AristoPower 460 - ESAB Welding & Cutting Products
Contents
1. 466801881 Use this option to access 5 different weld schedules saved to memory locations 1 through 5 Arc trim is remotely controlled from the box Aristo Control 5 Program Bar 466515881 The option has the same function as the 5 Program Box yet is more compact and mobile Aristo Synergic Control Box 466801880 Provides remote control for synergic wire feed speed and voltage trim Aristo Synergic Control Bar 466515880 The option has the same function as the Synergic Box yet is more compact and mobile SECTION 2 DESCRIPTION 2 1 SAFETY Before the AristoPower 460 power source is put into operation the safety section atthe front ofthis manual should be read completely This will help avoid possible injury due to misuse or improper installation The definitions relating to the ARICA A ZEN ACT safety notations are described end of the Safety Section in the front of this manual read them and their specific text references carefully 2 2 DESCRIPTION This manual has been prepared for use by an experienced operator It provides information to familiarize the operator with the design installation and operation of the AristoPower 460 power source DO NOT attempt install or operate this equipment until you have read and fully understand these instructions The information presented here should be given2. 460 460 230 230 230 460 MO 60 T 230 YA a 460 7 J e E 30 gov 10 9 230 Vac Input 460 Vac Input 575 Vac Input Figure 3 3 Input Terminal Board Configuration for 230 460 575 Model factory supplied in the 575 configuration vd 4 230 Vac Input 200 Input 400 Input Figure 3 4 Input Terminal Board Configuration 230 Figure 3 5 Input Terminal Board Configuration 200 460 Model factory supplied in the 460 configuration 400 Model factory supplied in the 400 configuration 18 SECTION 3 TETE Be sure that the branch circuit or main disconnect switch is off or electrical input fuses are removed before at tempting any inspection or work inside the power source Placing the power switch in the off position does not remove all power frominside the power source INSTALLATION D OUTPUT WELDING CONNECTIONS SECONDARY The output connections are located on the front panel Figure 2 3 The positive connection is located at the bottom left corner and the negative connection 1 located the bottom right corner An additional twist lock connect is available on the rear panel In most instances the work cable is connected to the negative output terminal lug Table 3 6 provides the
3. 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a fire hazard 6 fter completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when necessary 7 For additional information refer to NFPA Standard 518 Fire Prevention in Use of Cutting and Welding Pro available from the National Fire Protection Asso ci N ation Batterymarch Park Quincy MA 02269 ELECTRICAL SHOCK Contact with live o electrical parts and ground can cause severe injury or death DO NOT use AC welding current in damp areas if move ment is confined or if there is danger of falling Be sure the power source frame chassis 15 connected to the ground system of the input power Connect the workpiece to a good electrical ground Connect the work cable to the workpiece poor or missing connection can expose you or others to a fatal shock Use well maintained equipment Replace worn or dam aged cables Keep everything dry including clothing work area cables torch electrode holder and power source Make sure that all parts of your body are insulated from work and from ground Do not stand directly metal or the earth while working in tight quarters or a damp area stand on dry boards or an insulating platform and wear rubber soled shoes Put
