
cny1se1 -- 107 --
Item
Qty Orderingno. Denomination Remarks C
no.
Cooling unit
501 1 467 031--001 Water tank
502 1 369 241--001 Cover
503 1 368 568--001 Water filling tube
504 1 368 556--001 Radiator

505 1 369 233--001 Pump Incl. motor M1
443 042--001 Sealing For the water pump
443 043--880 Assembling tool For the sealing
506 1 467 118--001 Flow guard min 0.7 I/min SF1
507 1 318 731--001 Fan
508 1 365 803--008 Quick coupling Red

1 365 803--009 Quick coupling Blue
509 2 365 803--001 Slip--in nipple
510 1 193 045--007 Terminal block XT3
511 1 467 861--001 Water hose
512 1 467 862--001 Water hose
513 1 321 030--002 Water hose
514 321 030--004 Water hose
515 321 030--001 Water hose
516 1 321 030--003 Water hose
517 1 321 030--011 Water hose
518 1 191 085--106 Capacitor For pump motor C02
519 1 467 030--001 Nipple
520 1 2152 012--08 O--ring 15.1/10.3 x 2.4 mm
521 1 467 029--001 Screw
cny1se1 -- 108 --
cny1se1 -- 109 --
Item
Qty Orderingno. Denomination Remarks C
no.
1 369 139--882 Data setting box Complete
601 1 369 138--880 Clamp
602 1 369 130--001 Side panel, left
603 1 369 329--880 Key plate
604 1 369 134--001 Display window
605 1 369 506--880 Casing Complete
606 1 481 417--880 Circuit board AP10
607 1 481 404--890 Circuit board AP11
608 1 369 129--001 Side panel, right
609 1 2126 022--01 Nut
610 1 369 143--880 Cable
611 Ribbon cable Included in item 606
612 1 193 069--201 Battery
613 1 369 135--001 Rubber stud
NOTE
When ordering a complete data setting box even the machine number must be indicated so
as to receive the right version of program.
cny1se1 -- 110 --
611
cny1se1 -- 111 --
ESAB subsidiaries, representative offices and agents
Europe NORWAY Asia/Pacific IRAN

