ESAB | Aristo 1000 | Instruction manual | ESAB Aristo 1000 User manual

ESAB Aristo 1000 User manual
Aristo® 1000 AC/DC SAW
Instruction manual
0462 985 101 GB 20170207
Valid for: serial no. 336-xxx-xxxx
TABLE OF CONTENTS
1
SAFETY ........................................................................................................
4
1.1
Meaning of symbols .................................................................................
4
1.2
Safety precautions ...................................................................................
4
2
INTRODUCTION ............................................................................................
7
3
TECHNICAL DATA ........................................................................................
8
4
INSTALLATION..............................................................................................
9
4.1
Lifting instructions ...................................................................................
9
4.2
Location.....................................................................................................
10
4.3
Example of welding equipment...............................................................
11
4.4
Cable routing ............................................................................................
12
4.5
Mains power supply .................................................................................
13
OPERATION ..................................................................................................
14
5.1
Connections and control devices ...........................................................
14
5.2
Connection of welding and return cable ................................................
15
5.3
Key to symbols .........................................................................................
15
5.4
Overheating protection ............................................................................
15
MAINTENANCE .............................................................................................
16
6.1
Welding power source .............................................................................
16
7
FAULT-TRACING...........................................................................................
18
8
ORDERING SPARE PARTS ..........................................................................
19
CABLE ROUTING REQUIREMENTS ..................................................................
20
CLEANING............................................................................................................
24
DIAGRAM .............................................................................................................
25
ASSEMBLY INSTRUCTIONS ...............................................................................
26
CONNECTION INSTRUCTION.............................................................................
27
ORDERING NUMBERS ........................................................................................
28
WEAR PARTS.......................................................................................................
29
ACCESSORIES ....................................................................................................
30
5
6
Rights reserved to alter specifications without notice.
0462 985 101
© ESAB AB 2017
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
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
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
• 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.
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.
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© ESAB AB 2017
1 SAFETY
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.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
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.
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© ESAB AB 2017
2 INTRODUCTION
2
INTRODUCTION
Aristo 1000 is a welding power source intended for high productivity submerged arc welding
with direct current (DC) or alternating current (AC). The power source has many setting
options for those who want to optimise their welding process.
The welding power source is used together with control unit PEK. The welding process
parameters are regulated via the control unit.
The power source is part of ESAB's A2 / A6 system, which means that most of the
components from this system can be used with Aristo 1000.
This includes components such as:
•
•
•
•
•
•
Welding tractors
Column and boom
Welding heads
Positioning equipment
Joint tracking equipment
Flux handling systems
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
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3 TECHNICAL DATA
3
TECHNICAL DATA
Aristo 1000
Mains voltage
380-575 V, ±10 %, 3~ 50/60 Hz
Mains supply
Ssc min 19.2 MVA
Primary current
Imax 84 A
Setting range
14–50 V / 0–1000 A
Permissible load 100 % duty cycle
1000 A / 44 V
Power factor at maximum current
0.92
Efficiency at maximum current
82 %
Open-circuit voltage U0 max
126 V
Apparent power at maximum current
55.3 kVA
Active power at maximum current
49.5 kW
No-load power
170 W
Operating temperature
-10 to +40 °C (+14 to +104 °F)
Transportation temperature
-20 to +55 °C (-4 to +131 °F)
Dimensions l × w × h
865×610×1320 mm (34x24x52 in.)
Weight
330 kg (727 lbs)
Insulation class
H
Enclosure class
IP23
Application class
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.
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.
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
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4 INSTALLATION
4
INSTALLATION
The installation must be carried out by a professional.
The power source must be calibrated by a professional.
CAUTION!
Installation shall be made to a symmetrical 3 phase system in respect to safety
ground.
Intended for fixed installation.
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.
NOTE!
The power source can be powered from a generator. For more information,
contact authorised ESAB service personnel.
4.1
0462 985 101
Lifting instructions
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© ESAB AB 2017
4 INSTALLATION
4.2
Location
WARNING!
Secure the equipment - particularly
if the ground is uneven or sloping.
