ESAB Aristo 500 User manual

Brand: ESAB

Model: Aristo 500

Category: Welding System

Type: User manual

This manual is also suitable for

ESAB Aristo 500 is a welding power source designed for MIG/MAG, FCAW-S, live TIG, and MMA welding processes. It offers a wide setting range for precise welding control, with adjustable voltage from 8 to 48 volts and amperage from 16 to 500 amps for MIG/MAG welding, 4 to 500 amps for MMA welding, and 4 to 500 amps for TIG welding. It features a 100% duty cycle at 300 amps for MIG/MAG, MMA, and TIG welding, ensuring continuous operation without overheating.

Valid for serial no. 033-xxx-xxxx, 044-xxx-xxxx0462 152 001 GB 20110708

Aristo 300

Aristo 400

Aristo 500

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Control panel A44 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Lifting instruction 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Mains supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Connections and control devices 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Connection of welding and return cable 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Turning the power source on/off 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Fan control 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Overheating protection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Remote control unit 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 MIG/MAG and FCAW-S welding 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 MMA welding 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 TIG welding 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Inspection and cleaning 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 FAULT TRACING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING OF SPARE PARTS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS LIST 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 SAFETY

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 ob

served 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 equip

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

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.

S Lubrication and maintenance must not be carried out on the equipment during operation.

WARNING

Do not use the power source for thawing frozen pipes.

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WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precausions 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.

PROTECT YOURSELF AND OTHERS!

CAUTION

This product is solely intended for arc welding.

CAUTION

Read and understand the instruction manual before

installing or operating.

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.

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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.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

The Aristo 300/400/500 series is a welding power source intended for MIG/MAG

welding, as well as for welding with powder filled cored wire (FCAW-S), live TIG

welding (power source with panel A44) and for welding with coated electrodes

(MMA).

The power sources are intended for use with the following wire feed units:

S Aristo F 300

S MobileFeed 300

ESAB's accessories for the product can be found on page 20.

2.1 Equipment

The power source is supplied with:

S 5 m return cable with earth clamp

S 5 m mains cable with 32 Amp connector

S instruction manual for the welding power source

S instruction manual for the control panel (if applicable)

Instruction manuals in other languages can be downloaded from the website,

www.esab.com.

2.2 Control panel A44

See separate instruction manual for

detailed description of the panels.

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3 TECHNICAL DATA

Aristo 300 Aristo 400 Aristo 500

Mains voltage 380-440V, +/- 10%, 3∼ 50/60 Hz

Mains supply S

scmin

from serial number 033-xxx-xxxx

from serial number 044-xxx-xxxx

Mains supply Z

max

from serial number 044-xxx-xxxx

3.0 MVA

3.8 MVA

4.0 MVA

6.0 MVA

5.0 MVA

8.4 MVA

0,22 Ω

Primary current

mains voltage 380V

mains voltage 400V

mains voltage 440V

18A

17A

16A

26A

25A

23A

35A

34A

31A

No-load power 40 W

Setting range (DC)

MIG/MAG

MMA

TIG

8-48V

16-300A

4-300A

8-48V

16-400A

4-400A

8-48V

16-500A

4-500A

Permissible load at MIG/MAG

60 % duty cycle

80 % duty cycle

100% duty cycle

300 A / 29.0 V

400 A / 34.0 V

300 A / 29.0 V

500 A / 39.0V

400 A / 34.0V

300 A / 29.0V

Permissible load at MMA

60 % duty cycle

80 % duty cycle

100% duty cycle

300 A / 32.0 V

400 A / 36.0 V

300 A / 32.0V

500 A / 40.0 V

400 A / 36.0 V

300 A / 32.0 V

Permissible load at TIG

60 % duty cycle

80 % duty cycle

100% duty cycle

300 A / 22.0 V

400 A / 26.0 V

300 A / 22.0 V

500 A / 30.0 V

400 A / 26.0 V

300 A / 22.0 V

Power factor at maximum current 0,91 0,92 0,93

Efficiency at maximum current 87 % 88 % 89 %

Open circuit voltage

VRD function inactive

VRD function active

55V

<35V

Operating temperature -10 to +40° C

Transportation temperature -20 to +55° C

Constant sound pressure when

idling

<70 db (A)

Dimensions lxwxh 610 x 250 x 445 mm

Weigh 40 kg

Insulation class H

Enclosure class IP 23

Application classification

The VRD function is explained in the instruction manual for the control panel.

