ESAB Aristo 500ix User manual

Aristo® 500ix
Instruction manual
0463 696 201  GB  20221122
Valid for: Serial number: 105-, 243-,
941-xxx-xxxx

TABLE OF CONTENTS
0463 696 201 -4- © ESAB AB 2022
1 SAFETY ...................................................................................................................................... 5
1.1 Meaning of symbols .................................................................................................... 5
1.2 Safety precautions ...................................................................................................... 5
2 INTRODUCTION ......................................................................................................................... 8
2.1 Equipment.................................................................................................................... 8
3 TECHNICAL DATA ..................................................................................................................... 9
4 INSTALLATION........................................................................................................................... 11
4.1 Location........................................................................................................................ 11
4.2 Lifting instructions ...................................................................................................... 12
4.3 Mains supply................................................................................................................ 13
5 OPERATION ............................................................................................................................... 16
5.1 Connections and control devices .............................................................................. 16
5.2 Symbols ....................................................................................................................... 17
5.3 Connection of welding and return cable ................................................................... 17
5.4 Turning the power source on/off................................................................................ 17
5.5 Fan control................................................................................................................... 18
5.6 Thermal protection ...................................................................................................... 18
5.7 VRD (Voltage Reducing Device)................................................................................. 18
5.8 Remote control unit..................................................................................................... 18
5.9 Arc voltage feedback .................................................................................................. 18
6 MAINTENANCE.......................................................................................................................... 19
6.1 Routine maintenance .................................................................................................. 19
6.2 Power source............................................................................................................... 20
7 TROUBLESHOOTING ................................................................................................................ 21
8 ORDERING SPARE PARTS ....................................................................................................... 22
ORDERING NUMBERS ......................................................................................................................... 23
BLOCK DIAGRAM................................................................................................................................. 24
ACCESSORIES ..................................................................................................................................... 25

1  SAFETY
0463 696 201 -5- © ESAB AB 2022
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual and follow
all labels, employer´s safety practices and Safety Data Sheets
(SDSs).
1.2 Safety precautions
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 observed
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 equipment.
Incorrect operation 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 equipment must be familiar with:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
• no unauthorised person is stationed within the working area of the
equipment when it is started up
• no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
• be suitable for the purpose
• be free from drafts

1  SAFETY
0463 696 201 -6- © ESAB AB 2022
4. Personal safety equipment:
• Always wear recommended personal safety equipment, such as safety
glasses, flame-proof clothing, safety gloves
• Do not wear loose-fitting items, such as scarves, bracelets, rings, etc.,
which could become trapped or cause burns
5. General precautions:
• Make sure the return cable is connected securely
• Work on high voltage equipment may only be carried out by a
qualified electrician
• Appropriate fire extinguishing equipment must be clearly marked and
close at hand
• Lubrication and maintenance must not be carried out on the equipment
during operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions when
welding and cutting.
ELECTRIC SHOCK - Can kill
• Do not touch live electrical parts or electrodes with bare skin, wet gloves
or wet clothing
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side
of your body. Secure them with tape when possible. Do not
place your body between the torch and work cables. Never coil
the torch or work cable around your body. Keep welding power
source and cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible
to the area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes
• 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
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing
• Protect bystanders with suitable screens or curtains
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1  SAFETY
0463 696 201 -7- © ESAB AB 2022
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
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.
NOTE!
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2012/19/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 has an assortment of welding accessories and personal protection equipment for
purchase. For ordering information contact your local ESAB dealer or visit us on our website.

2  INTRODUCTION
0463 696 201 -8- © ESAB AB 2022
2 INTRODUCTION
The power source Aristo®500ix combined with U6, U82or MA25 Pulse panels offer a complete
multi-process package supporting MIG, pulse MIG, TIG and gouging, depending on which feeder it is
used with.
The power source is intended for use with the wire feed unit RobustFeed U6, RobustFeed U82,
RobustFeed Pulse, Feed 3004/4804 or YardFeed 2000 and the cooling unit COOL2. For more
information about the feed units and the cooling unit, refer to the Instruction information for the specific
product.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.
2.1 Equipment
The power source is supplied with:
• 5m (16ft) return cable with earth clamp
• 5m (16ft) mains cable
• Instruction manual
• Safety instruction manual
• Quick start quide

3  TECHNICAL DATA
0463 696 201 -9- © ESAB AB 2022
3 TECHNICAL DATA
Aristo®500ix
Mains voltage 380-460V, ±10%, 3~ 50/60Hz
Mains supply Sscmin 7.2 MVA
Primary current Imax 380V 400V 460V
MIG/MAG 38A 35A 30A
MMA 40A 35A 31A
TIG 30A 27A 24A
Idle power 24W 25W 27W
Setting range (DC)
MIG/MAG 16A / 14.8V - 500A / 39V
MMA 16A / 20.6V - 500A / 40V
TIG 5A / 10.2V - 500A / 30V
Permissible load at MIG/MAG
60 % duty cycle 500A / 39.0V
100% duty cycle 400A / 34.0V
Permissible load at MMA
60 % duty cycle 500A / 40.0V
100% duty cycle 400A / 36.0V
Permissible load at TIG
60 % duty cycle 500A / 30.0V
100% duty cycle 400A / 26.0V
Power factor at maximum current 0.91
Efficiency at maximum current 88 %
Open circuit voltage 58V
Operating temperature -20 to 40°C (-4 to 104°F)
Transport temperature -20 to 55°C (-4 to 131°F)
Constant sound pressure when
idling
<70dB (A)
Dimensions l×w×h 712 × 325 × 470mm (28.0 × 12.8 × 18.5in.)
Weight 58.5kg (128.9lb)
Insulation class H
Enclosure class IP23
Application classification
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
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/104°F, or below.

