ESAB | Aristo 1000 AC/DC SAW | Instruction manual | ESAB Aristo 1000 AC/DC SAW User manual

ESAB Aristo 1000 AC/DC SAW User manual
GB
Aristo 1000
AC/DC SAW
Instruction manual
0462 985 001 GB 20120605
Valid for serial no. 145-xxx-xxxx, 221-xxx-xxxx
-2-
1
2
3
4
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
4.2
4.3
4.4
4.5
4
6
6
7
Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
9
10
11
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
5.1
5.2
5.3
5.4
Connections and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of welding and return cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
13
13
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
6.1
Welding power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
7 FAULT-TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
22
23
CONNECTION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDER NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
25
26
27
Rights reserved to alter specifications without notice.
TOCe
-3-
GB
1
SAFETY
Users of ESAB welding 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 welding
equipment. The following recommendations should be observed in addition to the standard regulations that apply to the work­
place.
All work must be carried out by trained personnel well-acquainted with the operation of the welding equipment. Incorrect oper­
ation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.
1.
Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2.
The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment when it is started up.
S no-one is unprotected when the arc is struck
3.
The workplace must:
S be suitable for the purpose
S be free from drafts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof clothing, safety gloves.
S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns.
5.
General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
WARNING
Do not use the power source for thawing frozen pipes.
-4bb01de
© ESAB AB 2012
GB
WARNING
Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
S
Install and earth the 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 take fumes and gases away 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.
NOISE - Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for arc welding.
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.
ESAB can provide you with all necessary welding protection and accessories.
-5bb01de
© ESAB AB 2012
GB
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/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.
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 and the welding
process parameters are regulated via it.
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.
Components such as:
S
Welding tractors
S
Column and boom
S
Welding heads
S
Positioning equipment
S
Joint tracking equipment
S
Flux handling systems.
ESAB's accessories for the product can be found on page 27.
3
TECHNICAL DATA
Aristo 1000
Mains voltage
380 - 575 V, $10%, 3∼ 50/60 Hz
Mains supply
Ssc min 6.7 MVA
Primary current
Imax 86 A
Setting range
14 - 50 V / 0 - 1000 A
Permissible load
100% duty cycle
1000 A / 44 V
Power factor at maximum current
0,93
Efficiency at maximum current
85 %
Open-circuit voltage with VRD U0 max
121 VDC
Apparent power at maximum current
58,1 kVA
Active power at maximum current
52,0 kW
No-load power
200 W
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© ESAB AB 2012
GB
Aristo 1000
Operating temperature
-10 to +40° C
Transportation temperature
-20 to +55° C
Dimensions lxwxh
865 x 610 x 1320 mm
Weight
330 kg
Insulation class
H
Enclosure class
IP 23S
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.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23S is designed for indoor and outdoor use; however, should
not be operated in precipitation.
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
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
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case 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 may be connected.
Note
The power source can be connected for generator power. For more information, contact
authorised ESAB service personnel.
-7bb01de
© ESAB AB 2012
GB
4.1
Lifting instructions
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
all the way around.
When installing the power source on the
floor, see the dimensions according to the
hole pattern on page 23.
-8bb01de
© ESAB AB 2012
GB
4.3
Example of welding equipment
1
Welding head
5
Return cable
9
Measurement cable,
speed
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
-9bb01de
© ESAB AB 2012
GB
4.4
3
Cable routing
Control cable
5
Return cable
6
Measurement
cable, workpiece
8
Welding cable
For more information regarding cable routing, see page 17 and onwards.
- 10 bb01de
© ESAB AB 2012
GB
4.5
Mains power supply
WARNING
The welding power source is connected for 400 V at delivery. For other mains
voltage, reconnect on the terminal block, according to the connection instructions
on page 24.
Tighten the screws A using a torque of 10 Nm. 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
Phase current I1eff
Fuse anti-surge
380V
86A
100A
400V
82 A
100A
415V
79A
80A
440V
74A
80A
460V
71A
80A
500V
66A
80A
550V
59A
63A
575V
57A
63A
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.
