ESAB | Aristo® 500ix | Instruction manual | ESAB Aristo® 500ix User manual

ESAB Aristo® 500ix User manual
Aristo® 500ix
Instruction manual
0463 725 001 GB 20191216
Valid for: 941-xxx-xxxx
TABLE OF CONTENTS
SAFETY .......................................................................................................
3
1.1
Meaning of symbols ...............................................................................
3
1.2
Safety precautions .................................................................................
3
1.3
User responsibility .................................................................................
7
1.4
California Proposition 65 warning ........................................................
9
INTRODUCTION ..........................................................................................
11
Equipment ...............................................................................................
11
3
TECHNICAL DATA ......................................................................................
12
4
INSTALLATION ............................................................................................
14
4.1
General ....................................................................................................
14
4.2
Location...................................................................................................
14
4.3
Lifting instructions .................................................................................
15
4.4
Mains supply...........................................................................................
16
OPERATION ................................................................................................
19
5.1
Connections and control devices .........................................................
19
5.2
Symbols ..................................................................................................
20
5.3
Connection of welding and return cable ..............................................
20
5.4
Turning the power source on/off...........................................................
20
5.5
Fan control ..............................................................................................
20
5.6
Thermal protection .................................................................................
20
5.7
VRD (Voltage Reducing Device)............................................................
21
5.8
Remote control unit................................................................................
21
5.9
Arc voltage feedback .............................................................................
21
MAINTENANCE ...........................................................................................
22
6.1
Routine maintenance .............................................................................
22
6.2
Power source ..........................................................................................
22
TROUBLESHOOTING .................................................................................
24
ORDERING SPARE PARTS ........................................................................
ORDERING NUMBERS .......................................................................................
BLOCK DIAGRAM...............................................................................................
ACCESSORIES ...................................................................................................
25
26
27
28
1
2
2.1
5
6
7
8
Rights reserved to alter specifications without notice.
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1 SAFETY
1
SAFETY
1.1
Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2
Safety precautions
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in Additional Safety Information section. Before
performing any installation or operating procedures, be sure to read and follow the
safety precautions listed below as well as all other manuals, material safety data
sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require
ear protection. The arc, like the sun, emits ultraviolet (UV) and other
radiation and can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential
to prevent accidents. Therefore:
1.
2.
3.
4.
Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
Always wear safety glasses with side shields in any work area, even if welding
helmets face shields and goggles are also required.
Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuff less trousers,
high-topped shoes and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.
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1 SAFETY
5.
6.
7.
Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of
clothing.
Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly far. Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS
Heat from flames and arcs can start fires. Hot slag or sparks can also
cause fires and explosions. Therefore:
1.
2.
3.
4.
5.
6.
7.
Protect yourself and others from flying sparks and hot metal.
Remove all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints and coatings paper, etc.
Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
Do not weld, cut or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not do hot work on closed containers, they may
explode.
Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.
Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
After completing operations, inspect the work area to make certain there are no hot
sparks or hot metal which could cause a later fire. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact with live electrical parts and ground can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:
1.
Be sure the power source frame (chassis) is connected to the ground system of the
input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
6. Make sure that all parts of your body are insulated from both the work piece and from
the ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a ground cable.
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1 SAFETY
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:
1.
2.
3.
Welders having pacemakers should consult their physician before welding. EMF may
interfere with some pacemakers.
Exposure to EMF may have other health effects which are unknown.
Welders should use the following procedures to minimise exposure to EMF:
a) Route the electrode and work cables together. Secure them with tape when
possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on
the same side of your body.
d) Connect the work cable to the workpiece as close as possible to the area being
welded.
e) Keep welding power source and cables as far away from your body as
possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therfore:
1.
2.
3.
4.
5.
6.
Keep your head out of the fumes. Do not breathe the fumes and gases.
Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe fumes from these materials.
Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other
irritant gases.
If you develop momentary eye, nose or throat irritation while operating, this is an
indication that ventilation is not adequate. Stop work and take necessary steps to
improve ventilation in the work area. Do not continue to operate if physical discomfort
persists.
Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
WARNING: This product when used for welding or cutting, produces fumes or gases
which contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:
1.