AUSTRIA AS ESAB AUSTRALIA Kavosh Azmoon
ESAB Ges.m.b.H Larvik ESAB Australia Pty Ltd Teheran
Vienna--Liesing Tel: +47 33 12 10 00 Ermington Tel: +98 21 884 39 14
Tel: +43 1 888 25 11 Fax: +47 33 11 52 03 Tel: +61 2 9647 1232 Fax: +98 21 884 13 46
Fax: +43 1 888 25 11 85 Fax: +61 2 9748 1685
POLAND ROMANIA
BELGIUM ESAB Sp.z.o.o INDIA ESAB Representative Office
S.A. ESAB N.V. Warszaw ESAB India Ltd Bucharest
Brussels Tel: +48 22 813 99 63 Calcutta Tel/Fax: +40 1 211 75 02
Tel: +32 2 745 11 00 Fax: +48 22 813 98 81 Tel: +91 33 478 45 17
Fax: +32 2 726 80 05 Fax: +91 33 468 18 80 RUSSIA-- CIS
PORTUGAL ESAB Representative Office
THE CZECH REPUBLIC ESAB Lda INDONESIA Moscow
ESAB VAMBERK s.r.o. Lisbon P.T. Esabindo Pratama Tel: +7 095 93 79 820
Vamberk Tel: +351 1 837 1527 Jakarta Fax: +7 095 93 79 580
Tel: +420 2 819 40 885 Fax: +351 1 859 1277 Tel: +62 21 460 01 88
Fax: +62 21 461 29 29 ESAB Representative Office
Fax: +420 2 819 40 120 St Petersburg
SLOVAKIA
DENMARK ESAB Slovakia s.r.o. MALAYSIA Tel: +7 812 325 6688
Aktieselskabet ESAB Bratislava ESAB (Malaysia) Snd Bhd Fax: +7 812 325 6685
Copenhagen--Valby Tel: +421 7 44 88 24 26 Selangor
Tel: +45 36 30 01 11 Fax: +421 7 44 88 87 41 Tel: +60 3 703 36 15 Agents
Fax: +45 36 30 40 03 Fax: +60 3 703 35 52 For addresses and phone
SPAIN numbers to our agents, please
FINLAND ESAB Ibrica S.A. SINGAPORE contact ESAB International AB,
ESAB Oy Alcobendas (Madrid) ESAB Singapore Pte Ltd Sweden
Helsinki Tel: +34 91 661 55 80 Singapore
Tel: +358 9 547 761 Fax: +34 91 661 51 83 Tel: +65 861 43 22 EUROPE
Fax: +358 9 547 77 71 Fax: +65 861 31 95 Cyprus, Greece, Malta
SWEDEN
FRANCE ESAB Sverige AB SOUTH KOREA AFRICA
ESAB France S.A. Gothenburg ESAB SeAH Corporation Angola, Cameron, Ethiopia,
Cergy Pontoise Tel: +46 31 50 95 00 Kyung--Nam Gabon, Ghana, Kenya, Liberia,
Tel: +33 1 30 75 55 00 Fax: +46 31 50 92 22 Tel: +82 551 2 89 81 11 Morocco, Mocambique, Nigeria,
Fax: +33 1 30 75 55 24 Fax: +82 551 289 88 63 Senegal, South Africa, Tanzania,
ESAB International AB Togo, Tunisia, Zambia, Zimbabwe
Gothenburg
GERMANY Tel: +46 31 50 90 00 THAILAND
ESAB GmbH ESAB (Thailand) Ltd ASIA
Fax: +46 31 50 93 60 Bahrain, Hongkong, Israel,
Solingen Samutprakarn
Tel: +49 212 298 0 Tel: +66 2 393 60 62 Japan, Jordania, Korea, Kuwait,
SWITZERLAND Lebanon, New Guinea, Oman,
Fax: +49 212 298 204 ESAB AG Fax: +66 2 748 71 11
Pakistan, The Philippines,
Dietikon Quatar, Saudi Arabia,
GREAT BRITAIN Tel: +41 1 741 25 25 UNITED ARAB EMIRATES
ESAB Group (UK) Ltd ESAB Middle East Sri Lanka, Syria, Taiwan,
Fax: +41 1 740 30 55 Turkey, Vietnam, Yemen
Waltham Cross Dubai
Tel: +44 1992 76 85 15 North and South America Tel: +971 4 338 88 29
Fax: +44 1992 71 58 03 Fax: +971 4 338 87 29 LATIN AMERICA
ARGENTINA Bolivia, Chile,
ESAB Automation Ltd CONARCO Colombia, Costa Rica, Curacao,
Andover Buenos Aires Representative offices Equador, El Salvador,
Tel: +44 1264 33 22 33 Tel: +54 11 4 753 4039 ALGERIA Guatemala, Honduras, Jamaica,
Fax: +44 1264 33 20 74 Fax: +54 11 4 753 6313 ESAB Algeria Paraguay, Peru, Trinidad,
Alger Uruguay, Venezuela
BRAZIL Tel: +213 2 67 24 93
HUNGARY
ESAB S.A. Fax: +213 2 68 32 90
ESAB Kft
Contagem--MG
Budapest
Tel: +55 31 333 43 33 BULGARIA
Tel: +36 1 20 44 182
Fax: +55 31 361 31 51 INTESA
Fax: +36 1 20 44 186
Sofia
CANADA Tel: +359 2 980 17 15
ITALY ESAB Group Canada Inc.
ESAB Saldatura S.p.A. Fax: +359 2 980 08 42
Missisauga, Ontario
Mesero (Mi) Tel: +1 905 670 02 20 CHINA
Tel: +39 2 97 96 81 Fax: +1 905 670 48 79
Fax: +39 2 97 28 91 81 Shanghai ESAB A/P
MEXICO Shanghai
THE NETHERLANDS ESAB Mexico S.A. Tel: +86 21 6539 7124
ESAB Nederland B.V. Monterrey Fax: +86 21 6543 6622
Utrecht Tel: +52 8 350 5959
Tel: +31 30 248 59 22 Fax: +52 8 350 7554 EGYPT
Fax: +31 30 248 52 60 ESAB Egypt
USA Dokki--Cairo
ESAB Welding & Cutting Products Tel: +20 2 390 96 69
Florence, SC Fax: +20 2 393 32 13
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
ESAB Welding Equipment AB