3  TECHNICAL DATA
0463 696 201 - 10 - © ESAB AB 2022
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 intended for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased electrical
hazard.
Class-H insulations can withstands a temperature of up to 180°C. It is made of inorganic material
glued with silicone resin or adhesives of equivalent performance.

4  INSTALLATION
0463 696 201 - 11 - © ESAB AB 2022
4 INSTALLATION
The installation must be carried out by a professional.
The equipment used together with Aristo®500ix must have at least the following program versions in
order for the power source to work properly:
• for RobustFeed U82: 3.02G or later
• for RobustFeed U6: 2.16P or later
• for MA25 Pulse: 1.88H or later
4.1 Location
Position the welding power source such way that its cooling air inlets and outlets are not obstructed.

4  INSTALLATION
0463 696 201 - 12 - © ESAB AB 2022
4.2 Lifting instructions

4  INSTALLATION
0463 696 201 - 13 - © ESAB AB 2022
WARNING!
Secure the equipment - particularly if the
ground is uneven or sloping.
4.3 Mains supply
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater
than or equal to Sscmin at the interface point between the user's supply and the public system.
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 is connected only to a supply
with a short-circuit power greater than or equal to Sscmin. Refer to the technical data in the
TECHNICAL DATA chapter.
Make sure that the welding power source is connected to the correct supply voltage and that it is
protected by the correct fuse rating. A protective earth connection must be made in accordance with
regulations.
1. Rating plate with supply connection data
Recommended fuse sizes and minimum cable area Aristo® 500ix
Aristo®500ix
Mains voltage 380 V 3~ 50/60 Hz 400 V 3~ 50/60 Hz 460 V 3~ 50/60 Hz
Mains cable area 4 × 6 mm² 4 × 6 mm² 4 × 6 mm²
Maximal current
rating Imax
40 A 35 A 31 A
I1eff
MIG/MAG 30 A 27 A 24 A
MMA 31 A 25 A 24 A
TIG 24 A 21 A 19 A

4  INSTALLATION
0463 696 201 - 14 - © ESAB AB 2022
Fuse
anti-surge 35 A 35 A 35 A
type C MCB 32 A 32 A 32 A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with Swedish
regulations. Use the power source in accordance with the relevant national regulations.
Supply from power generators
The power source can be supplied from different types of generators. However, some generators may
not provide sufficient power for the welding power source to operate correctly. Generators with
Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power
≥40kW, are recommended.
Connection instruction
WARNING!
The mains supply must be disconnected during installation.
WARNING!
Wait until the DC bus capacitors are discharged. The DC bus capacitor discharge time is at
least 2 minutes!
The power source is factory set to 400 V AC. If another mains voltage setting is required, the cable on
the printed circuit board has to be moved and put in the correct position. Also the label, at the rear of
the power source, marked with the mains voltage setting must be updated. This operation must be
done by a person who has the appropriate electrical knowledge.
NOTE!
This power source version is designed for a nominal input voltage from 380 to 460 V AC. This
means that the hardware to support 575 V input is not available, 575 V tab is not connected.
If the mains cable needs to be changed, the earth connection to the bottom plate and the ferrites must
be installed correctly. See the picture below for the installation order of the ferrites, washers, nuts and
screws.

4  INSTALLATION
0463 696 201 - 15 - © ESAB AB 2022

5  OPERATION
0463 696 201 - 16 - © ESAB AB 2022
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY" chapter
of this manual. Read it through before you start using the equipment!
NOTE!
When moving the equipment use intended handle. Never pull the cables.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
NOTE!
To achieve the best possible result at Mig short pulsing, the welding and return cables must
not exceed 10 m (33 ft).
5.1 Connections and control devices
1. Mains power supply switch, O / I 5. Negative welding terminal: Return cable
2. Connection for wire feed unit 6. Indicating LED, overheating
3. Fuse (10A) for supply voltage (42VAC) for
feeder unit
7. Indicating LED, power supply ON
4. Positive welding terminal: Welding cable 8. Mains cable inlet