2.
Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain
hoses and fittings in good condition. Follow manufacturer's operating instructions for
mounting regulator to a compressed gas cylinder.
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1 SAFETY
3.
4.
Always secure cylinders in an upright position by chain or strap to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause
injury. Therefore:
1.
2.
3.
4.
5.
6.
Keep all doors, panels, guards and covers closed and securely in place.
Stop engine or drive systems before installing or connecting unit.
Have only qualified people remove covers for maintenance and troubleshooting as
necessary
To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
Keep hands, hair, loose clothing and tools away from moving parts.
Reinstall panels or covers and close doors when service is finished and before
starting engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
•
•
•
•
Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any
other accessories.
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to extend beyond
opposite side of unit.
Keep cables and cords away from moving vehicles when working from an
aerial location.
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1.
2.
3.
4.
5.
6.
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Always have qualified personnel perform the installation, troubleshooting and
maintenance work. Do not perform any electrical work unless you are
qualified to perform such work.
Before performing any maintenance work inside a power source, disconnect
the power source from the incoming electrical power.
Maintain cables, earthing wire, connections, power cord and power supply in
safe working order. Do not operate any equipment in faulty condition.
Do not abuse any equipment or accessories. Keep equipment away from
heat sources such as furnaces, wet conditions such as water puddles, oil or
grease, corrosive atmospheres and inclement weather.
Keep all safety devices and cabinet covers in position and in good repair.
Use equipment only for its intended purpose. Do not modify it in any manner.
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1 SAFETY
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices for
Arc Welding, Cutting and Gouging”, Form 52-529.
The following publications are recommended to you:
1.
2.
3.
4.
5.
6.
7.
8.
9.
1
0.
1.3
ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
AWS SP - “Safe practices” - Reprint, Welding Handbook
ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of
Containers That Have Held Hazardous Substances”
OSHA 29 CFR 1910 - "Safety and health standards"
CSA W117.2 - "Code for safety in welding and cutting"
NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other
Hot Work"
CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in
Cylinders”
ANSI Z87.1, "Occupational and Educational Personal Eye and Face
Protection Devices"
User responsibility
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1.
2.
3.
Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
The workplace must:
○ be suitable for the purpose
○ be free from drafts
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1 SAFETY
4.
5.
Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
If equipped with ESAB cooler
Use ESAB approved coolant only. Non-approved coolant might damage the equipment and
jeopardize product safety. In case of such damage, all warranty undertakings from ESAB
cease to apply.
Recommended ESAB coolant ordering number: 0465 720 002.
For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
•
•
•
•
Install and ground the unit in accordance with instruction manual.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
Insulate yourself from work and ground.
Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
•
•
•
Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
Exposure to EMF may have other health effects which are unknown.
Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
•
•
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Keep your head out of the fumes.
Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
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1 SAFETY
ARC RAYS - Can injure eyes and burn skin
•
•
Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
MOVING PARTS - Can cause injuries
•
•
•
Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
Stop engine before installing or connecting unit.
Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
•
•
Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
Do not use on closed containers.
HOT SURFACE - Parts can burn
•
•
•
Do not touch parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
This product is solely intended for arc welding.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
1.4
California Proposition 65 warning
WARNING!
Welding or cutting equipment produces fumes or gases which contain chemicals
known in the State of Carlifornia to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Section 25249.5 et seq.)
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1 SAFETY
WARNING!
This product can expose you to chemicals including lead, which are known to the
state of California to cause cancer and birth defects or other reproductive harm.
Wash hands after use.
For more information, go to www.P65Warnings.ca.gov.
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© ESAB AB 2019
2 INTRODUCTION
2
INTRODUCTION
The power source Aristo® 500ix combined with U6, U82 or MA25 Pulse panels offer a
complete multi-process package supporting MIG, pulse MIG, TIG and gouging, depending on
which feeder it is used with.
