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.