ARISTODRIVE 4-30 & 4-48HD - ESAB Welding & Cutting Products

ARISTODRIVE 4-30 & 4-48HD - ESAB Welding & Cutting Products

ARISTODRIVE 4-30 & 4-48HD

WIRE FEEDER

INSTRUCTION MANUAL

ESAB ITEM NO. 0558003275, AristoDrive 4-48

ESAB ITEM NO. 0558003276, AristoDrive 4-30

Revision B

0558003750 10 / 2003

BE SURE THIS INFORMATION REACHES THE OPERATOR

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding,

Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

Copies of this manual can be obtained by any of the following;

Contacting your local ESAB supplier.

Downloading a copy from the ESAB web site at www.esabna.com

Sending a written request to

ESAB WELDING & CUTTING PRODUCTS

ATTN: LITERATURE DEPT.

411 S EBENEZER ROAD

FLORENCE SC 29501

2

TABLE OF CONTENTS

TITLE

1

2

3

4

SECTION

PARAGRAPH

5

PAGE

DESCRIPTION ...................................................................................................................... 11

INSTALLATION ..................................................................................................................... 19

OPERATION ......................................................................................................................... 23

TROUBLESHOOTING ..........................................................................................................25

Schematic .............................................................................................................26

Wiring Diagram .....................................................................................................27

REPLACEMENT PARTS .......................................................................................................29

AristoDrive 4-30 ....................................................................................................30

AristoDrive 4-48 ....................................................................................................39

3

TABLE OF CONTENTS

4

SAFETY PRECAUTIONS

WARNING:

T hese Safety Precautions are for your protection. They summarize 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.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.

6. 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.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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:

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.

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.

2. 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.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair 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.

4. 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

5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.

6. 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. 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 work and from 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 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.

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. Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. 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.“

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. 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.

5

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize 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.

SAFETY PRECAUTIONS

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

1. 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.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. 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.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.

5. 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. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. 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.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.

3. 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.

Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

1. 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.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. 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.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

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, which are available from the

American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc

Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert!

Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

6

PRECAUCION DE SEGURIDAD

ADVERTENCIA:

Estas Precauciones de

Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de

Seguridad puede resultar en daño a la persona o muerte

.

PROTEJASE USTED Y A LOS DEMAS--

Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco, como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto:

el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación

NFPA Standard 51B, "Fire Prevention in Use of Cutting and

Welding Processes", disponible a través de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corriente alterna (AC) en

áreas húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo.

1.

Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo. La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de

las flamas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones.

Por lo tanto:

1.

Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3.

No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inflamables.

4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.

5.

No use el equipo fuera de su rango de operación. Por ejemplo,

7

1.

Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones.

Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC Standard Z49.1

(listado en la próxima página) para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos.

La corriente eléctrica fluye através de cualquier conductor causando a nivel local Campos Eléctricos y Magnéticos

(EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto:

1. S oldadores u Operadores que use marcapasos para el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases.

El gas de protección puede causar falta de oxígeno.

Por lo tanto:

1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos,

Cancer. (California Health & Safety

Code

§

25249.5 et seq.)

MANEJO DE CILINDROS-- Los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones.

Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:

1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado.

No modifique el equipo en ninguna manera.

INFORMACION ADICIONAL DE SEGURIDAD --

Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc

Welding, Cutting and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de la

American Welding Society, 550 N.W. LeJuene Road, Miami,

FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc

Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous

Substances."

SIGNIFICADO DE LOS SIMBOLOS --

Según usted avanza en la lectura de este folleto: Los Símbolos Significan

¡Atención! ¡Esté Alerta! Se trata de su seguridad.

Significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

Significa el posible riesgo que puede resultar en menores daños a la persona.

8

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objet d’ assurer votre protection. Veillez à lire et à observer les précautions énoncées ci-dessous avant de monter l’

équipement ou de commercer à l’utiliser. Tout défaut d’observation de ces précautions risque d’entraîner des blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la peau et des yeux dues au rayonnement de l’arc

électrique ou du métal incandescent, lors du soudage au plasma ou à l’électrode ou lors du gougeage à l’arc, peuvent s’avérer plus graves que celles résultant d’une exposition prolongée au soleil. Aussi convient-il d’observer les précautions suivantes: a. Portez un écran facial adéquat muni des plaques protectrices et des verres filtrants appropriés afin de vous protéger les yeux, le visage, le cou et les oreilles des étincelles et du rayonnement de l’arc électrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité de façon à ce qu’elles ne regardent pas l’arc et à ce qu’elles ne s’exposent pas à son rayonnement, ni à celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans rebord, des chaussures à embout d’acier et un casque de soudage ou une calotte de protection, afin d’éviter d’exposer la peau au rayonnement de l’arc électrique ou du métal incandescent. ll est également souhaitable d’utiliser un tablier ininflammable de façon à se protéger des étincelles et du rayonnement thermique.

c. Les étincelles ou les projections de métal incandescent risquent de se loger dans des manches retroussées, des bords relevés de pantalons ou dans des poches.

Aussi convient-il de garder boutonnés le col et les manches et de porter des vêtements sans poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité

à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité lorsque vous vous trouvez dans un secteur où l’on effectue des opérations de soudage ou de coupage à l’arc. Utilisez des lunettes de sécurité à écrans ou verres latéraux pour piquer ou meûler le laitier. Les piquetures incandescentes de laitier peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma produisent un niveau de bruit extrêmement élevé (de

100 à 114 dB) et exigent par conséquent l’emploi de dispositifs appropriés de protection auditive.