The power source are intended for use with the wire feed unit Feed 3004/4804,
YardFeed 2000, Robust Feed U6 or Robust Feed Pulse and the cooling unit COOL 2. For
more information about the feed units and the cooling unit, refer to the Instruction manuals.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1
Equipment
The power source is supplied with:
•
•
3 m (9 ft 10.11 in.) return cable with earth clamp
instruction manual for the welding power source
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3 TECHNICAL DATA
3
TECHNICAL DATA
Aristo® 500ix
Mains voltage
380-575 V, ±10%, 3~ 50/60 Hz
Mains supply Sscmin
7.2 MVA
Primary current Imax
380 V
460 V
575 V
MIG/MAG
38 A
30 A
26 A
MMA
40 A
31 A
26 A
TIG
30 A
24 A
20 A
Idle power
25 W
28 W
33 W
Setting range (DC)
MIG/MAG
16 A / 14.8 V - 500 A / 39 V
MMA
16 A / 20.6 V - 500 A / 40 V
TIG
5 A / 10.2 V - 500 A / 30 V
Permissible load at MIG/MAG
60 % duty cycle
500 A / 39.0 V
100% duty cycle
400 A / 34.0 V
Permissible load at MMA
60 % duty cycle
500 A / 40.0 V
100% duty cycle
400 A / 36.0 V
Permissible load at TIG
60 % duty cycle
500 A / 30.0 V
100% duty cycle
400 A / 26.0 V
Power factor at maximum
current
0.9
Efficiency at maximum current
88 %
Open circuit voltage
58 V
Operating temperature
-20 to 40 °C (-4 to 104 °F)
Transport temperature
-20 to 55 °C (-4 to 131 °F)
Constant sound pressure
when idling
<70 dB (A)
Dimensions l×w×h
712 × 325 × 470 mm (28.0 × 12.8 × 18.5 in.)
Weight
58.5 kg (128.9 lb)
Insulation class
H
Enclosure class
IP23
Application classification
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40 °C / 104 °F, or below.
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3 TECHNICAL DATA
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
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© ESAB AB 2019
4 INSTALLATION
4
INSTALLATION
4.1
General
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
The equipment used together with Aristo® 500ix must have at least the following program
versions in order for the power source to work properly:
•
•
•
for U82: 3.02G or later
for U6: 2.16P or later
for MA25 Pulse: 1.88H or later
4.2
Location
Position the welding power source such way that its cooling air inlets and outlets are not
obstructed.
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4 INSTALLATION
4.3
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Lifting instructions
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© ESAB AB 2019
4 INSTALLATION
WARNING!
Secure the equipment - particularly
if the ground is uneven or sloping.
4.4
Mains supply
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit power is
greater than or equal to Sscmin at the interface point between the user's supply and
the public system. It is the responsibility of the installer or user of the equipment to
ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with a short-circuit power greater than or
equal to Sscmin. Refer to the technical data in the TECHNICAL DATA chapter.
Make sure that the welding power source is connected to the correct supply voltage and that
it is protected by the correct fuse rating. A protective earth connection must be made in
accordance with regulations.
Recommended fuse sizes and minimum cable area Aristo® 500ix
Aristo® 500ix
Mains voltage
Mains cable
area
380 V
400 V
460 V
575 V
3~ 50/60 Hz
3~ 50/60 Hz
3~ 50/60 Hz
3~ 50/60 Hz
4 × 6 mm²
4 × 6 mm²
4 × 6 mm²
4 × 6 mm²
35 A
31 A
Maximal current 40 A
rating Imax
I1eff
MIG/MAG
30 A
27 A
24 A
MMA
31 A
25 A
24 A
TIG
24 A
21 A
19 A
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4 INSTALLATION
Fuse
anti-surge
35 A
35 A
35 A
type C MCB
32 A
32 A
32 A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. Use the power source in accordance with the relevant national
regulations.
Supply from power generators
The power source can be supplied from different types of generators. However, some
generators may not provide sufficient power for the welding power source to operate
correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better
type of regulation, with rated power ≥40 kW, are recommended.
Connection instruction
WARNING!
The mains supply must be disconnected during installation.
WARNING!
Wait until the DC bus capacitors are discharged. The DC bus capacitor discharge
time is at least 2 minutes!
The power source is factory set to 400 V AC. If another mains voltage setting is required, the
cable on the printed circuit board has to be moved and put in the correct position. Also the
label, at the rear of the power source, marked with the mains voltage setting must be
updated. This operation must be done by a person who has the appropriate electrical
knowledge.
