ESAB Aristo 300 User manual

GB
Valid for serial no. 033-xxx-xxxx0462 255 001 GB 101221
Aristo F 300
Instruction manual

DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2006/95/EC of 12 December 2006, entering into force 16 January 2007
The EMC Directive 2004/108/EC of 15 December 2004, entering into force 20 January 2005
Type of equipment
Wire feeder for MIG/MAG welding
Brand name or trade mark
ESAB
Type designation etc.
AristoF 300 Valid from serial number 033 xxx xxxx (2010 w.33)
AristoF 300 may be used with different MMC panels in combinations with or without water
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No, telefax No:
ESAB AB, Welding Equipment
Esabvägen, SE--695 81 LAXÅ, Sweden
Phone: [phone], Fax: [phone]
The following harmonised standard in force within the EEA has been used in the design:
EN 60974--5, Arc welding equipment – Part 5: Wire feeders
EN 60974--10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Additional information: Restrictive use, Class A equipment, intended for use in locations other than residential
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety
requirements stated above.
Place and Date
Laxå 2010--09--10 Signature Position Global Director
Equipment and Automation
Kent Eimbrodt
Clarification
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TOCe
Rights reserved to alter specifications without notice.
1SAFETY 3...........................................................
2 INTRODUCTION 5...................................................
2.1 Equipment 5................................................................
2.2 Control panel 5.............................................................
3 TECHNICAL DATA 6.................................................
4 INSTALLATION 7....................................................
4.1 Lifting instructions 7.........................................................
5 OPERATION 7.......................................................
5.1 Connections and control devices 9............................................
5.2 Water connection 9..........................................................
5.3 Wire feed pressure 10........................................................
5.4 Replacing and inserting wire 10................................................
5.5 Connecting to MarathonPac 11.................................................
5.6 Changing feed rollers 11......................................................
5.7 Changing nozzles 12.........................................................
6 MAINTENANCE 12....................................................
6.1 Inspection and cleaning 12....................................................
7 ORDERING SPARE PARTS 13.........................................
DIAGRAM 14............................................................
ORDERING NUMBER 15.................................................
WEAR PARTS 16........................................................
ACCESSORIES 17.......................................................