4. AZL 6 24 lt 0 9 V NVO EL Y V S0y 008550 24 TROUBLESHOOTING SECTION 6 969008550 LIM 3S0H 318v9 vorso 08550 LIM 07 008660 WVYOVIC SONIMVJO 39N3383333 XLEXV 11 11 2 6 8 4 9 6 9 7 t zar IHM 933 6 11 282 8 11 11 X SsX2 1 X 9X2 X vYX2 1 9x8 11 X sx8 11 9 1 5 1 OIA 1 189 134 63 7894 134 23 282d 134 13 899 134 13 789 NYO LH 1824 039 ZH 189d ma lt 14 99 9H 182d ZH 189d 79 o lt NYO v0 282d 033 69 6854 0 282d YOLOJNNOD NVI 6 JO 1 214 1 NVI 1894 9 AS2S 09p 0 Z 09p 5 194194 INYO ZNv2 18224 v 1 185 v pna 858 e el 1 19 038 6Nv2 182d Z nya Ix 182d Z 134 8 281 z anvo 624 H 1 334 EAS AI du 11130 33S 7834 X 89d Y 2839 Bu 1V130 1HM 11 581 1933 0933 9 1894 118 959 1893 118 79 1893 ______ rfs 8 ms 7 298 EE 49d 9 Ju 33S 8 Y AIYO 894 3015 13 1NOYJY CT
5. du secteur l on ex cute des soudures ou des coupes l arc moins de les recouvrir compl tement d une b che non inflammable Ce type de mat riaux comprend notamment le bois les v tements la sciure l essence le k ros ne les peintures les solvants le gaz naturel l ac tyl ne le propane et autres substances combus tibles semblables Les tincelles ou les projections de m tal incandescent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y d clencher une ignition lente cach e Veiller prot ger ces ouvertures des tincelles et des projections de m tal N ex cutez pas de soudures de coupes d op rations de gougeage ou autres travaux chaud la surface de barils bidons r servoirs ou autres contenants usag s avant de les avoir nettoy s de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques En vue d assurer la pr vention des incendies il convient de disposer d un mat riel d extinction pr t servir imm diatement tel qu un tuyau d arrosage un seau eau un seau de sable ou un extincteur portatif Une fois le travail l arc termin inspectez le secteur de fa on vous assurer qu aucune tincelle ou projection de m tal incandescent ne risque de provoquer ult rieurement un feu CHOC LECTRIQUE Le gougeage l arc et l arc au plasma exige l emploi de tensions vide relativement importantes or cel
6. Be Alert Your safety is involved Means immediate hazards which if EXT 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 Means hazards which could result in CAUTION minor personal injury SECTION 1 ADVERTENCIA Estas Precauciones de Seguridad son para su protecci n Ellas hacen resumen de informaci n proveniente de las referencias listadas en la secci n Informaci n Adicional Sobre La Seguridad Antes de hacer cualquier instalaci n o procedimiento de operaci n aseg rese de leer y seguirlas precauciones de seguridad listadas a continuaci n as como tambi n todo manual hoja de datos de seguridad del material calcomanias etc El no observar las Precauciones de Seguridad puede resultar en da o a la persona o muerte PROTEJASE USTED Y A LOS DEMAS Algunos procesos de soldadura corte y p ranurado son ruidosos y requiren protecci n QE para los oidos El arco como el sol emite rayos ultravioleta UV y otras radiaciones que pueden danar la piel y los ojos El metal caliente causa quemaduras EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes Por lo tanto 1 Utilice gafas de seguridad con protecci n a los lados siempre que est en el rea de trabajo a n cuando est usando careta de soldar protector para su cara u o
7. The feeder can freely rotate relieving potential wire feed problems caused by sharp bends in the gun cable while at the same time increasing the radius of the working area 135 SECTION 3 Do not use filters on this unit as they would restrict the volume of intake air required for proper cooling Output ratings on this unit are based on an unobstructed supply of cooling air drawn over its internal components Warranty is void if any type of filtering device is used For lifting purposes and for keeping dust moisture and other foreign ma terial from entering the power source the lifting eyebolt must be fully tight ened with a tool WARNING ELECTRIC SHOCK KILL Before making electrical input connections to the power source Machinery Lockout Procedures should be em ployed If the connections are to be made from a line disconnect switch place the switch in the off position and padlock it to prevent inadvertent tripping the connection is made from a fuse box remove the corre sponding fuses and padlock the box cover If itis not possible to use pad locks attach a red tag to the line disconnect switch orfuse box warn ing others that the circuit is being worked on INSTALLATION 3 1 INSTALLATION A LOCATION A proper installation site is necessary for the power source to provide dependable service A proper installation site permits freedom of air movement through the unit while minimizing
