ESAB AristoMig U500 User manual

GB
Valid for serial no. 304--xxx--xxxx, 445--xxx--xxxx,
524--xxx--xxxx
0459 291 001 GB 050517
AristoMig U500
400 V version
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 4...................................................
3.1 Equipment 5................................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Lifting instructions 6.........................................................
5.2 Placing 7...................................................................
5.3 Mains power supply 7........................................................
5.4 Terminating resistor 7........................................................
6 OPERATION 8.......................................................
6.1 Connections and control devices 8............................................
6.2 Turning on the power source 9................................................
6.3 Fan control 9...............................................................
6.4 Overheating protection 9.....................................................
6.5 Cooling unit 9...............................................................
6.6 Remote control unit 10........................................................
7 MAINTENANCE 10....................................................
7.1 Cleaning the air filter 10.......................................................
7.2 Topping up the coolant 11.....................................................
8 FAULT TRACING 11...................................................
9 ORDERING OF SPARE PARTS 11......................................
DIAGRAM 12............................................................
ORDERING NUMBER 15.................................................
SPARE PARTS LIST 16...................................................
ACCESSORIES 17.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source AristoMig U500 from serial number 304 complies with standard IEC/EN 60974--1, in
accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with
standard EN 50199 in accordance with the requirements of directive (89/336/EEC) and addendum
(93/68/EEC).
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Henry Selenius
Vice President
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2003--04--07
2SAFETY
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 recommen-
dations 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 welding
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 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.
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 PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
SInstall and earth the welding 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!
ESAB can provide you with all necessary welding protection and accessories.
WARNING!
Read and understand the instruction manual before installing
or operating.
Do not use the power source for thawing frozen pipes.
WARNING!
This product is solely intended for arc welding.
3 INTRODUCTION
The AristoMig U500 is a MIG/MAG / TIG welding power source, which can also be
used for MMA welding.
There are two variants of the power source:
SAristoMig U500 without cooling unit
SAristoMig U500 with cooling unit
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NB: These instructions describe an AristoMig U500 with a cooling unit.
The power source is intended for use with the AristoFeed 30 or AristoFeed 48 wire
feed units.
All the settings are made from the wire feed unit or control box AristoPendant U8.
ESAB’s accessories for the product can be found on page 17.
3.1 Equipment
The AristoMig U500 power source is supplied complete with terminating resistor, 5m
return cable and instruction manual.
4 TECHNICAL DATA
AristoMig U500
Mains voltage 400V, ±10%, 3∼50/60 Hz
Primary current
Imax MIG/MAG
Imax MMA
Imax TIG
39 A
40 A
31 A
No--load power demand when in the energy--saving mode,
6.5 min. after welding 50 W
Voltage/current range
MIG/MAG
MMA
TIG
8--60 V / 16--500 A
16-- 500 A
4 -- 500 A
Permissible load at MIG/MAG
60 % duty cycle
100% duty cycle 500 A / 39 V
400 A / 34 V
Permissible load at MMA
60 % duty cycle
100% duty cycle 500 A / 40 V
400 A / 36 V
Permissible load at TIG
60 % duty cycle
100% duty cycle 500 A / 30 V
400 A / 26 V
Power factor at maximum current 0.85
Efficiency at maximum current 86 %
Open--circuit voltage
MIG/MAG
MMA
TIG
72 -- 88 V
68 -- 80 V
72 -- 88 V
Operating temperature -- 1 0 t o + 4 0 ˚C
Dimensions, lxwxh
with cooling unit 625 x 394 x 496 mm 625 x 394 x 776 mm
Continual A--weighted sound pressure <70 db
Weight
with cooling unit 69 kg 89 kg
Insulation class transformer H
Enclosure class IP 23
Application class
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Cooling unit
Cooling power 2500 W at 40˚C temp. difference and flow1.5
l/min
Coolant 50 % water / 50% glycol
Coolant quantity 5.5 l
Maximum water flow 2.0 l/min
Maximum number of water--cooled welding
guns/torches that may be connected two MIG welding guns or one TIG torch and one MIG welding gun
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.
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.
5 INSTALLATION
The installation must be executed by a professional.
WARNING!
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.
5.1 Lifting instructions
Power source Trolley and power source Trolley2 and power source
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5.2 Placing
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
5.3 Mains power supply
Check that the unit is connected to the correct mains power
supply voltage, and that it is protected by the correct fuse sizes.
A protective earth connection must be made, in accordance
with regulations.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable areas
AristoMig U500 400 V 3µ50 Hz
Mains voltage 400 V
Mains cable area, mm24G6
Phase current, I RMS 31 A
Fuse
Anti--surge
Type C MCB 35 A
40 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.
5.4 Terminating resistor
In order to avoid communication interference, the ends