2

PRÉVENTION DES INCENDES-- Les projections de laitier incandescent ou d’étincelles peuvent provoquer de graves incendies au contact de matériaux combustibles solides, liquides ou gazeux. Aussi faut-il observer les précautions suivantes: a. Éloigner suffisamment tous les matériaux combustibles du secteur où l’on exécute des soudures ou des coupes

à l’arc, à moins de les recouvrir complètement d’une bâche non-inflammable. Ce type de matériaux comprend notamment le bois, les vêtements, la sciure, l’essence, le kérosène, les peintures, les solvants, le gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.

b. Les étincelles ou les projections de métal incandescent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y déclencher une ignition lente cachée. Veiller à protéger ces ouvertures des

étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations de gougeage ou autres travaux à chaud à la surface de barils, bidons, réservoirs ou autres contenants usagés, avant de les avoir nettoyés de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il convient de disposer d’un matériel d’extinction prêt à servir immédiatement, tel qu’un tuyau d’arrosage, un seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur de façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc au plasma exige l’emploi de tensions à vide relativement importantes; or, celles-ci risquent de causer des dommages corporels graves et même mortels en cas d’utilisation inadéquate. La gravité du choc électrique reçu dépend du chemin suivi par le courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous tension venir au contact direct de la peau ou de vêtements humides. Veillez à porter des gants bien secs.

b. Si vous devez effectuer un travail sur une surface métallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secs et des chaussures à semelles de caoutchouc et en vous tenant sur une planche ou une plate-forme sèche.

c. Mettez toujours à la terre le poste de soudage/coupage en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne surchargez jamais le câble. Utilisez toujours un

équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en service. une mise à la masse accidentelle peut en effet provoquer une surchauffe de l’équipement et un danger d’incendie. Ne pas enrouler ou passer le câble autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en un point aussi proche que possible de la zone de travail. Le branchement des câbles de masse à l’ossature du bâtiment ou en un point éloigné de la zone de travail augmente en effet le risque de passage d’un courant de sortie par des chaînes de

9

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objet d’ assurer votre protection. Veillez à lire et à observer les précautions énoncées ci-dessous avant de monter l’

équipement ou de commercer à l’utiliser. Tout défaut d’observation de ces précautions risque d’entraîner des blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la peau et des yeux dues au rayonnement de l’arc

électrique ou du métal incandescent, lors du soudage au plasma ou à l’électrode ou lors du gougeage à l’arc, peuvent s’avérer plus graves que celles résultant d’une exposition prolongée au soleil. Aussi convient-il d’observer les précautions suivantes: a. Portez un écran facial adéquat muni des plaques protectrices et des verres filtrants appropriés afin de vous protéger les yeux, le visage, le cou et les oreilles des étincelles et du rayonnement de l’arc électrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité de façon à ce qu’elles ne regardent pas l’arc et à ce qu’elles ne s’exposent pas à son rayonnement, ni à celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans rebord, des chaussures à embout d’acier et un casque de soudage ou une calotte de protection, afin d’éviter d’exposer la peau au rayonnement de l’arc électrique ou du métal incandescent. ll est également souhaitable d’utiliser un tablier ininflammable de façon à se protéger des étincelles et du rayonnement thermique.

c. Les étincelles ou les projections de métal incandescent risquent de se loger dans des manches retroussées, des bords relevés de pantalons ou dans des poches.

Aussi convient-il de garder boutonnés le col et les manches et de porter des vêtements sans poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité

à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité lorsque vous vous trouvez dans un secteur où l’on effectue des opérations de soudage ou de coupage à l’arc. Utilisez des lunettes de sécurité à écrans ou verres latéraux pour piquer ou meûler le laitier. Les piquetures incandescentes de laitier peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma produisent un niveau de bruit extrêmement élevé (de

100 à 114 dB) et exigent par conséquent l’emploi de dispositifs appropriés de protection auditive.

2

PRÉVENTION DES INCENDES-- Les projections de laitier incandescent ou d’étincelles peuvent provoquer de graves incendies au contact de matériaux combustibles solides, liquides ou gazeux. Aussi faut-il observer les précautions suivantes:

10 a. Éloigner suffisamment tous les matériaux combustibles du secteur où l’on exécute des soudures ou des coupes

à l’arc, à moins de les recouvrir complètement d’une bâche non-inflammable. Ce type de matériaux comprend notamment le bois, les vêtements, la sciure, l’essence, le kérosène, les peintures, les solvants, le gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.

b. Les étincelles ou les projections de métal incandescent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y déclencher une ignition lente cachée. Veiller à protéger ces ouvertures des

étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations de gougeage ou autres travaux à chaud à la surface de barils, bidons, réservoirs ou autres contenants usagés, avant de les avoir nettoyés de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il convient de disposer d’un matériel d’extinction prêt à servir immédiatement, tel qu’un tuyau d’arrosage, un seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur de façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc au plasma exige l’emploi de tensions à vide relativement importantes; or, celles-ci risquent de causer des dommages corporels graves et même mortels en cas d’utilisation inadéquate. La gravité du choc électrique reçu dépend du chemin suivi par le courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous tension venir au contact direct de la peau ou de vêtements humides. Veillez à porter des gants bien secs.

b. Si vous devez effectuer un travail sur une surface métallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secs et des chaussures à semelles de caoutchouc et en vous tenant sur une planche ou une plate-forme sèche.

c. Mettez toujours à la terre le poste de soudage/coupage en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne surchargez jamais le câble. Utilisez toujours un

équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en service. une mise à la masse accidentelle peut en effet provoquer une surchauffe de l’équipement et un danger d’incendie. Ne pas enrouler ou passer le câble autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en un point aussi proche que possible de la zone de travail. Le branchement des câbles de masse à l’ossature du bâtiment ou en un point éloigné de la zone de travail augmente en effet le risque de passage d’un courant de sortie par des chaînes de

SECTION 1 DESCRIPTION

AristoDrive 4

TM

-Wire Feeders

Modular MMC panel for easy function and

feature upgradability (MMC=Man/Machine

Communications) .