8. careful consideration to ensure proper installation and optimum weld performance of this equipment Table 2 1 Rating Label for AristoPower 460 ESAB WELDING amp CUTTING PRODUCTS IV NEZ ARISTOPOWER MULTIPOWER 460 TEN ON 50A 14V 500A 40V E U MAX X 6096 100 se 5004 450 7 gts U 40A 38A INPUT U P 3a DD 60 Hz 230 76A 66A 400 38A 33A COOLING AF IP 21 575V 31 26A 954672 B 4 02 The AristoPower 460 power source is a constant current CC and constant voltage CV three phase secondary chopper dc design with solid state contactor and control circuitry This is a multi process power source designed to provide the volt ampere characteristics desired for conventional MIG GMAW and flux core FCAW arc welding in the CV constant voltage mode Mig Pulse GMAW P arc or stick SMAW welding and air carbon arc cutting gouging CAC A in the CC constant current mode Table 2 1 outlines the electrical and physical specifications 12 SECTION 2 DESCRIPTION Features Auto Fan The AristoPower 460 fan will run when the power source 15 first powered up and will remain running for 30 seconds then shut down The fan will start again when welding begins The fan will remain running for 6 5 minutes after welding stops and then shut down automatically i
9. completely under the base C PRIMARY INPUT ELECTRICAL CONNECTION This power source is a three phase unit and must be connected to a three phase power supply It is recommended that the unit be operated on a dedicated circuit to prevent impairment of performance due to an overloaded circuit 1 The primary power leads must be insulated copper conductors Three power leads and one ground wire are required Either rubber covered cable or conduit flexible or solid may be used Table 3 1 provides recommended input conductors and line fuse sizes 2 Remove the top cover Identify primary power input connection block chassis ground lug on the fan shroud frame and primary input terminal board Refer to Figures 3 1 thru 3 5 3 When using the provided strain relief refer to Figure 3 2 for proper cable strip lengths It is important to follow the cable strip guide to ensure that if the primary input cable is ever pulled from the strain relief the input conductors will be pulled from the Terminal Block before the ground lead is pulled from the ground lug Once stripped thread the input and ground conductors through the large strain relief in the rear panel of the power source Connect the ground wire to the terminal lug located on the fan shroud frame Connect the primary power leads to terminals L1 L2 and L3 on the input power block Secure the strain relief on the input cable 4 Check all connections for proper tightness Ensure all connectio
10. energy savings Automatically turns the fan motor on and off Convenient 115vac auxiliary power receptacle Compatible with AristoDrive 4 30 and AristoDrive 4 48 wire feeders NAS Tweco style Quick Disconnect gun to feeder connection is standard DESCRIPTION YEAR WARRANTY Shown with AristoDrive 4 30 wire feeder GM 400 Mig welding torch TR 29 truck kit work cable clamp and welding wire Specifications Rated DC Output 100 Duty Cycle 50 60HZ CV CC 450 amps 38 vdc Rated DC Output 60 Duty Cycle DO COZ CV Or 500 amps 39 vdc Welding Range 10A 12V to 500A 40V Open Circuit Voltage 80vdc Primary Input Voltage and Current Y 100 DutyCycle 230 460 575vac 60Hz 3ph 66 33 26 amps Power Factor at Rated Output 89 Efficiency at Rated Output 92 Auxiliary Output Power 115vac 50 60Hz 10 amps Physical Dimensions WxLxH 18 8 483mm 32 5 819mm 25 622 in ne A 322 155 146 Kg Shipping Weight nn 375 lbs 170Kg Build a Custom AristoPower Welding System TM 1 TM AristoPow er 4 Connection Cable Pow er Source Wire Feeder 64 2m 0456527880 AristoDrive 4 30 0558003276 AristoDrive 4 48 Balance Boom 16ft 0558003365 10 0558003275 AristoPow er 460 Aristo