NOTE!
This power source version is designed for a nominal input voltage from 380 to 460 V
AC. This means that the hardware to support 575 V input is not available, 575 V tab
is not connected.
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4 INSTALLATION
If the mains cable needs to be changed, the earth connection to the bottom plate and the
ferrites must be installed correctly. See the picture below for the installation order of the
ferrites, washers, nuts and screws.
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5 OPERATION
5
OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
NOTE!
When moving the equipment use intended handle. Never pull the cables.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
NOTE!
To achieve the best possible result at Mig short pulsing, the welding and return cables
must not exceed 10 m (33 ft).
5.1
Connections and control devices
1. Mains power supply switch, 0 / 1
2. Connection of wire feed unit
3. Fuse (10 A) for supply voltage (42 VAC)
for feeder unit
4. Positive welding terminal: Welding cable
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5. Negative welding terminal: Return cable
6. Indicating LED, overheating
7. Indicating LED, power supply ON
8. Mains cable inlet
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© ESAB AB 2019
5 OPERATION
5.2
5.3
Symbols
Power supply ON (4)
Overheating (3)
Protective earth
Positioning of lifting eye
Connection of welding and return cable
The power source has two outputs, a positive terminal (+) and a negative terminal (-), for
connecting welding and return cables.
Connect the return cable to the negative terminal on the power source. Secure the return
cable's contact clamp to the work piece and ensure that there is good contact between the
work piece and the output for the return cable on the power source.
Recommended maximum current values for connection set cables
Imax
Cable area
Cable length
95 mm2
2 - 35 m
350 A (100% duty cycle)
430 A (100% duty cycle)
2 - 35 m
460 A (60% duty cycle)
120
510 A (60% duty cycle)
mm2
2 - 35 m
2 - 35 m
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40 °C (104 °F).
5.4
Turning the power source on/off
Turn the power source on by turning switch (1) to the ”1” position. Turn the power source off
by turning the switch (1) to the ”0” position. Regardless the mains supply is interrupted
abnormally or the power source is switched off in the normal manner, the welding data will be
stored, so it will be available next time the unit is turned on.
5.5
Fan control
The power source has a time control that means that the fans continue to run for 6.5 minutes
after welding has stopped, and the power source switches to energy-saving mode. The fans
start again when welding restarts.
5.6
Thermal protection
The welding power source has thermal protection circuit that operates if the internal
temperature becomes too high. If this occurs the welding current is blocked and the
indicating LED (6) lights. The thermal protection resets automatically when the temperature
has fallen within normal operation temperature.
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5 OPERATION
5.7
VRD (Voltage Reducing Device)
The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding
is not being carried out. The VRD function must be activated by a qualified service
technician, by means of ESAT (ESAB Software Administration Tool, a kit for technical service
including a software to manage settings, update of software etc.).
The VRD function is blocked when the system senses that welding has started.
5.8
Remote control unit
For more information about the operation of the remote control unit, see the instruction
manual for the control panel.
5.9
Arc voltage feedback
To achieve a good welding result, the arc voltage feedback is a crucial factor. In MIG/MAG
welding, the power source is prepared to sense the arc voltage in the wire feeder.
Prerequisite for this functionality is that an ESAB wire feeder and an ESAB interconnection
cable is used! This method of measuring the arc voltage, compensates for the voltage drop
in the welding cable to the wire feeder. With an ESAB torch supporting "TrueArcVoltage", the
voltage drop all the way to the contact tip is compensated.
NOTE!
To compensate the voltage drop in the return cable, the power source can be
configured (by authorised ESAB service personnel) to use an external arc voltage
sense wire from the workpiece.
0463 725 001
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© ESAB AB 2019
6 MAINTENANCE
6
MAINTENANCE
WARNING!
The mains supply must be disconnected during cleaning and maintenance.
CAUTION!
Only persons with the appropriate electrical knowledge (authorised personnel) may
remove the safety plates.
CAUTION!
The product is covered by manufacturer's warranty. Any attempt to carry out repair
work by non-authorised service centers or personnel will invalidate the warranty.