Use with AristoPower-460 Power Source

Heavy duty compact wire feed motor.

Quick release 4-roll drive assembly; no read-

justment of pressure required when rethreading wire.

Quick release “No Tools” feed roll system.

Driven upper and lower feed rolls for positive

feed force and maximum wire grip.

Presettable arc voltage and wire speed

All control circuits incorporated on one solid-

state printed circuit board, mounted for easy access and removal.

Slow run-in button sets the wire feed speed to

1/2 the preset until the arc is struck for smoother arc starting.

Jog button for wire inching without energizing

the power source contactor.

Anti-stick wire burnback control for precise

adjustment of amount of wire burnback after wire feed stops, to eliminate freezing of wire in weld pool.

Low voltage circuit (12V) for gun trigger switch,

to assure operator safety.

NAS (#4 Tweco) gun adapter factory installed.

“Sure Start” wire conditioning to eliminate wire

balling and ensure good arc starting

Specifications:

AristoDrive 4-30

Wire Feed Range:

Speed Range ........ 30-999 in/min (.8 - 25 m/min)

Wire Sizes:

Hard (V-Groove) ...... .023 - 1/16 in.(.6-1.6mm)

Cored (Knurled) ....... .035 - 5/64 in.(.9-2.0mm)

Soft (U-Groove) ....... .035 - 1/16 in.(.9-1.6mm)

Input power ................................................ 42 Vac / 60hz.

Drive Roll Diameter ................................................. 30mm

Dimensions:

Length ....................................... 22.5 in.(572mm)

Width ......................................... 10.5 in.(268mm)

Height ....................................... 16.5 in.(419mm)

Weight. ....................................... 45-lbs.(20.5Kg)

AristoDrive 4-30

AristoDrive 4-48

AristoDrive 4-48

Wire Feed Range:

Speed Range ..... 30-800 in/min (.8 - 20.5 m/min)

Wire Sizes:

Hard (V-Groove) .... .035 - 1/16 in.(.9 - 1.6mm)

Tubular (Knurled) .. .035 - 1/8 in. (.9 - 3.2mm)

Soft (U-Groove) ..... .045 - 3/32 in.(.9 - 2.4mm)

Input Power ................................................ 42 Vac / 60hz.

Drive Roll Diameter ................................................. 48mm

Dimensions:

Length .......................................... 23 in.(584mm)

Width ......................................... 14.5 in.(368mm)

Height ....................................... 16.5 in.(419mm)

Weight ............................................ 53 lbs.(24Kg)

11

SECTION 1 DESCRIPTION

MMA-6 MMC (Man/Machine Communications)

Easy to set weld parameters for MIG, MIG Pulse, Stick or Gouging.

Choose synergic weld parameters from of 107 possibilities. Set the wire feed speed and weld!

Internal Memory stores up to 10 different weld parameter setups. Recall parameters with a simple push of a button.

Programmable soft keys allow direct access to flexible functions, such as hot start, crater fill, 2/4 stroke trigger, wire inch, gas purge, etc.

Large display gives real time voltage, current, and wire feed speed read-outs.

Preset inductance, gas pre & post flow, inch or metric units, auto weld schedule select, arc force, burnback and more. Update and change weld data using optional ESAT software for maximum flexibility.

Options & Accessories

AristoDrive 4

Hanging Bail .................................................... 0558003047

Handle Kit ....................................................... 0558002356

Wheel Kit ................................................................... 34324

Swivel Post ................................................................ 36172

Marathon Pack Inlet Guide ............................. 0558002519

Requires ............................................................... 899F50

Counterbalance Mini-Boom ............................ 0458705881

Reel Assembly .......................................................... 34323

Spool Cover .................................................... 0558003047

Control Cable, 6.5ft.(2m) ................................. 0456527880

Control Cable, 260ft. (8m) ............................... 0456527881

Control Cable, 52ft. (16m) ............................... 0456527882

Control Cable, 82ft. (25m) ............................... 0456527883

Control Cable, 114ft. (35m) ............................. 0456527884

Trigger Leads, ESAB Style

Trigger Lead, GunMaster 250 ......................... 0558001815

Trigger Lead, GunMaster 400 ............................... 2075216

12

Marathon Pack

Inlet Guide

Handle

Hanging bail

Control Cable

SECTION 1 DESCRIPTION

1.0

SAFETY

Before the AristoDrive 4-30 or 4-48 wire feeder is put into operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper installation.

The definitions relating to the: safety notations are described at the end of the Safety Section in the front of this manual — read them and their specific text references carefully.