11. les v tements la sciure l essence le k ros ne les peintures les solvants le gaz naturel l ac tyl ne le propane et autres substances combus tibles semblables Les tincelles ou les projections de m tal incandescent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y d clencher une ignition lente cach e Veiler prot ger ces ouvertures des tincelles et des projections de m tal N ex cutez pas de soudures de coupes d op rations de gougeage ou autres travaux chaud la surface de barils bidons r servoirs ou autres contenants usag s avant de les avoir nettoy s de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques En vue d assurer la pr vention des incendies il convient de disposer d un mat riel d extinction pr t servir imm diatement tel qu un tuyau d arrosage un seau eau un seau de sable ou un extincteur portatif Une fois le travail l arc termin inspectez le secteur de fa on vous assurer qu aucune tincelle ou projection de m tal incandescent ne risque de provoquer ult rieurement un feu CHOC LECTRIQUE Le gougeage l arc et l arc au plasma exige l emploi de tensions vide relativement importantes or celles ci risquent de causer des dommages corporels graves et m me mortels en cas d utilisation inad quate La gravit du choc lectrique recu d pend du chemin suivi par le courant tra
12. n adicional haga referencia a la publicaci n NFPA Standard 518 Fire Prevention in Use of Cutting and Welding Processes disponible a trav s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 CHOQUE ELECTRICO El contacto con las partes el ctricas energizadas y tierra puede causar da o severo o muerte NO use soldadura de corriente alterna AC en reas h medas de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo 1 Aseg rese de que el chasis de la fuente de poder est conectado a tierra atrav s del sistema de electricidad primario 2 Conecte la pieza de trabajo a un buen sistema de tierra f sica 3 Conecte el cable de retorno a la pieza de trabajo Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque el ctrico fatal 4 Use el equipo solamente si est en buenas condiciones Reemplaze cables rotos da ados o con conductores expuestos 5 Mantenga todo seco incluyendo su ropa el rea de trabajo los cables antorchas pinza del electrodo y la fuente de poder 6 Aseg rese que todas las partes de su cuerpo est n insuladas de ambos la pieza de trabajo y tierra 7 Nose pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o reas h medas trabaje sobre un pedazo de madera seco una plataforma insulada y use zapatos con suela de goma 8 Use guantes secos y sin a
13. units can be connected to the Aristo via the Remote Control Adaptor A REMOTE PROGRAM AND SYNERGIC CONTROLS SEE OPTIONS amp ACCESSORIES PG 11 The remote control adapter converts analog signals from the remote control to a digital signal which is transmitted to the power source Power ON Lamp Figure 2 2 Standard Control Panel 14 SECTION 2 DESCRIPTION 115 Vac 42Vac and 115 Receptacle Switch Circuit Breakers Component Connection Positive Input Cable Component Receptacles Output Strain Relief Connection Secondary Receptacle Receptacles Weld Cable Figure 2 3 Front View Connection Lugs Figure 2 4 Rear View When the adapter is connected the power source and wire feed unit 15 in remote control mode the buttons on the MMC control man machine communications mounted in the wire feeder are blocked and only adjustment of the voltage and wire feed speed trim is allowed When a remote control unit is used the function will be changed to the setting of current during MMA welding Only one adapter may be connected to the welding system B TR 29 TRUCK KIT PN 37924 This truck kit provides complete mobility of the power source The kit consists of front castors rear cylinder rack and wheels gas cylinder bracket cylinder chain and pull handle C SWIVEL MOUNT KIT PN 36172 This kit allows the wire feeder to be placed on an insulated swivel post on top of the power source
