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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4.5 Mains power supply
WARNING
The welding power source is connected for 400 V at delivery. For other mains
voltage, reconnect on the terminal block, according to the connection instructions
on page 24.
Tighten the screws A using a torque of 10 Nm. Ensure that the plastic protector Bis
still loose.
Make sure that the welding power source is connected to the
correct mains voltage and that it is protected by the correct
fuse rating. A protective earth connection must be made in
accordance with regulations.
Rating plate with supply connection data
Recommended fuse sizes
Aristo 1000
50/60 Hz at DC welding
Mains voltage 380V 400V 415V 440V 460V 500V 550V 575V
Phase current I1eff 86A 82 A 79A 74A 71A 66A 59A 57A
Fuse anti-surge 100A 100A 80A 80A 80A 80A 63A 63A
Note! The fuse sizes as shown above are in accordance with Swedish regulations. Use the welding
power source in accordance with the relevant national regulations.
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5 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
5.1 Connections and control devices
1Knob for setting control* 7Connection black for measurement cable,
workpiece
2Fault indicating lamp orange 8Fuse
3Push button white ON 9Connection red for measurement cable,
welding head
4Push button black OFF 10 Connection for return cable
5Connection for control unit PEK 11 Connection for welding current cable
to welding head
6Connection for service tool 12 Connection for mains voltage cable
13 Cable groove for signal cables
*) There are three knob positions:
SPosition 1, ON / OFF of mains voltage controlled from remote control unit
SPosition 2, ON / OFF blocked
SPosition 3, ON / OFF controlled using button 3 and 4
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5.2 Connection of welding and return cable
Ensure that the welding and return cables are installed as illustrated.
5.3 Key to symbols
Power source ON Power source OFF
Remote controlled start Local control from the
power source
Fault indication
5.4 Overheating protection
The welding power source has overheating protection that operates if the
temperature becomes too high. When this occurs, the welding current is interrupted
and the yellow indicating lamp comes on. A fault code appears in the control unit
(PEK) settings panel.
The overheating protection resets automatically and the welding process can be
restarted when the temperature has fallen.
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6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer attempts any
work to rectify any faults in the product during the guarantee period.
6.1 Welding power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on:
Swelding process
Soperation time
Splacement
Ssurrounding environment
The power source should be regularly blown clean using dry compressed air at
reduced pressure, see page 21. This should be done more frequently in dirty
environments.
Clogged or blocked air inlets and outlets otherwise result in overheating.
Orderingnumber for dust filter see page 26.
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Replacing and cleaning the dust filter
1. Release the dust filter according to the figure.
2. Blow the filter clean with compressed air (reduced pressure).
3. Reinstall the filter.
Ensure that the filter with the finest mesh is placed towards the grille.
Replacing and cleaning the air filter
1. Release the air filter according to the figure
2. Clean the filter with soap and water
3. Reinstall the filter.
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7 FAULT-TRACING
Try these recommended checks and inspections before sending for an authorized
service technician.
Type of fault Corrective action
No arc. SCheck that the mains voltage is switched on.
SCheck that the welding and return cables are correctly
connected.
SCheck that the correct current value is set.
SCheck the mains power supply fuses.
The welding current is
interrupted during welding.
SCheck whether the thermal cut-outs have tripped (a fault
code appears on the control module's panel).
SCheck the mains power supply fuses.
The thermal cut-out trips
frequently.
SCheck to see whether the dust filter is clogged.
SMake sure that you are not exceeding the rated data for the
welding power source (i.e. that the unit is not being
overloaded).
SCheck that the welding power source is not clogged with dirt.
SCheck the ambient temperature.
Poor welding performance. SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct filler material (wire and powder) is
used.
8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Aristo 1000 is designed and tested in accordance with the international and European
standards IEC-/EN 60974-1 and IEC-/EN 60974-10. It is the obligation of the service
unit which has carried out the service or repair work to make sure that the product still
conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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