1.1

DESCRIPTION AND SPECIFICATIONS

The AristoDrive 4-30 & 4-48 are heavy duty 4 roll drive 42 vac wire feeders with the ability to meet immediate and long term welding requirements of any weld shop. It's "Modular Design" technology permits simplicity and flexibility without unnecessary configuration and installation complexity. The innovative and "easy to use" MA-6 AristoDrive control panel (MMC or Man/Machine Communications) simplifies the functionality and features selection of the welding system. The drive stand gears are totally enclosed for safety, dependable and reliable operation.

The AristoDrive 4-48 wire feeder will handle the most demanding welding applications using short arc, spray and pulsed spray arc Mig (GMAW, GMAW-P

& MCAW) welding or cored wire (FCAW ) welding using the AristoPower 460 power source.

A. FEATURES:

• Modular MMC (Man/Machine Communications) panel for easy function and feature selection

• Heavy duty compact wire feed motor

• AristoDrive 4-48 has a heavy duty drive stand and large 48 mm drive rolls

• AristoDrive 4-30 has a heavy duty drive stand with 30mm rolls.

• Quick release 4-roll drive assembly; no readjustment of pressure required when rethreading wire.

• Quick change “No Tools” feed roll system

• Driven upper and lower drive rolls for positive feed force and maximum wire grip.

• All control circuits incorporated on one solid-state printed circuit board, mounted for easy access and removal.

• Gas purge switch for shield gas flowrate preset.

• Slow run-in panel button sets the wire feed speed at 1/2 the preset until the arc is struck for smoother arc starting.

• Jog panel button for wire inching without energizing power source contactor.

• 4-stroke, Hot Start and Craterfill panel buttons for easy feature selection.

• Low voltage circuit (12v) for gun trigger switch, to assure operator safety.

• NAS (#4 Tweco) gun adapter

• All cable and hose connections are quickly detachable.

13

SECTION 1 DESCRIPTION

B. Specifications AristoDrive 4-30 & AristoDrive 4-48

(See page 10)

C. Modular MMC System

Introduction

The interchangeable control panels (MMC) are available in 4 different models depending on the needs of the welding operator and the welding application.

The panels are designed for easily removal and replacement. The following describes the functions and capability of each MMC panel.

MA-6 MMC MIG/STICK PANEL

The MA-6 MMC panel is a simple, intuitive yet feature rich control panel that will meet the weld requirements of most Mig, Stick and Arc Gouging applications. The flow chart below summarizes the features available.

14

SECTION 1 DESCRIPTION

D. Front Panel Components

1. MA-6 MIG/STICK/GOUGING MMC PANEL

2. Power On/Off Switch

Controls the 42 vac power from the AristoPower 460 power source.

A two prong “twist to lock” receptacle used to connect the Mig gun trigger circuit to the wire feeder.

3. NAS (#4 Tweco) Power Pin Mig gun connection

E. Rear Panel:

1. Control Cable Receptacle

Receptacle that accepts the 19 pin control interconnect cable between the wire feeder and power source.

2. Shield Gas Connection

Connect the shielding gas hose from the regulator/flowmeter to this fitting.

3. Circuit Breaker

Prevents damage to the Main control PC board caused by excessive line current.

4. Power Connection Block

Insulated connection point for the welding cables from the secondary side of the welding power source.

1.2

RECOMMENDED EQUIPMENT AND ACCESSORIES

A. Control Cable Assembly:

For connection of the AristoDrive 4-48 to ESAB power sources with a

12-pin receptacle, the following control cable assemblies are available:

6-foot (2 m) - 0456 527 880

25-foot (8 m) - 0456 527 881

50-foot (16 m) - 0456 527 882

80-foot (25 m) - 0456 527 883

C. Mig Welding Guns:

Gun Master 250 Gas Cooled

Gun Master 400 Gas Cooled

D. Mig Gun Adapters

Only Tweco #4 is supported

E. Feed Rolls and Outlet Guides:

The appropriate feed roll, outlet guide and center guide is required for optimum wire feeding. See Table 2-1 & 2-2.

F. Shielding Gas Regulator/Flowmeter:

R-33 FM 580 (Argon) - P/N 21557

R-33 FM 360 (CO2) - P/N 21558

R-5007 Argon/Helium/Nitrogen - P/N 998124

R-5008 CO

2

- P/N 998125.

*

G. Gas Hoses:

Argon/Helium, Nitrogen - P/N 40V77 (12-1/2 ft.) or P/N 34V38 (25 ft.)

Heavy Duty - P/N 19416 (12-1/2 ft.)* or P/N 19415 (25 ft.)*

Must be used for CO

2

and can also be used for Argon/Helium/Nitrogen.

15

SECTION 1 DESCRIPTION

SPOOL/REEL

SPINDLE POST

MODULAR MMI

(MAN/MACHINE INTERFACE)

PANEL

HEAVY DUTY

30mm ROLL

ENCLOSED

DRIVE STAND

MIG TORCH

CONNECTOR

RECEPTACLE

MIG TORCH

TRIGGER

RECEPTACLE

WIRE FEED

SPEED AND

VOLTAGE*

POWER "ON/OFF"

SWITCH

REMOTE

RECEPTACLE

Figure 1-1. AristoDrive 4-30 Wire Feeder

SPOOL/REEL

SPINDLE POST

MODULAR MMI

(MAN/MACHINE INTERFACE)

PANEL

HEAVY DUTY

48mm ROLL

DRIVE STAND

MIG TORCH

CONNECTOR

RECEPTACLE

MIG TORCH

TRIGGER

RECEPTACLE

WIRE FEED

SPEED AND

VOLTAGE*

POWER "ON/OFF"

SWITCH

REMOTE

RECEPTACLE

Figure 1-2. AristoDrive 4-48 Wire Feeder

16

SECTION 1

NOTE

The Counterbalance Mini-Boom cannot be used with 14" spools ofr 65 lb. coils.