14. 0 hi wa en TT LE amp 320 3409 98185 N d 70 1 la gt 108 gt gt g ig 9899 9 33 9 Id 29 17 3 Ta 19 zA _ a Y 1 cda NE AE ER 001 O WHO 001 1 i ona OND IN3NdIN03 M pi 3svHd nit XS ML SIIOA 097 055 WA 4 1 ASAZ POL y SITOA 009 066 one L70 0 zi LND 151 Ga Hg ar AA A 1 d KINO SINA 39 A00y 02 ZSL 24 E ees RS 12 gt 5 73 2854 vol 25 1 91 8 gt 7 28 11 2824 n o gt __ _____ 2 t n on m Ya X 2 2X IX 61 147 IN3NAINDI M ZH 09 ISVHd 6 6 097 052 V Gc0 008GG0 23 TROUBLESHOOTING SECTION 6 0308 NOISSIUAANS 7624 GANNILNOD 626 097 062 5 015 3 444 cad VA gt 430333 CN 2 AB 178 gt 37 gt lt NYOM ZA lt lt 1 lt AZL 6 I 1 lt 0 9 99 79 gt NY sis 9 gt 79 gt lt IX lt X 2 E 1824 12 9H gt CH gt LH gt 4 NA lt NVO L lt 1 9 lt
15. 85 SW THML D T 176 15A 120V Q D 0558003077 IGBT 600V 300A 951940 Capacitor 1 0uf 600VDC 10 34 Revision History The A revision updates the replacement parts section and editorial changes throughout this manual Replacement Parts listings and diagrams have also been updated See dneco 023350 revision changes the Control PC item number from 0486846884 to 0486958884 per CN 043009 35 ESAB Welding amp Cutting Products Florence SC Welding Equipment COMMUNICATION GUIDE CUSTOMER SERVICES A CUSTOMER SERVICE QUESTIONS Telephone 800 362 7080 Fax 800 634 7548 Hours 8 00 AM to 7 00 PM EST Order Entry Product Availability Pricing Order Information Returns B ENGINEERING SERVICE Telephone 843 664 4416 Fax 800 446 5693 Hours 7 30 AM to 5 00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations D LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Registrations G WE
16. A Craterfill Craterfill 0 0 Volt Hot Start Hot Start i ETE SO 100 Amps Wire Inch Im MIG PULSE STICK STEEL Fe 045 ER7018 BASIC Ar 8 5 CO2 120 AMPS 0 0 VOLTS 250 IN MIN 0 0 VOLTS 250 IN MIN SELECT MENU SELECT MENU SELECT MENU Settings Menu Configure Menu De 22 ee EAE Pulse Gouge Synergic W Type Gas Wire Diam W Type Gas Wire Diam Inductance Preflow Hot Start Carterfill Burnback Postflow E Type Preflow Hot Start Carterfill Burnback Postflow Arc Force Hot Start Options amp Accessories AristoPower 460 TR 29 Truck 37924 This truck kit provides complete mobility of the power source The kit consists of front casters rear cylinder rack for two cylin ders gas cylinder bracket and chain and pull handle Wire Feeder Swivel Mount Kit 36172 This kit allows the wire feeder to be placed on an insulated swivel post on top of the power source The feeder can freely rotate minimizing potential wire feed problems ESAT PC Software Package 0458847880 PC software for service diaignostics troubleshooting and upgrading PC is not included 11 MEMORY MENU Language Trigger Data Language Dimensions Panel Enable 23456789 EMPTY Dimensions Panel Enable Store Recall Delete Air Carbon Arc Gouging is selected as an electrode type Aristo Control 5 Program Box
17. AA 0 e Ts 1 re ES a 9 9 9 el e e gt OSSWOd v Tr tehar 8 18 824 mae 24 1809 2 zpme Jemo z a z iHs z 19 1894 2 iinva z S z8l 1582 me seame O aa tias 1 1 22681 i neo 22281 O A X M S 9 82d Va 11134 9 Do H 3 IOYLNOD NIVA V 907 008SS0 25 TROUBLESHOOTING SECTION 6 Qv3l 3135 5310 30 2 3914 5310 30 e AJO SALON 651 lt 9 65 lt 824 29 75 lt 824 GANNILNOD 626 097 0 lt 2 09 12MOJOJSLIY 39 6 19 1S 89d 151 O 11130 33S tal dOl 3SV8 Z3 189d NYO 13 18999 89 75 18249 le 751 IHM 12 1828 V 9H 61 5 8 IH V ZH 8 lt V CH 2 9 HL IS AY9_Z 1YSS 8 2 lt 8 lt 2 7 1 15 9 ZH 9 LH 2 lt LHM 2 1515 097 062 807 ma 3NVd 10 1 002 OIA 1999 90 50084940 26 SECTION 7 REPLACEMENT PARTS 7 1 REPLACEMENT PARTS Replacement Parts are illustrated on the fo