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1SAFETY
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:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
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. Note! Do not use safety gloves when replacing wire.
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.
SLubrication and maintenance must not be carried out on the equipment during operation.
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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
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
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.
CAUTION
This product is solely intended for arc welding.
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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 wire feed units Aristo F 300 and Aristo F 300w with control panels MA43 and
MA44 are designed for MIG/MAG welding together with 300 A, 400 A and 500 A
power sources.
The wire feed units contain four-wheel drive wire feed mechanisms as well as control
electronics.
They can be used together with wire on ESAB’s MarathonPac, or on wire bobbin
(standard Ø 300 mm).
The wire feed unit can be installed either at the power source trolley, suspended above
the workplace or on the floor.
ESAB's accessories for the product can be found on page 20.
2.1 Equipment
The wire feed unit is supplied with:
Sinstruction manual for the wire feed unit
Sinstruction manual for the control panel in English
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
Sdecal with recommended wear parts
2.2 Control panel
The wire feed unit is supplied with one of the following control panels:
MA43 Knobs for setting the voltage and the wire feed speed /
welding current. Other settings with push buttons.
MA44 Knobs for setting the voltage / QSettand wire feed
speed / current. Other settings with push buttons.
See the separate instruction manual for a detailed description of the control panels.
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3 TECHNICAL DATA
Aristo F 300
Mains voltage 48 V DC
Power requirement 150 W
Supply current I13.2 A
Wire feed speed 0.8 - 25 m/min
Gun connection EURO
Max. diameter wire bobbin 300 mm
Wire dimension
Fe
Ss
Al
Cored wire
0.8 - 1.6 mm
0.8 - 1.6 mm (PSF 3m PTFE)
0,9 - 1.6 mm
0.8 - 1.6 mm
Weight 14 kg
Dimensions (l x w x h) 613 x230 x 450 mm
Operating temperature -10to+40°C
Transportation temperature -20to+55°C
Shielding gas
max pressure All types intended for MIG/MAG welding 0.5 MPa ( 5 bar)
Maximum permissible load at
60% intermittence
100% intermittence 500 A
385 A
Enclosure class IP23
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.
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4 INSTALLATION
The installation must be executed by a professional.
WARNING
When welding in an environment with increased electrical danger, only power
sources intended for this environment may be used. These power sources are
marked with the symbol
4.1 Lifting instructions
Order number for lifting eyelet can be found on page 20.
NOTE! If another mounting device is used, this must be electrically insulated from
the wire feed unit.
5OPERATION
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
NOTE: When moving the equipment use intended handle. Never pull on the gun.
WARNING
Assure that the side panels are closed during operation.
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WARNING
To prevent the reel from sliding off the hub: Lock the
reel in place by turning the red knob as shown on the
warning label attached next to the hub.
WARNING
Rotating parts can cause injury, take great care.
WARNING
Risk of crushing! Do not use safety gloves when replacing wire, feed rollers
and wire bobbins.
AH 0935
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5.1 Connections and control devices
1Control panel,
(see separate instruction manual) 6Connection for shielding gas
2Connection for remote control unit 7Connection for control cable from power
source or cooling unit
3Connection BLUE, with ELP* for coolant to
the welding gun 8Connection for welding current from power source. (OKC)
4Connection RED, for coolant from welding
gun 9Connection BLUE for coolant from cooling unit
5Connection for welding gun 10 Connection RED for coolant to cooling unit
NOTE! Display (digital instrument) and coolant connections only available on certain models.
* ELP = ESAB Logic Pump, see point 5.2.
5.2 Water connection
The wire feed unit with water connection is equipped with a detection system ELP
(ESAB Logic Pump) which checks that the water hoses are connected. When
connecting a water-cooled welding gun, the water pump starts.
Detection only works with power sources that are equipped with ELP.
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5.3 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder's pressure rollers. It is important that the
pressure is not too great.
Fig 1 Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against
an insulated object, e.g. a piece of wood.
When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed
rollers should slip.
If you hold the gun approx. 50 mm from the piece of wood, the wire should be
fed out and bend (fig. 2).
5.4 Replacing and inserting wire
SOpen the side panel.
SDisconnect the pressure sensor by folding it downwards. The upper rollers slide
up.
SIf necessary, roll back the wire and remove the wire bobbin.
SStraighten out the new wire 10-20 cm. File away burrs and sharp edges from the
end of the wire before inserting it into the wire feed unit.
SMake sure that the wire goes properly into the feed roller’s track and into the
outflow nozzle or wire guide.
SSecure the pressure sensor.
SClose the side panel.
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5.5 Connecting to MarathonPac
SOpen the side panel
SDisconnect the pressure sensor (1) by folding it downwards.
SUnscrew the inlet nozzle (2).
SInstall the inlet nozzle and quick release connector for MarathonPac (3)
SRemove the blind plug (4) from the rear of the feed unit and insert the wire guide
from MarathonPac. Connect to the quick release connector (3).
5.6 Changing feed rollers
SOpen the side panel
SDisconnect the pressure sensor by folding it downwards. The upper rollers slide
up.
SThe upper rollers are released by turning the knob clockwise (1) and pulling out
(2). The roller detaches and can be removed.
SRemove the protective cover by slackening the screw and depressing the hook.
SThe lower rollers are released by turning the knob anti-clockwise and pulling out.
During installation, repeat the above in reverse order.
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5.7 Changing nozzles
SOpen the side panel
SDisconnect the pressure sensor by folding it downwards.
STo remove the inlet nozzle (1), turn it anti-clockwise.
SRemove the intermediate nozzle (2) using a screwdriver and pull it straight up.
STo remove the outlet nozzle (3), undo the screw and pull the nozzle out.
During installation, repeat the above in reverse order.
6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
6.1 Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
SCleaning and replacement of the wire feed unit mechanism's worn parts should
take place at regular intervals in order to achieve trouble-free wire feed. Note
that if pre-tensioning is set too hard, this can result in abnormal wear on the
pressure roller, feed roller and wire guide.
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The brake hub
The hub is adjusted when delivered, if
readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly
slack when wire feed stops.
SAdjusting the braking torque:
STurn the red handle to the locked position.
SInsert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs counterclockwise to increase the braking torque. NB: Turn
both springs through the same amount.
Welding gun
SCleaning and replacement of the welding gun's wear parts should take place at
regular intervals in order to achieve trouble-free wire feed. Blow the wire guide
clean regularly and clean the contact tip.
7 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Aristo F 300 is designed and tested in accordance with the international and European
standards EN 60974-5 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.
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Edition 101221
Diagram
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Edition 101221
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Aristo F 300
Edition 101221
Ordering number
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Ordering no. Denomination Type
0462 250 883 Wire feed unit Aristo F 300 MA43
0462 250 884 Wire feed unit Aristo F 300 MA44
0462 250 893 Wire feed unit with water Aristo F 300w MA43
0462 250 894 Wire feed unit with water Aristo F 300w MA44
0459 839 043 Spare parts list Aristo F 300
0463 010 Instruction manual MA43 MA44
Instruction manuals and the spare parts list are available on the Internet at www.esab.com

