ESAB Aristo 300 User manual

GB
Valid for serial no. 033-xxx-xxxx, 044-xxx-xxxx0462 152 001 GB 101119
Aristo 300
Aristo 400
Aristo 500
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
Welding power sources for MIG/MAG welding
Brand name or trade mark
ESAB
Type designation etc.
Aristo®300, Aristo®400, Aristo®500, Valid from serial number 033 xxx xxxx (2010 w.33)
Aristo®300, 400 and 500 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 60974−1, Arc welding equipment – Part 1: Welding power sources
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 2010−09−15 Signature Position Global Director
Equipment and Automation
Kent Eimbrodt
Clarification
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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:
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.
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
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
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:
SAristo F 300
SMobileFeed 300
ESAB's accessories for the product can be found on page 20.
2.1 Equipment
The power source is supplied with:
S5 m return cable with earth clamp
S5 m mains cable with 32 Amp connector
Sinstruction manual for the welding power source
Sinstruction 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 Sscmin
from serial number 033-xxx-xxxx
from serial number 044-xxx-xxxx
Mains supply Zmax
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 inactive1)
VRD function active1) 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
1) The VRD function is explained in the instruction manual for the control panel.
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12
Mains supply, Zmax
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 at a cer
tain 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 executed 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 mm24G4 mm24G6 mm2
Phase current Ieff
Uin 380V
18 A 24 A 28 A
Fuse anti-surge
Fuse CMCB-surge
20 A
20 A
25 A
32 A
35 A
32 A
Phase current Ieff
Uin 400V
17 A 23 A 27 A
Fuse anti-surge
Fuse CMCB-surge
20 A
20 A
25 A
32 A
35 A
32 A
Phase current Ieff
Uin 440V
16 A 21 A 24 A
Fuse anti-surge
Fuse CMCB-surge
20 A
20 A
25 A
25 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 the 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
1Mains supply switch 4Connection for welding current cable (+)
2Indicating lamp, power supply ON 5Control cable socket (from / to wire feed
unit) or remote control
3Indicating lamp, overheating 6Connection 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:
Swire feed unit
Swelding torch
Sconnection cable between power source and wire feed unit
Sshielding gas bottle
5.8 MMA welding
For welding with coated electrodes, the power source is supplemented with:
Swelding 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:
STIG torch with tungsten electrode and gas valve
Sargon gas bottle
Sargon 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 himself
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.
SRelease the dust filter according to the figure.
SBlow the filter clean with compressed air (reduced pressure).
SEnsure that the filter with the finest mesh is placed towards the grille.
SReinstall 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. SCheck that the mains power supply switch is turned on.
SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
Welding current is interrupted
during welding
SCheck whether the thermal overload trip has operated
(indicated by the orange lamp on the front)
SCheck the main power supply fuses.
The thermal overload trips
operate frequently
SCheck to see whether the air filters are clogged.
SMake 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. SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct welding wires are being used.
SCheck 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.
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Edition 101119
Diagram
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Edition 101119
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Aristo 300, Aristo 400, Aristo 500
Edition 101119
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
Edition 101119
Spare parts list
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Item Ordering no. Denomination
10462 197 001 Dust filter

Aristo 300, Aristo 400, Aristo 500
Edition 101119
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