NOTE!
Regular maintenance is important for safe and reliable operation.
NOTE!
Perform maintenance more often during severe dusty conditions.
Before each use - make sure that:
•
•
Product and cables are not damaged,
The torch is clean and not damaged.
6.1
Routine maintenance
Maintenance schedule during normal conditions. Check equipment prior to every use.
Interval
Area to maintain
Every 3 months
Clean or replace
unreadable labels.
Clean weld terminals. Check or replace weld
cables.
Every 6 months
Clean inside
equipment. Use dry
compressed air with
reduced pressure.
6.2
Power source
To maintain the performance and increase the lifetime of the power source it is mandatory to
clean the product regularly. How often depends on:
•
•
the welding process
the arc time
0463 725 001
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© ESAB AB 2019
6 MAINTENANCE
•
•
the working environment
the surrounding environment, that is grinding etc.
Tools needed for the cleaning procedure:
•
•
•
torx screwdriver, T25 and T30
dry compressed air at a pressure of 4 bar
protective equipment like ear plugs, safety glasses, masks, gloves and safety shoes
CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared workspace.
Cleaning procedure
1.
2.
3.
4.
5.
6.
Disconnect the mains supply.
Wait for 4 minutes to discharge the capacitors.
Remove the side panels on the power source.
Remove the top panel on the power source.
Remove the plastic cover between the heat sink and fan (b).
Clean the power source with dry compressed air (4 bar) as follows:
a) The upper rear part.
b) From the rear panel through the secondary heat sink.
c) The inductor, transformer and current sensor.
d) The power components side, from the rear side behind PCB 15AP1.
e) The PCBs at both sides.
7. Make sure that there is no dust left on any part.
8. Install the plastic cover between the heat sink and the fan (b) and make sure it is
correctly fitted against the heat sink.
9. Install the top panel on the power source.
10. Install the side panels on the power source.
0463 725 001
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© ESAB AB 2019
7 TROUBLESHOOTING
7
TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorised service
technician.
Type of fault
No arc.
Corrective action
•
•
•
•
The welding current is interruppted during
welding.
•
•
The thermal protection trips frequently.
•
•
Poor welding performance.
•
•
•
•
0463 725 001
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Check that the mains power supply
switch is turned on.
Check that the mains, welding and
return cables are correctly connected.
Check that the correct current value is
set.
Check the mains power supply fuses.
Check whether the thermal protection
trip has operated (indicated by the
orange LED on the front (6))
Check the main power supply fuses if
the LED indicating power supply (7) is
not lit.
Make sure that you are not exceeding
the rated data for the power source (i.e.
that the unit is not being overloaded).
Check that the ambient temperature is
not above the one for the rated duty
cycle 40 °C/104 °F.
Check that the welding current supply
and return cables are correctly
connected.
Check that the correct current value is
set.
Check that the correct welding wires
are being used.
Check the main power supply fuses.
© ESAB AB 2019
8 ORDERING SPARE PARTS
8
ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Aristo® 500ix is designed and tested in accordance with international and European
standards IEC/EN 60974-1 and IEC/EN 60974-10 Class A, Canadian standards
CAN/CSA-E60974-1 and US standards ANSI/IEC 60974-1. On completion of service or
repair work, it is the responsibility of the person(s) performing the work to ensure that the
product still complies with the requirements of the above standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.