SE-- 695 81 LAX
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.com
990922

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LUC 400

740 800--070 9305 -- 1

INSTRUCTION MANUAL ARISTO 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Rights reserved to alter specifications without notice.

2 These symbols indicate that Aristo incorporates an inverter, a transformer and a

4 Indicates the voltage/current characteristic for MMA welding.

5 Indicates that the unit is intended for connection to a 400 V three--phase 50 Hz or

Component positions on circuit board AP6

Circuit diagram and component positions on circuit board AP7

AP8 Interference suppression board: protects against the effect of mains--borne

Circuit diagram and component positions, circuit board AP12.

WARNING High voltage within the shaded area.

An arc voltage signal is connected to:

Pin N Input J6 Welding data 1 1

The opto interface consists of a transmitter, IC4, and a receiver, IC3.

The shunt provides a signal of 24 mV at 100 A, linearly proportional to the welding

Waveform of current trace at Mp14 for a resistive load to

DANGER: MAINS VOLTAGE

LED Error message Fault

Positions of the diodes on the control board

Voltage ref. Power pack

Principle for control of the process regulator

14 OPEN--CIRCUIT VOLTAGE CONTROL

S Mp10 Input signal to the pulse width modulator.

S Turn off the machine.

Measuring the control pulses with a separate gate load

Connecting the oscilloscope to the gate load

Control pulses as measured across separate gate load

S Disconnect the power source from the mains.

S Press the TEST pushbutton.

Connection point for positive supply from the power unit

S Adjust the power supply to a maximum of 40 V, with 0.5 A current limit.

Connecting the oscilloscope when measuring

Secondary voltage from TM1 (TM2) with a 40 V supply across C01

S Check that the no--load voltage is 55 -- 65 V, (normal value 58 V).

S Connect the load.

S Make a test weld as a final check.

Circuit diagram, suppressor board AP9

Component positions, suppressor board AP9

Circuit diagram, diode bridge board AP13

Component positions, diode bridge board AP13

The three--phase bridge is protected against line interference by capacitors C1 - C6 and

THE THERMAL OVERLOAD CUTOUTS CIRCUIT

7. Check that capacitor C01 is not short--circuited.

REMOVAL OF THE UPPER SWITCH UNITS

S Measure the diodes, one at a time.

S Carefully remove the faulty diodes from the heat sink.

S Replace the lower diodes in the same way.

Construction of the welding settings control unit.

Inputs and outputs to/from the microprocessor board

DESCRIPTION OF OPERATION, MICROPROCESSOR BOARD

S WAITING FOR MACHINE IDENT.

Erasure of the welding data memory:

until the display shows:

Construction of the weldings settings control unit

S Remove the clip (1) from the case.

S Unscrew the right--hand end (8).

S Disconnect the yellow--green earth wire from the casing.

1. Faults in the power electronic circuits of the machine

b. MACHINE ERROR: HIGH CURRENT

c. MACHINE ERROR: HEATSINK TEMP

d. MACHINE ERROR: NO WATER FLOW

b. RAM ERROR IN CONTROL UNIT

c. ROM ERROR IN POWER SOURCE