ESAB Aristo 1000 AC/DC SAW User manual

GB
Valid for serial no. 145-xxx-xxxx, 221-xxx-xxxx0462 985 001 GB 20120605
Aristo 1000
AC/DC SAW
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
3 TECHNICAL DATA 6.................................................
4 INSTALLATION 7....................................................
4.1 Lifting instructions 8.........................................................
4.2 Location 8..................................................................
4.3 Example of welding equipment 9..............................................
4.4 Cable routing 10.............................................................
4.5 Mains power supply 11........................................................
5 OPERATION 12.......................................................
5.1 Connections and control devices 12............................................
5.2 Connection of welding and return cable 13.......................................
5.3 Key to symbols 13............................................................
5.4 Overheating protection 13.....................................................
6 MAINTENANCE 14....................................................
6.1 Welding power source 14......................................................
7 FAULT-TRACING 16..................................................
8 ORDERING SPARE PARTS 16.........................................
DIAGRAM 22............................................................
ASSEMBLY INSTRUCTIONS 23...........................................
CONNECTION INSTRUCTION 24..........................................
ORDER NUMBER 25.....................................................
SPARE PARTS LIST 26..................................................
ACCESSORIES 27.......................................................

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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:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is started up.
Sno-one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof clothing, safety gloves.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
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 precautions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
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.
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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.
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:
SWelding tractors
SColumn and boom
SWelding heads
SPositioning equipment
SJoint tracking equipment
SFlux 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 U0max 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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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.
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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.
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4.3 Example of welding equipment
1Welding head 5Return cable 9Measurement cable,
speed
2Control unit 6Measurement cable,
workpiece
10 Motor cable
3Control cable 7Workpiece 11 Measurement cable,
welding voltage
4Welding power source 8Welding cable
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4.4 Cable routing
3Control cable 5Return cable 6Measurement
cable, workpiece
8Welding cable
For more information regarding cable routing, see page 17 and onwards.
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