0463 725 001
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© ESAB AB 2019
ORDERING NUMBERS
ORDERING NUMBERS
Ordering number
Denomination
Type
Notes
0446 200 880
Power source
Aristo® 500ix
CE
0446 200 881
Power source
Aristo® 500ix
CSA
0446 200 882
Power source
Aristo® 500ix
AUS
0446 200 883
Power source
Aristo® 500ix
CCC
0463 696 001
Instruction manual
0460 701 001
Spare parts list
Technical documentation is available on the Internet at: www.esab.com
0463 725 001
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© ESAB AB 2019
BLOCK DIAGRAM
BLOCK DIAGRAM
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© ESAB AB 2019
ACCESSORIES
ACCESSORIES
Wire feeders
0460 526 886
Aristo® Feed 3004 U6
0460 526 896
Aristo® Feed 3004w U6
0460 526 881
Aristo® Feed 3004 U82, (U82 not included)
0460 526 891
Aristo® Feed 3004w U82, (U82 not included)
0459 906 896
Yardfeed 2000w U6, for 200mm (8 in.) spools
0445 800 893
Robust Feed Pulse,
Tweco connector, heater and flow meter
included
0445 800 889
0445 800 890
Robust Feed U6,
Tweco connector, heater and flow meter
included
Robust Feed U6,
with Push-Pull, Tweco connector, heater and
flow meter included
0465 427 880
Cooling unit, Cool2
0349 313 450
Trolley, compatible with Robust Feed and
Aristo® Feed 3004
0465 416 880
Wheel kit
0463 725 001
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© ESAB AB 2019
ACCESSORIES
0458 705 880
Counter balance device, for Aristo® Feed
3004 (not Robust Feed)
for 300 mm (11 in.) spools. Includes mast and
counter balance
For use of the counter balance device, a
stabilizer kit is required!
IP23 protection is not valid for wire feeder with
counterbalance arm!
0465 509 880
Stabilizer kit
Control units
0460 820 880
Aristo® U82, complete including holder
0460 820 881
Aristo® U82 Plus, complete including holder
0463 725 001
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© ESAB AB 2019
ACCESSORIES
Remote controls
0459 491 880
Remote control MTA1
0459 491 896
Remote control unit AT1
MMA and TIG current
0459 491 897
Remote control unit AT1 CF
MMA and TIG: course and fine setting of
current
0459 491 911
Remote control adapter RA 23
Remote control cable 12 pole - 8 pole
0459 552 880
5 m (16 ft 4.85 in.)
0459 552 881
10 m (32 ft 9.7 in.)
0459 552 882
15 m (49 ft 2.55 in.)
0459 552 883
25 m (82 ft 0.25 in.)
0465 424 880
Remote outlet kit
0463 725 001
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© ESAB AB 2019
ACCESSORIES
Aristo® Feed 3004 Interconnection cables, gas-cooled, 70 mm², 10 poles
0459 528 780
1.7 m (5 ft 6.93 in.)
0459 528 781
5 m (16 ft 4.85 in.)
0459 528 782
10 m (32 ft 9.7 in.)
0459 528 783
15 m (49 ft 2.55 in.)
0459 528 784
25 m (82 ft 0.25 in.)
0459 528 785
35 m (114 ft 9.95 in.)
Aristo® Feed 3004 Interconnection cables, water-cooled, 70 mm², 10 poles
0459 528 790
1.7 m (5 ft 6.93 in.)
0459 528 791
5 m (16 ft 4.85 in.)
0459 528 792
10 m (32 ft 9.7 in.)
0459 528 793
15 m (49 ft 2.55 in.)
0459 528 794
25 m (82 ft 0.25 in.)
0459 528 795
35 m (114 ft 9.95 in.)
Robust Feed U6 and Robust Feed Pulse, Interconnection cables with pre-assembled
strain relief, gas-cooled, 70 mm2, 10 poles
0446 255 880
2 m (6 ft 6.74 in.)
0446 255 881
5 m (16 ft 4.85 in.)
0446 255 882
10 m (32 ft 9.7 in.)
0446 255 883
15 m (49 ft 2.55 in.)
0446 255 884
20 m (65 ft 7.4 in.)
0446 255 885
25 m (82 ft 0.25 in.)
0446 255 886
35 m (114 ft 9.95 in.)
Robust Feed U6 and Robust Feed Pulse, Interconnection cables with pre-assembled
strain relief, water-cooled, 70 mm2, 10 poles
0446 255 890
2 m (6 ft 6.74 in.)
0446 255 891
5 m (16 ft 4.85 in.)
0446 255 892
10 m (32 ft 9.7 in.)
0446 255 893
15 m (49 ft 2.55 in.)
0446 255 894
20 m (65 ft 7.4 in.)
0446 255 895
25 m (82 ft 0.25 in.)
0446 255 896
35 m (114 ft 9.95 in.)
0463 725 001
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© ESAB AB 2019
For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
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