ESAB Aristotig 405 AC/DC - Service Manual

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0458 165 002 9910

DTG 405

Aristotig 405 AC/DC

Welding rectifier

Service manual

Table of Contents

Default Chapter2
- Table of Contents2
Contents6
Safety6
Principal Diagram Dtg 4058
Connection Diagram Dtg 40510
Function Diagram Dtg 40512
Component Description12
Block Diagram Dtg 40516
General Description18
- Connections18
- Power Electronics Energy Flow18
- Function of Control and Adjustment19
- Protection against Excessive Output Voltage20
- Path of the Start-Up Signals20
A1 Component Positions21
A1 Description of Operation21
- A1-1 Start-Up Circuit22
- A1-2 Supply Inverter22
- A1-3 Mains Voltage Monitoring23
- A1-4 Temperature Monitoring23
- A1-5 Primary Overcurrent Shutdown24
- A1-6 DC-Output Voltage Buffer and Overvoltage Protection25
- A1-7 Primary Mosfet Driver25
- A1-8 Mains Switch Monitoring26
A2 Component Positions27
A2 Description of Operation28
- General Function28
- Down Slope Ramp Function28
- Signal Description X429
A4, A11 Component Positions30
A5, A12 Component Positions31
Testing Modules A4, A5, A11, A1231
- Measurements on an Enclosed Power Block31
  - Checking with Tester It0131
  - Checking with Multimeter31
- Measurements on an Open Power Block31
  - CHECKING the Mosfets and DIODES31
- Checking the Gate Pulses32
  - Checking with Tester It0132
  - Checking with Oscilloscope32
A6 Component Positions33
A6 Description of Operation33
- A6-1 Supply A2, A633
- A6-2 Control Hf-Ignition Unit34
- A6-3 Arc-Voltage Sense34
- A6-4 Solenoid Valve Control35
- A6-5 Torch Button Monitoring35
- A6-6 Monitoring the Cooling Circuit35
Description of Operation36
- A8 Principal Function36
- A8-1 Secondary Current Monitoring37
- A8-2 Arc Voltage Sensing38
- A8-3 Secondary Mosfet Driver38
- Signal Description of X239
A8 Component Positions36
A9, A13 Component Positions40
A10, A14 Component Positions40
A15 Component Positions41
T2 Component Positions41
Instructions for Fault Tracing and Repair42
- Safety Instructions42
- Protection against Hazardous Fault Currents42
  - Testing Protective Conductors42
  - Insulation Resistance42
  - Dielectric Strength43
- Power Supply During Fault Tracing43
- Load Application During Fault Tracing44
- Instruments, Measuring in Floating Mode45
- Opening the System45
- Uniterror Codes46
  - General Fault - no Error Code (Blank)46
  - Error Code 1: Primary Overcurrent46
  - Error Code 2: Mains Undervoltage46
  - Error Code 3: Mains Overvoltage46
  - Error Code 4: Thermal Overload47
  - Error Code 5: Cooling Water Fault, General Error Interrupt47
  - Overvoltage Trip47
- Testing with Tester It0147
  - General Description47
  - Test Procedure with It0149
- Testing of A4, A5, A9, A10, A11, A12, A13, A1450
- Repairs on A4, A5, A9, A10, A11, A12, A13, A1451
- Potentiometer on Control Panel A2-2 Defective51
- Unit Has Crashed52
- Unit Switches off after a Short Time Interval52
- Fault on Mains Power Input53
- Torch Button Connection53
- Weak Insufficient Hf-Ignition53
- Hf Arc-Over on the Shrouded Socket Outlet54
- High-Voltage Starting Pulses (Hf)54
- Gas54
- Continuous Gas Flow55
- Water Cooling, Adjust Pressure Contact55
- Renewal of Control Boards55
- Renewing Electronic Module A155
- Exchange Power Package Dtg 40556
Output Current in Different Modes58
- Four Stroke Lift Arc DC58
- Four Stroke Hf-Ignition DC58
- Four Stroke Hf-Ignition Ac59
- Two Stroke Lift Arc DC60
- Two Stroke Hf-Ignition DC60
- Two Stroke Hf-Ignition Ac61
- Waveform Ac1 (Square Wave)61
- Waveform Ac2 (Smooth Wave)62
Starting up63
- General Information63
- Commissioning of Dtg405 Power Section63
- Commissioning A266
Load Characteristics67
Operation68
- Generally68
- Control Installations and Connections68
- Remote Control68
- Overheating Protection69
- Control Panel69
- Electrode Welding (Mma)74
  - Settings on the Control Panel When Electrode Welding74
- Tig Welding75
  - Settings on the Control Panel When TIG Welding75
  - Setting, DC and AC79
- Forced Interruption79
Maintenance80
Accessories80
Spare Parts List82

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