DESCRIPTION

H. OPTIONAL ACCESSORIES

1. Lifting Bracket - Hanging Bail (P/N 0558003047):

Mounts at the top of the wire feeder spool support. Enables you to mount the wire feeder overhead on a boom or trolley system.

2. Reel Assembly (P/N 34323):

Reel slips over spindle to allow use of coiled wire.

3. Swivel Post (P/N 36172):

Installs on power sources such as ESAB 353cv, 453cv MultiPower

460 and 460 Pulse, or 653cvcc and allows the wire feeder to swivel freely.

4. Swivel Post w/Mounting Bracket (P/N 34075):

Attaches to inverter cart (P/N 31700) or other flat mounting surface and allows the feeder to swivel freely

5. Handle Kit (P/N 0558002356)

Includes handle with rubber grip and mounting hardware.

6. Wheel Kit (P/N 34324))

Makes it easy to roll wire feeder around job site Cart includes base, front swivel caster wheels, rear caster wheels and mounting hardware.

7. Spool Enclousure Kit (AristoDrive 4-30 Only P/N 0558002357)

Cover and enclosure provides protection for a 12" spool of wire against dust and dirt.

8. Counterbalance Mini-Boom (P/N 0458705881)

Mounts to the power source swivel post and reduces wire feeding problems caused by sharp bends in the gun liner and cables by keeping the gun cable off the floor. Includes boom and mounting hardware. (requires Swivel Post - P/N 36172)

9. Marathon Pack Inlet Guide for AristoDrive 4-30 (P/N

0558002354)

Allows the secure connection of a Marathon Pack conduit/liner to the rear panel of the AristoDrive wire feeder.

Requires Quick Disconnect Adaptor Kit (QAC) ......... P/N 899F50

10. Marathon Pack Inlet Guide for AristoDrive 4-48 (P/N 0558002519)

Allows the secure connection of a Marathon Pack conduit/liner to the rear panel of the AristoDrive wire feeder.

Requires Quick Disconnect Adaptor Kit (QAC) P/N 899F50

11. Heavy Duty Pressure Spring (P/N - 0558002142)

Recommended for the 4-48 Drivestands using solid wires of 1/16" diameter and greater.

17

SECTION 1 DESCRIPTION

18

SECTION 2

PRESSURE

ADJUSTMENT

UPPER ROLL

PRESSURE ROLL

BOGEY

CENTER GUIDE

LOCKING KNOB

RETAINING KNOB

INLET GUIDE

LOCKING KNOB

INLET GUIDE

LOWER ROLL

RETAINING NUTS

INSTALLATION

CENTER

GUIDE

GUN LOCKING

KNOB

OUTLET

GUIDE

OUTLET GUIDE

LOCKING KNOB

GEAR PIN

AXLE

Figure 2-1 AristoDrive 4-30 Drive Stand

UPPER ROLL

RETAINING KNOB

CENTER GUIDE

LOCKING KNOB

PRESSURE

ADJUSTMENT

PRESSURE ROLL

ARMS

INLET

GUIDE

LOWER ROLL

RETAINING KNOB

Figure 2-2 AristoDrive 4-48 Drive Stand

19

FEED ROLL

SHAFT

SECTION 2

Table 2-1 - AristoDrive 4-30 Feed Roll Table

Wire Size inch

Wire Size mm

Part

Number

Solid Wire V Groove (4 req'd.)

.023-.030 0.8-0.9

.035/.040-.045

0.9/1.0-1.2

.052-1/16 1.4-1.6

.035-.045

.045-.052

1/16-5/64

.035-3/64

3/64-1/16

All

Cored Wire Serrated (4 req'd.)

0.9-1.2

1.2-1.4

1.6-2.0

0558002352

37319

37320

Aluminum U Grooved

0.9-1.2

1.2-1.6

Inlet Guide

3mm

(4 req'd.)

36860

36861

(1 req'd.)

0455049001

Center Guides (1 req'd.)

Steel 2mm

Steel 3mm

Aluminum 2mm

0455072001

0455072002

0456615001

Steel

Steel

Steel

Aluminum

Outlet Guides (1 req'd.)

1.5mm

2mm

3mm

2mm

0458690880

0458690881

0458690882

0458690883

INSTALLATION

Table 2-2 - AristoDrive 4-48 Feed Roll Table

Wire Size inch

.023

.030

.035/.040

.045

.052

1/16" (.062)

.035

.045

.052

1/16" (.062)

5/64 (.078)

3/32 (.093)

.109

.125

Wire Size Part mm

Solid Wire V Groove

Number

(4 req'd.)

.6mm

.8mm

.9/1.0mm

1.2mm

1.4mm

1.6mm

Cored Wire Serrated

1.0mm

1.2mm

1.4mm

1.6mm

2.0mm

2.4mm

2.8mm

3.2mm

Aluminum U Grooved

0558002235

0558002236

0558002237

0558002238

0558002239

0558002240

(4 req'd.)

058002227

058002228

058002229

058002230

058002231

058002232

058002233

058002234

(4 req'd.)