Position the welding power source so that its
cooling air inlets and outlets are not
obstructed, with a distance of at least 250
mm (9.86") all the way around.
When installing the power source on the floor,
see the dimensions according to the hole
pattern in the "ASSEMBLY INSTRUCTIONS"
appendix to this manual.
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© ESAB AB 2017
4 INSTALLATION
4.3
Example of welding equipment
1 Welding head
5 Return cable
2 Control unit
6 Measurement cable,
workpiece
10 Motor cable
3 Control cable
7 Workpiece
11 Measurement cable,
welding voltage
4 Welding power source
8 Welding cable
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9 Measurement cable,
speed
© ESAB AB 2017
4 INSTALLATION
4.4
Cable routing
*Recommended
3 Control cable
5 Return cable
6 Measurement
cable, workpiece
8 Welding cable
For more information regarding cable routing, see the "CABLE ROUTING
REQUIREMENTS" appendix.
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© ESAB AB 2017
4 INSTALLATION
4.5
Mains power supply
WARNING!
The welding power source is connected for 400 V at delivery. For other mains
voltages, reconnect on the terminal block, according to the "CONNECTION
INSTRUCTION" appendix.
Tighten the screws A using a torque of 10 Nm (88.5 in lb). Ensure that the plastic
protector B is still loose.
Make sure that the welding power source is connected to the correct
mains voltage and that it is protected by the correct fuse rating.
A protective earth connection must be made in accordance with
regulations.
Rating plate with supply connection data
Recommended fuse sizes
Aristo 1000
50/60 Hz at DC welding
Mains voltage
380 V 400 V 415 V 440 V 460 V 500 V 550 V 575 V
Phase current I1eff
84 A
79 A
75 A
72 A
69 A
64 A
60 A
55 A
Fuse anti-surge
100 A 100 A
80 A
80 A
80 A
80 A
63 A
63 A
NOTE!
The fuse sizes as shown above are in accordance with Swedish regulations. Use
the welding power source in accordance with the relevant national regulations.
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© ESAB AB 2017
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!
5.1
Connections and control devices
1 Knob for setting control*
8 Connection of internal bus for
parallel/tandem connection (identical to 7)
2 Fault indicating lamp orange
9 Connection black for measurement cable,
workpiece
3 Push button white ON
10 Fuse
4 Push button black OFF
11 Connection red for measurement cable,
welding head
5 Connection for control unit PEK
12
Connection for return cable
6 Connection for service tool
13
Connection for welding current
cable to welding head
7 Connection of internal bus for
14 Connection for mains voltage cable
parallel/tandem connection (identical to 8)
15 Cable groove for signal cables
*) There are three knob positions:
•
•
•
Position 1, ON / OFF of mains voltage controlled from remote control unit
Position 2, ON / OFF blocked
Position 3, ON / OFF controlled using button 3 and 4
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© ESAB AB 2017
5 OPERATION
5.2
Connection of welding and return cable
Ensure that the welding and return cables are installed as illustrated.
5.3
Key to symbols
Power source ON
Power source OFF
Remote controlled start
Local control from the power source
Fault indication
5.4
Overheating protection
The welding power source has overheating protection that operates if the temperature
becomes too high. When this occurs, the welding current is interrupted and the yellow
indicating lamp comes on. A fault code appears in the control unit (PEK) settings panel.
The overheating protection resets automatically and the welding process can be restarted
when the temperature has fallen.
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© ESAB AB 2017
6 MAINTENANCE
6
MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1
Welding power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on:
•
•
•
•
welding process
operation time
location
surrounding environment
The power source should be regularly blown clean using dry compressed air at reduced
pressure, see the "CLEANING" appendix. This should be done more frequently in dirty
environments.
Clogged or blocked air inlets and outlets may result in overheating. Orderingnumber for dust
filter, see the "WEAR PARTS" appendix.
Replacing and cleaning the dust filter
1.
2.
3.
Release the dust filter according to the illustration.
Blow the filter clean using compressed air (reduced pressure).
Reinstall the filter.
Ensure that the filter with the finest mesh is placed towards the grille.