- 11 bb01de
© ESAB AB 2012
GB
5
OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
5.1
Connections and control devices
1
Knob for setting control*
7
Connection black for measurement cable,
workpiece
2
Fault indicating lamp orange
8
Fuse
3
Push button white ON
9
Connection red for measurement cable,
welding head
4
Push button black OFF
10
Connection for return cable
5
Connection for control unit PEK
11
Connection for welding current cable
to welding head
6
Connection for service tool
12
Connection for mains voltage cable
13
Cable groove for signal cables
*) There are three knob positions:
S Position 1, ON / OFF of mains voltage controlled from remote control unit
S Position 2, ON / OFF blocked
S Position 3, ON / OFF controlled using button 3 and 4
- 12 bb01de
© ESAB AB 2012
GB
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.
- 13 bb01de
© ESAB AB 2012
GB
6
MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer attempts any
work to rectify any faults in the product during the guarantee 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:
S
welding process
S
operation time
S
placement
S surrounding environment
The power source should be regularly blown clean using dry compressed air at
reduced pressure, see page 21. This should be done more frequently in dirty
environments.
Clogged or blocked air inlets and outlets otherwise result in overheating.
Orderingnumber for dust filter see page 26.
- 14 bb01de
© ESAB AB 2012
GB
Replacing and cleaning the dust filter
1. Release the dust filter according to the figure.
2. Blow the filter clean with compressed air (reduced pressure).
3. Reinstall the filter.
Ensure that the filter with the finest mesh is placed towards the grille.
Replacing and cleaning the air filter
1. Release the air filter according to the figure
2. Clean the filter with soap and water
3. Reinstall the filter.
- 15 bb01de
© ESAB AB 2012
GB
7
FAULT-TRACING
Try these recommended checks and inspections before sending for an authorized
service technician.
Type of fault
Corrective action
S
S
No arc.
S
S
The welding current is
interrupted during welding.
S
S
The thermal cut-out trips
frequently.
S
S
S
S
Poor welding performance.
S
S
S
8
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.
Check whether the thermal cut-outs have tripped (a fault
code appears on the control module's panel).
Check the mains power supply fuses.
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.
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.
ORDERING SPARE PARTS
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 said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
- 16 bb01de
© ESAB AB 2012
- 17 bb01cable
© ESAB AB 2012
- 18 bb01cable
© ESAB AB 2012
- 19 bb01cable
© ESAB AB 2012
- 20 bb01cable
© ESAB AB 2012
Cleaning
- 21 bb01clean
© ESAB AB 2012
Diagram
- 22 bb01e
© ESAB AB 2012
Assembly instructions
- 23 bb01as
© ESAB AB 2012
Connection instruction
- 24 bb01c
© ESAB AB 2012
Aristo 1000 AC/DC SAW
Order number
Ordering no.
Denomination
Type
0462 100 880 Welding power source
Aristoâ 1000 AC/DC SAW
0740 800 205 Service manual
Aristoâ 1000 AC/DC SAW
0459 839 050 Spare parts list
Aristoâ 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
- 25 bb01o
© ESAB AB 2012
Aristo 1000 AC/DC SAW
Spare parts list
Qty
Ordering no.
3
0458 398 003
Filter
1
0441 828 003
Airfilter
bb01s
Denomination
- 26 -
© ESAB AB 2012
Aristo 1000 AC/DC SAW
Accessories
Control unit PEK . . . . . . . . . . . . . . . . . . .
0460 504 880
Joint tracking unit GMH . . . . . . . . . . . .
0460 503 881
Control unit for motorised slides PAV 0460 502 881
bb01a
Welding automat A6 Mastertrac . . . . .
0461 235 880
Welding head A6 SF F1 SAW . . . . . . . .
0449 270 900
- 27 -
© ESAB AB 2012
Aristo 1000 AC/DC SAW
Flux recovery unit . . . . . . . . . . . . . . . . . .
0148 140 880
For more information regarding components for the A2 / A6 system see separate
brochures.
bb01a
- 28 -
© ESAB AB 2012
NOTES
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- 30 notes
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- 31 notes
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.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
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
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
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
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
www.esab.com
© ESAB AB
110915
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