.030

.035/.040

3/64 (.047)

1/16" (.062)

3/32 (.093)

All

HD Brass

.023-.045 Steel

.052-.062 Steel

5/64 (.078) Steel

.093-.125 Steel

.023-.045 Aluminum

.047-.062 Aluminum

3/32 (.093) Aluminum

.023-.045 Steel

.052-.062 Steel

5/64 (.078) Steel

.093-.125 Steel

.023-.045 Aluminum

.047-.062 Aluminum

3/32 (.093) Aluminum

.8mm

.9/1.0mm

1.2mm

1.6mm

2.4mm

Inlet Guide

055800243

055800244

055800245

055800247

055800248

(1 req'd.)

3.5mm

3.5mm

0558002347

0558002517

(1 req'd.)

Center Guides

1.5mm

2.0mm

2.5mm

3.5mm

1.5mm

2.0mm

3.5mm

Outlet Guides

0558002223

0558002224

0558002225

0558002226

0558002307

0558002308

0558002310

(1 req'd.)

1.5mm

2.0mm

3.0 mm

3.5mm

1.5mm

2.0mm

3.0mm

0558002215

0558002216

0558002217

0558002218

0558002219

0558002220

0558002222

20

SECTION 2 INSTALLATION

2.0

INSTALLATION

After checking to be sure you have all required components and accessories, proceed as follows:

A. HOSE AND ELECTRICAL CONNECTIONS

1. Connect shielding gas supply hose to the rear panel of the feeder.

2. Connect the 19-pin control cable between the AristoDrive rear panel and power source wire feeder connection.

3. Connect suitably sized power cable between the power source and the power block at the rear base of the feeder.

B. CENTER AND OUTLET GUIDES

1. Choose the correct type and size center and outlet guide for the type of drive stand on the feeder. See Figure 2-1 or 2-2 and Table

2-1 or 2-2.

2. Insert the center guide into the drive stand center support between the front and rear drive axles. Tighten the locking knob to secure in place.

3. Insert the outlet guide tapered end first into the front of the Mig gun adapter and secure with locking knob.

C. MIG GUN CONNECTIONS

Gun Master 250 and 400

1. Connect Mig Gun to feed roll accessory drive by loosening the locking knob on the drive roll accessory gun adapter and insert the gun power pin into the gun adaptor then tighten locking knob.

2. Connect the gun trigger twist lock plug into the mating receptacle on the front panel of the AristoDrive feeder and lock by twisting 1/4 turn.

D. INSTALLING 4-30 FEED ROLL

Lower Feed Rolls

1. Release the tension lever on the pressure roll bogey and flip up to access the drive rolls

2. Remove the lower feed roll retaining knobs.

3. Separate the feed roll from the gear pin axle and slip the new feed roll on the gear shaft, engaging the gear pins.

4. Reinstall the feed roll retaining knobs.

Upper Feed Rolls

1. Release the tension lever on the pressure roll bogey and flip up to access the drive rolls

2. Remove the upper feed roll retaining knobs by turning knob 1/4 turn and pulling axle straight out.

3. Separate the feed roll from the gear pin axle and slip the new feed roll on the gear shaft, engaging the gear pins.

4. Reinstall the feed roll retaining knob and axle.

21

SECTION 2 INSTALLATION

E. INSTALLING 4-48 FEED ROLLS

1. Release the tension levers on the pressure roll arms and flip outward

(away from the center of the drive stand) to lift the top rolls from the bottom rolls.

2. Twist the feed roll retaining knobs so that the flutes align with the axle pin.

3. Slip the feed roll on the axle and over the axle pins.

4. Twist the retaining knob 1/8 turn to lock the rolls in place.

F. INSTALLING SPOOL OF WIRE (4-48)

1. Remove “S-pin” clip from spindle.

2. Position the spool of wire so that when it is placed on the spindle, wire will be drawn to the feed roll from the bottom of the spool. The spool should be held so that the index hole on the spool will engage the pin on the spindle.

3. Slide the spool onto the spindle until it engages the spindle pin. Lock in place with the S-pin clip.

4. Loosen the brake screw in the center of the spindle hub, then tighten it just enough to prevent coasting of the spool when wire is drawn from it. Too much pressure will load the wire feed motor unnecessarily. Too little pressure will permit the spool to overrun, causing the wire to come loose and tangle.

5. Thread wire to gun as follows: a. Round off the free end of the welding wire with a file.

b. Release the tension levers on the pressure roll arm assembly.

c. Thread the wire through the inlet guide, over the feedroll grooves and into the outlet guide.

d. Close the pressure roll making sure the wire is seated in both the top and bottom feed roll grooves.

e. Remove nozzle and contact tip from the gun. Turn on the

Power Source using the main power switch. Inch the wire, using the AristoDrive jog switch, until the wire exits the front end of gun. Thread the contact tip over the wire and tighten into the tip adapter. Replace gun nozzle.

6. When wire coils are to be used, raise the spindle assembly to its highest mounting position in the spindle post. Mount the wire reel onto the spindle as though it were a spool (see 1 and 3 above). Remove wing nuts and cover plate from reel. Remove coil from its package, but do

not remove its binding wires or straps. Slide coil onto reel so that wire will be drawn from bottom of coil (starting end for a coil is always the outer end). Replace reel cover plate and wing nuts. Cut off coil tie wires. Adjust brake screw and thread wire to the gun as covered in 4 and 5 above.