of the CAN bus must be fitted with terminating
resistors.
One end of the CAN bus is at the control panel, which
has an integral terminating resistor. The other end at
the power source must be fitted with the terminating
resistor, as shown on the right.
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6OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
6.1 Connections and control devices
1Connection for cooling water from the TIG
torch -- RED 10 White indicating lamp -- Power supply ON
2Connection with ELP* for cooling water to
the TIG torch -- BLUE 11 Orange indicating lamp -- Overheating
3Cooling water filler 12 Fuse
4Connection for welding current cable (+)
at MMA welding or for return cable at TIG
welding
13 Connection for control cable to the wire
feed unit or to the terminating resistor
5Connection for remote control 14 Connection for gas hose
6Connection for return cable (--) or for wel-
ding current cable at TIG welding 15 Connection for welding current to the wire feed unit
7Connection for start signal from the torch. 16 Connection for cooling water to the wire
feed unit -- BLUE
8Connection for gas to the TIG torch 17 Connection for cooling water from the wire
feed unit -- RED
9Main power supply switch, 0 / 1 / START
* ELP = ESAB Logic Pump, see point 6.5
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6.2 Turning on the power source
Turn on the mains power by turning switch (7) to the ”START” position. Release the
switch, and it will return to the ”1” position.
If the mains power supply should be interrupted while welding is in progress, and
then be restored, the power source will remain de--energised until the switch is again
turned manually to the ”START” position.
Turn the unit off by turning the switch to the ”0” position.
Whether in the event of a loss of power supply or of turning the power source off in
the normal manner, welding data will be stored so that it is available next time the
unit is started.
6.3 Fan control
The power source fans continue to run for 6,5 minutes after welding has stopped,
and the unit switches to energy--saving mode. They start again when welding
restarts.
The fans run at reduced speed for welding currents up to 180 A, and at full speed for
higher currents.
6.4 Overheating protection
The power source has three thermal overload trips which operate if the internal
temperature becomes too high, interrupting the welding current and lighting the
orange indicating lamp on the front of the unit. They reset automatically when the
temperature has fallen.
6.5 Cooling unit
Water connection (TIG welding)
The cooling unit is equipped with a detection system ELP (ESAB Logic Pump)
which checks that the water hoses are connected.
The power source On/Off switch must be in the “0” position (Off) when connecting a
water--cooled TIG torch.
If a water--cooled TIG torch is connected, the water pump starts automatically when
the main On/Off switch is turned to ”START” and/or when welding starts. After
welding, the pump continues to run for 6,5 minutes, and then switches to the
energy--saving mode.
Function when welding
To start welding, the welder presses the welding gun trigger switch. The power
source turns on and starts the wire feed and the cooling water pump.
To stop welding, the welder releases the welding gun trigger switch. Welding ceases,
but the cooling water pump continues to run for 6,5 minutes, after which the unit
switches to energy--saving mode.
Water flow guard
The water flow guard interrupts the welding current in the event of loss of coolant,
and displays an error message on the control panel. The water flow guard is an
accessory.
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6.6 Remote control unit
The program version in AristoPendant U8 should be 1.20 or higher. Aristo machines
with intergral control panels should have program version 1.21 or higher, in order for
the remote control to function correctly.
When the remote control unit is connected, the power source and wire feed unit are
in remote control mode; the buttons and knobs are blocked. The functions can only
be adjusted via the remote unit.
If the remote control unit is not to be used, the remote control unit must be
disconnected from the power source / wire feed unit, as otherwise it will remain in
remote control mode.
For more information about the operation of the remote control unit, see the
operating instructions for the control panel.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Maintenance must be executed by a professional.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
Note!
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.
7.1 Cleaning the air filter
SRelease the cover plate with the dust
filter (1).
SSwing out the cover plate (2).
SRemove the dust filter (3).
SBlow it clean with compressed air at
reduced pressure.
SReplace the filter with the finer mesh
on the side against the cover plate (2).
SReplace the cover plate with the filter.
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7.2 Topping up the coolant
We recommend a 50/50 % mixture of water and ethylene
glycol.
Top up with coolant until it is up to the level of the filling hole.
8 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised
service technician.
Type of fault Action
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.
SCheck the fuse.
Welding current is interrupted during welding SCheck whether the thermal overload trips
have operated (indicated by the orange
lamp on the front panel).
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 electrodes are being
used.
SCheck the main power supply fuses.
9 ORDERING OF SPARE PARTS
AristoMig U500 is designed and tested in accordance with the international an Europe-
an standards IEC/EN 60974--1 and EN 50199.
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.
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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Diagram
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Cooling unit