Mains supply, S

min

Minimum short circuit power on the network in accordance with IEC 61000-3-12

Mains supply, Z

max

Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

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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 IP23 is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

4 INSTALLATION

The installation must be carried out by a professional.

CAUTION

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

WARNING

Straps must be used when lifting the power

source. The handle is only intended for

pulling it.

4.1 Location

Position the welding power source such way that its cooling air inlets and outlets are not obstructed.

4.2 Lifting instruction

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4.3 Mains supply

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

distrubution network operator if necessary, that the equipment may be connected.

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Check that the unit is connected to the correct mains power supply voltage, and that

it is protected by the correct fuse size. A protective earth connection must be made,

in accordance with regulations.

Rating plate with supply connection data

Recommended fuse sizes and minimum cable areas

Aristo 300 Aristo 400 Aristo 500

Mains voltage 380-440V, +/- 10%, 3∼ 50/60 Hz

Mains cable area 4G4 mm

4G4 mm

4G6 mm

Phase current I

eff

Uin 380V

18 A 24 A 28 A

Fuse anti-surge

Fuse CMCB-surge

20 A

25 A

32 A

35 A

32 A

Phase current I

eff

Uin 400V

17 A 23 A 27 A

Fuse anti-surge

Fuse CMCB-surge

20 A

25 A

32 A

35 A

32 A

Phase current I

eff

Uin 440V

16 A 21 A 24 A

Fuse anti-surge

Fuse CMCB-surge

20 A

25 A

32 A

NB: The mains cable areas and fuse sizes as shown above are in accordance with Swedish

regulations. They may not be applicable in other countries: make sure that the cable area and fuse

sizes comply with the relevant national regulations.

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5 OPERATION

General safety regulations for handling of the equipment can be found on

page 4. Read through before you start using the equipment!

WARNING

Fasten the equipment - particularly if the

ground is uneven or sloping.

AH 0935

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5.1 Connections and control devices

1 Mains supply switch 4 Connection for welding current cable (+)

2 Indicating lamp, power supply ON 5 Control cable socket (from / to wire feed

unit) or remote control

3 Indicating lamp, overheating 6 Connection for welding current cable (-)

5.2 Connection of welding and return cable

There are two terminals on the power source, a positive terminal (+) and a negative

terminal (-), for connecting welding and return cables. Selected welding method and

type of used electrode determines to which terminal the welding and the return cable

should be connected to. Before welding make sure that cables are firmly attached to

the power source, and that return cable clamp is properly attached on the workpiece.

5.3 Turning the power source on/off

Turn the machine on by turning switch (1) to the ”1” position. Turn the machine off by

turning the switch (1) to the ”0” position. Regardless the mains supply is interrupted

abnormally or the machine is switched off in the normal manner, the welding data will

be stored, so it will be available next time the unit is turned on.

5.4 Fan control

The power source has a time circuit, which keeps the fans running for 6.5 minutes

after welding has stopped, then the unit switches to energy-saving mode. The fans

start again when welding begins. The fans run at reduced speed for welding currents

up to 200 A, and at full speed for higher currents.

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5.5 Overheating protection

The welding power source has overheating protection circuit that operates if the

internal temperature becomes too high. When this occurs the welding is blocked and

a fault code is displayed on the control panel. The overheating protection resets

automatically when the temperature has fallen down.

5.6 Remote control unit

For more information about the operation of the remote control unit, see the

operating instructions for the control panel.

5.7 MIG/MAG and FCAW-S welding

An arc melts a continuously supplied wire. The weld pool is protected by shielding

gas. For MIG/MAG and FCAW-S welding, the power source is supplemented with:

S wire feed unit

S welding torch

S connection cable between power source and wire feed unit

S shielding gas bottle

5.8 MMA welding

For welding with coated electrodes, the power source is supplemented with:

S welding cable with electrode clamp.