G. ADJUSTING THE PRESSURE ROLL ASSEMBLY

When a new wire size or type installed, set the pressure adjustment as follows:

1. Unscrew the pressure adjustment knob until the pressure knob is free.

2. Alternately press and release the gun trigger switch while slowly tightening the pressure adjusting knob until the wire begins to feed without slipping. The pressure applied should be the minimum required to provide positive, nonslip wire feed. Too little pressure will result in wire slippage while excessive pressure will scar and deform the wire.

22

SECTION 3 OPERATION

3.0

ADJUSTMENTS AND OPERATION

A. CONTROL SETTINGS

1. Turn the AristoDrive POWER switch to the “ON” position then turn on the AristoPower power source.

2. Set the weld process, wire type, wire size and shielding gas being used on the MA-6 MMC panel. See the MA-6 Instruction manual for more details and complete MA-6 operation.

3. Set the wire feed rate by adjusting the WIRE FEED SPEED control knob on the MMC panel. The wire feed rate controls the weld current furnished by the CV power source.

B. FEEDING WIRE

If wire has been threaded through gun and contact tip, simply operate the jog button or cut off wire, as required, so that the wire extends about 1/2 in. beyond the end of the gun nozzle.

C. SHIELDING GAS FLOW RATE

Actuate the gas purge button on the MA-6 Panel and set gas flow rate at the shielding gas regulator-flowmeter to 35 to 40 cfh. Maintain flow for at least 15 seconds to insure adequate purging of gas hose and gun. Preflow/postflow times can be set under the SETTINGS menu on the MA-6 MMC panel.

D. SLOW INCH BUTTON

Press the SLOW INCH button if a slow run-in of the weld wire is desired. The wire feed speed will then be at 1/2 the preset wire feed rate when the gun trigger is pulled until the arc is struck. The wire speed will then increase to the preset speed for welding. This functions gives smoother arc starting for some weld applications.

E. MAKING THE WELD

Start to weld by pressing the gun trigger lever. This closes the welding contactor, and starts gas flow and wire feed. When the welding wire touches the workpiece an arc will be established. The trigger switch lever must be depressed for the duration of the weld (unless the trigger latch option has been installed and set in the trigger latch position). Welding action will be stopped and all services discontinued when the trigger switch lever is released and returns to its original position. If the gun is withdrawn from the workpiece during welding, the arc will be interrupted, but shielding gas flow and welding wire feed will continue until the switch lever is released.

23

SECTION 3 OPERATION

3.1

OPERATING SEQUENCE

NORMAL

1 . Close gun trigger switch.

— Gas solenoid opens, weld contactor closes, wire feed motor runs at preset wire feed speed, or slow inch, whichever has been selected.

2. Release gun trigger switch.

— Wire feed motor de-energized, brake circuit enabled.

— Anti-stick circuit energized.

— Weld contactor opens.

— Burnback circuit times out

(delay determined by setting of Burnback potentiometer).

— Gas solenoid valve closes.

24

SECTION 4 TROUBLESHOOTING

4.0

TROUBLESHOOTING

Table 4-1 AristoDrive 4-48 Troubleshooting Chart

Nothing works Check if power source is energized

Wire Feeder is "ON", motor does not run, gas valve and welding power source contactor do not energize

Check weld gun trigger plug connection

Wire feeds, shielding gas flows, but no power to electrode wire

Check if power source has Open Circuit Voltage

Check if weld cables are connected

Check interconnect cable for continuity or loose connection

Motor runs slowly and/or gas solenoid vale is "chattering"

Welding wire feed cannot be shut OFF and feeds continuously

Check for 42 vac input voltage

Short in welding gun trigger leads.

during welding

Check weld gun trigger connection

Check weld gun trigger switch

Readjust spool spindle brake and pressure roll tension

Check for the correct size and type drive rolls for the electrode wire being used.

Clean or replace dirty or worn drive rolls.

Check for incorrect type or sized outlet and center guides

Check and/or replace the weld gun contact tip and/or liner if worn or damaged

Remove weld spatter and debris form weld gun nozzle and contact tip

Have an ESAB Authorized Repair station check the motor drive and control PCB.

A. MAINTENANCE

If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.

B. GENERAL MAINTENANCE

Little maintenance is required to keep the wire feeder in top operating condition. It is important, however, that moving parts such as feed and pressure rolls, wire feed motor, etc., be kept clean and free of dust or dirt. Cleaning is best accomplished by regularly blowing off these parts with dry compressed air. This should be done once for every eight hours of operating time, more often if necessary.

25

SECTION 4 TROUBLESHOOTING

26

SECTION 4 TROUBLESHOOTING

27

SECTION 4 TROUBLESHOOTING

28

SECTION 5 REPLACEMENT PARTS

5.0 SPARE AND REPAIR PARTS

Replacement Parts are illustrated on the following pages. When ordering replacement parts, order by part number and part name, as illustrated on the figure

Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

5.1 ORDERING

To assure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB distributor or from:

ESAB Welding & Cutting Products

Attn: Customer Service Dept.

P.O. Box 100545, 411 S. Ebenezer Road

Florence, SC 29501-0545

Be sure to indicate any special shipping instructions when ordering replacement parts.

To order parts by phone, contact ESAB at 1-843-664-5540. Orders may also be faxed to 1-800-634-7548. Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communication Guide located on the last page of this manual for a list of customer service phone numbers.