AristoMig U500
Edition 050517
Ordering number
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1.
Ordering no. Denomination Type Notes
0459 230 885 Welding power source AristoMig U500
0459 230 886 Welding power source AristoMig U500 with cooling unit
0459 291 990 Spare part list AristoMig U500
The spare parts list is available on the Internet at www.esab.com
Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page where you can
both search for and download instruction manuals and spare parts lists.

AristoMig U500
Edition 050517
Spare parts list
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Item Qty Ordering no. Denomination
10458 398 001 Filter
20458 383 001 Front grill

AristoMig U500
Edition 050517
Accessories
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Trolley forAristoMig ...................... 0458 530 880
Trolley 2 for AristoMig (for feeder with
counterbalance device and/or 2 gas bottles) . 0458 603 880
Guidepin............................... 0458 731 880
Autotransformer TUA2 ................... 0459 145 880
Handle (1 piece) with mounting screws . . 0459 307 881

AristoMig U500
Edition 050517
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Feeder stand ............................ 0458 522 880
Remote control adapter RA12 12pole ....
For analogue remote controls to CAN based
equipment.
0459 491 910
RemotecontrolunitMTA1CAN ..........
MIG/MAG: wire feed speed and voltage
MMA: current and arc force
TIG: current, pulse and background current
0459 491 880
RemotecontrolunitM110ProgCAN......
Choice of on of 10 programs
MIG/MAG: voltage deviation
TIG and MMA: current deviation
0459 491 882
RemotecontrolunitAT1CAN ............
MMA and TIG: current
0459 491 883
RemotecontrolunitAT1CFCAN .........
MMA and TIG: rough and fine setting of
current.
0459 491 884

AristoMig U500
Edition 050517
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Remote control cable 12 pole -- 4 pole
5m ....................................
10m ...................................
15m ...................................
25m....................................
0.25m .................................
0459 554 880
0459 554 881
0459 554 882
0459 554 883
0459 554 884
Connection set
1.7m ..................................
5m ....................................
10m ...................................
15m ...................................
25m ...................................
35m ...................................
Connection set water
1.7m ..................................
5m ....................................
10m ...................................
15m ...................................
25m ...................................
35m ...................................
0456 528 880
0456 528 890
0456 528 881
0456 528 882
0456 528 883
0456 528 884
0456 528 885
0456 528 895
0456 528 886
0456 528 887
0456 528 888
0456 528 889
Return cable 5m70mm
2............... 0156 743 881
Water flow guard 0.7l/min ............... 0456 855 880
MMC kit AristoMig ....................... 0459 579 880
Connection set
for connection of two wire feed units ........ 0459 546 880

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]
www.esab.com
041227
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Tel: [phone]
Fax: [phone]
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Tel: [phone]
Fax: [phone]
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Tel: [phone]
Fax: [phone]
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Tel:[phone]
Fax:[phone]
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Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com