Aristo F 300
Edition 101221
Wear parts
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Item 1
Feed roller Item 2A
Inlet nozzle Item 2B Inlet nozzle
MarathonPac
Item 3
Intermediate
nozzle
Item 4
Outlet
nozzle
Wire Ø
mm Wire Ø inch Wire type Groove typ
0460 898 881 0462 037 001 0462 037 002 0462 043 001 0469 837 880 0.8 .030 Fe, Ss & Cored V
0460 898 882 0462 037 001 0462 037 002 0462 043 001 0469 837 880 0.9-1.0 .035-.040 Fe, Ss & Cored V
0460 898 883 0462 037 001 0462 037 002 0462 043 001 0469 837 880 1.2 .045 Fe, Ss & Cored V
0460 898 884 0462 037 001 0462 037 002 0462 043 001 0469 837 880 1.4 .052 Fe, Ss & Cored V
0460 898 885 0462 037 001 0462 037 002 0462 043 001 0469 837 880 1.6 1/6 Fe, Ss & Cored V
0462 295 882 0462 037 001 0462 037 002 0462 043 001 0469 837 881 1.0 .040 Al U
0462 295 883 0462 037 001 0462 037 002 0462 043 001 0469 837 881 1.2 .045 Al U
0462 295 885 0462 037 001 0462 037 002 0462 043 001 0469 837 881 1.6 1/16 Al U

Aristo F 300
Edition 101221
Accessories
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Lifting eye (suspension device) ........... 0463 068 880
Connection set, 70 mm2
With12 pole (8+4) cable plug/socket
2m......................................
5m......................................
10m.....................................
15m.....................................
25m.. .................................
35m.....................................
Connection set water, 70 mm2
With12 pole (8+4) cable plug/socket
2m......................................
5m......................................
10m.....................................
15m.....................................
25m.....................................
35m.....................................
Connection set, 95 mm2
With12 pole (8+4) cable plug/socket
2m......................................
Connection set water, 95 mm2
With12 pole (8+4) cable plug/socket
2m......................................
0462 150 780
0462 150 781
0462 150 782
0462 150 783
0462 150 784
0462 150 785
0462 150 790
0462 150 791
0462 150 792
0462 150 793
0462 150 794
0462 150 795
0462 150 980
0462 150 990