29

SECTION 5

118

REPLACEMENT PARTS

81

98

86, 87

89

26

79

AristoDrive 4-30 Wire Feeder

30

SECTION 5 REPLACEMENT PARTS

95

22, 69, 80

101

4, 82, 83

5, 24

66, 70

31, 32

84, 85

66, 70

4, 82, 83

81

71 43, 87

4, 82, 83

AristoDrive 4-30 Wire Feeder

31

SECTION 5

16

75

29

38

REPLACEMENT PARTS

92

67

121

1 105

11, 12, 18, 25, 124 2

11, 13, 18, 25

AristoDrive 4-30 Wire Feeder

32

SECTION 5

99

72

74

REPLACEMENT PARTS

78

*

30

91

20

21

2

100

102

96

17

34

93

76, 77, 90

97

19

14

7

AristoDrive 4-30 Wire Feeder

33

94

7, 109

15

23

3

33

106, 107

28

78

73

SECTION 5 REPLACEMENT PARTS

AristoDrive 4-30 Wire Feeder

34

SECTION 5 REPLACEMENT PARTS

Items marked with * are: Screw, .375-16 x 1.00" Lg., RH and Washer, .375" Flat

AristoDrive 4-30 Wire Feeder

35

SECTION 5 REPLACEMENT PARTS

AristoDrive 4-30 Wire Feeder

36

SECTION 5 REPLACEMENT PARTS

AristoDrive 4-30 Wire Feeder

37

SECTION 5 REPLACEMENT PARTS

ITEM

NO.

QTY.

REQ.

PART

NO.

DESCRIPTION

1 1

2 1 0459001880 PRESSURE ARM COMPLETE

0458997001

4 1

8 1

9 2 0458722001 AXLE FEED ROLL

34612

34613

INTERMEDIATE NOZZLE, .023” - .062”

INTERMEDIATE NOZZLE, .062” - .093”

0455048001

19 1

20 4 0459052003 FEED / PRESS.ROLLER

22 1 MOTOR

0192238368

GEAR

SCREW

26 1

27 3 952927 SCREW FOR NOZZLE

30 2 0215100013 WASHER, D12 / 6.4 x 1.5

31 1

33 1 0191548009 FLAT PIN 6, 3 x 0, 8 M6

34 1 34609

35 1

SCREW, MRX STEEL 4.8

WASHER

0443514001

39 1

40

41

1

1

0458687001

0215702708

SCREW WITH KNOB

LOCKING WASHER D6

42 1 0212106282 SCREW, IN6 STAL 12.9

43 2

AristoDrive 4-30 Wire Feeder

38

SECTION 5

118

86, 87

REPLACEMENT PARTS

100

73

5

AristoDrive 4-48HD Wire Feeder

39

SECTION 5

62

72

6, 75, 76

21, 58, 78

81

98

55, 59

28, 29

84, 85

55, 59

6, 75, 76

80

REPLACEMENT PARTS

61

7, 23

67

50, 87

73

AristoDrive 4-48HD Wire Feeder

40

SECTION 5

63

16

26

REPLACEMENT PARTS

93

77

14, 18, 27, 30

56

3

121

14, 24, 27, 30

AristoDrive 4-48HD Wire Feeder

41

SECTION 5

15

1

71

70

REPLACEMENT PARTS

65

60

22

48

68

20

17

79

74

92

19

31

*

32

91

97

89

82

AristoDrive 4-48HD Wire Feeder

42

69

64

2

38

107

3

4, 83

88, 90, 94, 101

95

66

SECTION 5 REPLACEMENT PARTS

AristoDrive 4-48HD Wire Feeder

43

SECTION 5 REPLACEMENT PARTS

Items marked with * are: Screw, .375-16 x 1.00" Lg., RH and Washer, .375" Flat

AristoDrive 4-48HD Wire Feeder

44

SECTION 5 REPLACEMENT PARTS

20

14

32

4

13

29

28

24

26, 27

30

17

25

8, 18

34

7

30

14

13

31

21

AristoDrive 4-48HD Wire Feeder

45

33

20

SECTION 5

22

REPLACEMENT PARTS

29, 32

24

35, 36

30

19

6

22

16

15

12

11

AristoDrive 4-48HD Wire Feeder

46

9

1

10

2

3

5

SECTION 5 REPLACEMENT PARTS

AristoDrive 4-48HD Wire Feeder

47

NOTES

48

NOTES

49

NOTES

50

Revision History

1.

03 / 2003 revision: Updated entire replacement parts section per latest SmarTeam drawing informa tion.

2.

08 / 2003 revision: Removed ".023" and ".030" V-Groove wire sizes data from Table 2-2.

3.

10 / 2003 revision-B: Updated Table 4-1 (page 25) AristoDrive Troubleshooting Chart per Joe Devito mark-up.

51

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548

Order Entry Product Availability Pricing

Hours: 8:00 AM to 7:00 PM EST

Order Information Returns

B. ENGINEERING SERVICE:

Telephone: (843) 664-4416 / Fax : (800) 446-5693

Warranty Returns

Hours: 7:30 AM to 5:00 PM EST

Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:

Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Specifications

D. LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557

Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864

Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070

Hours: 8:00 AM to 5:00 PM EST

Equipment Recommendations

Hours: 7:30 AM to 4:00 PM EST

Hours: 7:30 AM to 3:30 PM EST

Hours: 7:30 AM to 4:00 PM EST

Hours: 7:30 AM to 4:00 PM EST

Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4452

Hours: 7:30 AM to 5:00 PM EST or visit us on the web at http://www.esabna.com

The ESAB web site offers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

0558003750 10 / 2003

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