5  OPERATION
0463 696 201 - 17 - © ESAB AB 2022
5.2 Symbols
Power supply ON (4) Overheating (3)
Protective earth Positioning of lifting eye
5.3 Connection of welding and return cable
The power source has two outputs, a positive terminal (+) and a negative terminal (-), for connecting
welding and return cables.
Connect the return cable to the negative terminal on the power source. Secure the return cable's
contact clamp to the work piece and ensure that there is good contact between the work piece and the
output for the return cable on the power source.
Recommended maximum current values for connection set cables
At an ambient temperature of +25 °C and normal 10 minutes cycle:
Cable area Duty cycle Voltage loss/10m
100% 60%
50mm2290 320 0.35V / 100A
70mm2360 400 0.25V / 100A
95mm2430 500 0.19V / 100A
At an ambient temperature of +40 °C and normal 10 minutes cycle:
Cable area Duty cycle Voltage loss/10m
100% 60%
50mm2250 280 0.37V / 100A
70mm2310 350 0.27V / 100A
95mm2370 430 0.20V / 100A
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(104°F).
5.4 Turning the power source on/off
Turn the power source on by turning switch (1) to the ”I” position. Turn the power source off by turning
the switch (1) to the ”O” position. Regardless the mains supply is interrupted abnormally or the power
source 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  OPERATION
0463 696 201 - 18 - © ESAB AB 2022
5.5 Fan control
The power source has a time control that means that the fans continue to run for 6.5 minutes after
welding has stopped, and the power source switches to energy-saving mode. The fans start again
when welding restarts.
5.6 Thermal protection
The welding power source has thermal protection circuit that operates if the internal temperature
becomes too high. If this occurs the welding current is blocked and the indicating LED (6) lights. The
thermal protection resets automatically when the temperature has fallen within normal operation
temperature.
5.7 VRD (Voltage Reducing Device)
The VRD function ensures that the open-circuit voltage does not exceed 35V when welding is not
being carried out. The VRD function must be activated by a qualified service technician, by means of
ESAT (ESAB Software Administration Tool, a kit for technical service including a software to manage
settings, update of software etc.).
The VRD function is blocked when the system senses that welding has started.
5.8 Remote control unit
For more information about the operation of the remote control unit, see the instruction information for
the control panel.
5.9 Arc voltage feedback
To achieve a good welding result, the arc voltage feedback is a crucial factor. In MIG/MAG welding,
the power source is prepared to sense the arc voltage in the wire feeder. Prerequisite for this
functionality is that an ESAB wire feeder and an ESAB interconnection cable is used! This method of
measuring the arc voltage, compensates for the voltage drop in the welding cable to the wire feeder.
With an ESAB torch supporting "TrueArcVoltage", the voltage drop all the way to the contact tip is
compensated.
NOTE!
To compensate the voltage drop in the return cable, the power source can be configured (by
authorised ESAB service personnel) to use an external arc voltage sense wire from the
workpiece.

6  MAINTENANCE
0463 696 201 - 19 - © ESAB AB 2022
6 MAINTENANCE
WARNING!
The mains supply must be disconnected during cleaning and maintenance.
CAUTION!
Only persons with the appropriate electrical knowledge (authorised personnel) may remove
the safety plates.
CAUTION!
The product is covered by manufacturer's warranty. Any attempt to carry out repair work by
non-authorised service centers or personnel will invalidate the warranty.
NOTE!
Regular maintenance is important for safe and reliable operation.
NOTE!
Perform maintenance more often during severe dusty conditions.
Before each use - make sure that:
• Product and cables are not damaged,
• The torch is clean and not damaged.
6.1 Routine maintenance
Maintenance schedule during normal conditions. Check equipment prior to every use.
Interval Area to maintain
Every 3 months
Clean or replace
unreadable labels.
Clean weld terminals. Check or replace weld
cables.
Every 6 months
Clean inside
equipment. Use dry
compressed air with
reduced pressure.

6  MAINTENANCE
0463 696 201 - 20 - © ESAB AB 2022
6.2 Power source
To maintain the performance and increase the lifetime of the power source it is mandatory to clean the
product regularly. How often depends on:
• the welding process
• the arc time
• the working environment
• the surrounding environment, that is grinding etc.
Tools needed for the cleaning procedure:
• torx screwdriver, T25 and T30
• dry compressed air at a pressure of 4 bar
• protective equipment like ear plugs, safety glasses, masks, gloves and safety shoes
Cleaning procedure
CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared workspace.
CAUTION!
The cleaning procedure should be carried out by authorised service technician.
1. Disconnect the mains supply.
2. Wait for 4 minutes to discharge the capacitors.
3. Remove the side panels on the power source.
4. Remove the top panel on the power source.
5. Remove the plastic cover between the heat sink and fan (b).
6. Clean the power source with dry compressed air (4 bar) as follows:
a) The upper rear part.
b) From the rear panel through the secondary heat sink.
c) The inductor, transformer and current sensor.
d) The power components side, from the rear side behind PCB 15AP1.
e) The PCBs at both sides.
7. Make sure that there is no dust left on any part.
8. Install the plastic cover between the heat sink and the fan (b) and make sure it is
correctly fitted against the heat sink.
9. Reassemble the power source after cleaning and perform testing according to
IEC60974-4. Follow the procedure in section “After repair, inspection and test” in the
Service manual.