5.9 TIG welding

TIG welding melts the workpiece, using the arc struck from a tungsten electrode, that

does not melt itself. The weld pool and the electrode are protected by shielding gas.

For TIG welding, the welding power source is supplemented with:

S TIG torch with tungsten electrode and gas valve

S argon gas bottle

S argon gas regulator

”Live TIG-start”

At a ”Live TIG-start” the tungsten electrode must touch the workpiece. When the

electrode is then lifted away from workpiece, the arc is struck with limited current

value (12 - 15 A).

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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.

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any

work in the product during the guarantee period in order to rectify any faults.

6.1 Inspection and cleaning

Check regularly that the power source is free from dirt.

The power source should be regularly blown clean using dry compressed air at

reduced pressure. More frequently in dirty environments.

Otherwise the air inlet/outlet may become blocked and cause overheating. To avoid

this, the airfilter should be regurarly cleaned.

Replacing and cleaning the dust filter.

S Release the dust filter according to the figure.

S Blow the filter clean with compressed air (reduced pressure).

S Ensure that the filter with the finest mesh is placed towards the grille.

S Reinstall the filter.

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7 FAULT TRACING

Try these recommended checks and inspections before sending for an authorised

service technican.

Type of fault Actions

No arc. S Check that the mains power supply switch is turned on.

S Check that the welding current supply and return cables are

correctly connected.

S Check that the correct current value is set.

Welding current is interrupted

during welding

S Check whether the thermal overload trip has operated

(indicated by the orange lamp on the front)

S Check the main power supply fuses.

The thermal overload trips

operate frequently

S Check to see whether the air filters are clogged.

S Make sure that you are not exceeding the rated data for the

power source (i.e. that the unit is not being overloaded).

Poor welding performance. S Check that the welding current supply and return cables are

correctly connected.

S Check that the correct current value is set.

S Check that the correct welding wires are being used.

S Check the main power supply fuses.

8 ORDERING OF SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman.

Use only ESAB original spare and wear parts.

Aristo 300, Aristo 400, Aristo 500 is designed and tested in accordance with the inter

national and European standards EN 60974-1 and 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.

Diagram

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Aristo 300, Aristo 400, Aristo 500

Ordering number

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Ordering no. Denomination Type Notes

0462 153 880 Welding power source Aristo

300 Without control panel

0462 183 882 Welding power source Aristo

300 A44 With control panel

0462 154 880 Welding power source Aristo

400 without control panel

0462 154 882 Welding power source Aristo

400 A44 With control panel

0462 155 880 Welding power source Aristo

500 With control panel

0462 155 882 Welding power source Aristo

500 A44 Without control panel

0459 839 049 Spare parts list Aristo

300, Aristo

400, Aristo

500

0462 305 001 Instruction manual Cooling unit COOL 1

0463 009 074 Instruction manual Control panel A44

Instruction manuals and the spare parts list are available on the Internet at www.esab.com

Aristo 300, Aristo 400, Aristo 500

Spare parts list

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Item Ordering no. Denomination

1 0462 197 001 Dust filter

Aristo 300, Aristo 400, Aristo 500

Accessories

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Trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare parts list for trolley . . . . . . . . . . . . . . . . . . .

0462 151 880

0459 839 039

Trolley bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .

option when no cooling unit is assembled

0463 125 880

Aristo F 300 MA43 . . . . . . . . . . . . . . . . . . . . . . .

Aristo F 300 MA43, with water . . . . . . . . . . . .

Aristo F 300 MA44 . . . . . . . . . . . . . . . . . . . . . . .

Aristo F 300 MA44, with water . . . . . . . . . . . .

0462 250 883

0462 250 893

0462 250 884

0462 250 894

MobileFeed 300 AVS . . . . . . . . . . . . . . . . . . . . . 0558 005 728

Cooling unit COOL 1 . . . . . . . . . . . . . . . . . . . . . 0462 300 880

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ESAB Aristo 500 User manual

Brand: ESAB

Model: Aristo 500

Category: Welding System

Type: User manual

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ESAB Aristo 500 User manual

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