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© ESAB AB 2017
6 MAINTENANCE
Replacing and cleaning the air filter
1.
2.
3.
Release the air filter according to the illustration.
Clean the filter using soap and water
Reinstall the filter.
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© ESAB AB 2017
7 FAULT-TRACING
7
FAULT-TRACING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault
Corrective action
No arc
• Check that the mains voltage is switched on.
• Check that the welding and return cables are correctly
connected.
• Check that the correct current value is set.
• Check the mains power supply fuses.
The welding current is
interrupted during welding.
• Check whether the thermal cut-outs have tripped (a fault
code appears on the control module's panel).
• Check the mains power supply fuses.
The thermal cut-out trips
frequently.
• Check to see whether the dust filter is clogged.
• Make sure that you are not exceeding the rated data for
the welding power source (i.e. that the unit is not being
overloaded).
• Check that the welding power source is not clogged with
dirt.
• Check the ambient temperature.
Poor welding performance
• Check that the welding current supply and return cables
are correctly connected.
• Check that the correct current value is set.
• Check that the correct filler material (wire and powder) is
used.
0462 985 101
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© ESAB AB 2017
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 1000 is designed and tested in accordance with the international and European
standards IEC-/EN 60974-1 and IEC-/EN 60974-10. It is the obligation of the service unit
which has carried out the service or repair work to make sure that the product still conforms
to the mentioned standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. 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.
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© ESAB AB 2017
CABLE ROUTING REQUIREMENTS
CABLE ROUTING REQUIREMENTS
*Recommended
*Recommended
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© ESAB AB 2017
CABLE ROUTING REQUIREMENTS
0462 985 101
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© ESAB AB 2017
CABLE ROUTING REQUIREMENTS
0462 985 101
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© ESAB AB 2017
CABLE ROUTING REQUIREMENTS
0462 985 101
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© ESAB AB 2017
CLEANING
CLEANING
0462 985 101
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© ESAB AB 2017
DIAGRAM
DIAGRAM
0462 985 101
- 25 -
© ESAB AB 2017
ASSEMBLY INSTRUCTIONS
ASSEMBLY INSTRUCTIONS
0462 985 101
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© ESAB AB 2017
CONNECTION INSTRUCTION
CONNECTION INSTRUCTION
0462 985 101
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© ESAB AB 2017
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
Type
0462 100 880
Welding power source
Aristo® 1000 AC/DC SAW
0740 800 205
Service manual
Aristo® 1000 AC/DC SAW
0459 839 050
Spare parts list
Aristo® 1000 AC/DC SAW
0740 801 030
Installation manual
For tandem and parallel connection
of Aristo® 1000 AC/DC SAW
Technical documentation is available on the Internet at: www.esab.com
0462 985 101
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© ESAB AB 2017
WEAR PARTS
WEAR PARTS
0462 985 101
Qty
Ordering no.
Denomination
3
0458 398 003
Dust filter
1
0441 828 003
Air filter
- 29 -
© ESAB AB 2017
ACCESSORIES
ACCESSORIES
0460 504 880
Control unit PEK
0460 503 881
Joint tracking unit GMH
0460 502 881
Control unit for motorised slides PAV
0461 235 880
Welding automat A6 Mastertrac
0449 270 900
Welding head A6 SF F1 SAW
0148 140 880
Flux recovery unit
For more information regarding components for the A2 / A6 system, see separate brochures.
0462 985 101
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© ESAB AB 2017
ACCESSORIES
0462 985 101
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© ESAB AB 2017
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 15 25 79 30
Fax: +32 15 25 79 44
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: +359 2 974 42 88
Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting
Products
Florence, SC
Tel: +1 843 669 4411
Fax: +1 843 664 5748
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
GERMANY
ESAB Welding & Cutting GmbH
Langenfeld
Tel: +49 2173 3945-0
Fax: +49 2173 3945-218
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
SWITZERLAND
ESAB Europe GmbH
Baar
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
www.esab.com
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 0220
Fax: +1 905 670 4879
SPAIN
ESAB Ibérica S.A.
San Fernando de Henares
(MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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