18. AristoPower 460 DC WELDING POWER SOURCES INSTRUCTION MANUAL This manual provides complete instructions for the following power sources starting with Serial Number MORJ30001 August 2002 ESAB ITEM NO 0558002668 AristoPower 460 230 460 575 vac 3 ph 60 Hz Revision B 0558003748 03 2004 BE SURE THIS INFORMATION REACHES THE OPERATOR These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment we urge you to read our booklet Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions If you do not fully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions before installing or operating this equipment USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and orinserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Malfunctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should b
19. CEMENT PARTS QTY ITEM CIRCUIT DESCRIPTION SYMBOL 0558002668 AristoPower Power 460cvcc 678025 Terminal Assembly 91514 Label Warning Arc Welding amp Cutting 954008 Danger High Voltage 9512240 Label Caution Lifting Eye 0558002969 Panel Right Side 950945 SW Pwr Disc 100A 600V 678025 Terminal Assembly 29 SECTION 7 0558002668 1312733 950219 0558001371 0558001370 DESCRIPTION AristoPower Power 460 Label for Install Use COP Wire Relief Strain 2 Non enclosed Panel Top Kydex Env Panel Left Side Kydex Env 30 REPLACEMENT PARTS CIRCUIT SYMBOL REPLACEMENT PARTS SECTION 7 a gt 0 2 D Q QTY ITEM REQ NO AristoPower Power 460 0558002668 Diode Fwd 200V 250A Diode Rev 200V 250A Fan Motor 1 3 HP 1625 RPM Label Warning Fan Hazard Blade Fan 14 5 or 6 Fin Inductor 7 Turn Label 3 Phase 9511916 9511915 954864 31 SECTION 7 0558002668 17280110 0558002712 672065 36110 REPLACEMENT PARTS 5 PE TUERI if DESCRIPTION SYMBOL AristoPower Power 460cvcc Res WW Fix d ST 100W 5 100 00 Transformer 230 460 575V Strap Terminal Board Input Terminal 230 460 575V 32 SECTION 7 REPLACEMENT PARTS EX E 4 6 QTY ITEM DESCRIPTION SYMBOL 0558002668 AristoPower Power 460cvcc 952938 SCR 480V 18A Panel MNT 951997 Transducer Current 9510
20. Drive 4 48 0456527881 0558002668 Boom System 52ft 16m 0558003700 821 25m Balance Boom 12ft 0456527883 pi 0456527884 Gunmaster 400 NAS Connection 12 ft x 035 045 15 ft x 035 045 Options amp Accessories Complete Y our Custom System by Ordering Components from the Options amp Accessories List on the follow ing page 12 ft x 052 1 16 15 ft x 052 1 16 Includes MA 6MMC See Boom Sales Sheets for complete information SECTION 2 MMA 6 MMC Man Machine Communications DESCRIPTION Easy to set weld parameters for MIG MIG Pulse Stick or Gouging Choose synergic weld parameters from of 107 possibilities wire feed speed and weld Internal Memory stores up to 10 different weld parameter set ups Recall parameters with a simple push of a button Programmable soft keys allow direct access to flexible functions such as hot start crater fill 2 4 stroke trigger wire inch gas purge etc Large display gives real time readout of voltage current and wire speed Preset inductance gas pre amp post flow inch or metric units auto weld schedule select arc force burnback and more Update and change Display Set the Voltage Set Wire Feed Speed and Current Set Soft Buttons Function Keys Menu Button weld data using optional ESAT software for maximum flexibility LA Stroke MIG Pulse a stroke STICK GOUGE MIG GMAW P SMAW CAC
21. HOCK CAN KILL Before making electrical input connections to the power source Machinery Lockout Procedures should be employed If the connections are to be made from a line disconnect switch place the switch in the off position and padlock it to pre vent inadvertent tripping If the connec tion is made from a fuse box remove the corresponding fuses and padlock the box cover If itis not possible to use padlocks attach a red tag to the line disconnect switch or fuse box warn ing others that the circuit is being OPERATION 4 1 OPERATION A WIRE FEEDER COMPATIBILITY The AristoPower 460 Pulse power source MUST be used with an AristoDrive wire feeder only There are two models available The AristoDrive 4 30 30 mm drive rolls and the AristoDrive 4 48HD 48 mm drive rolls B MA 6 MAN MACHINE COMMUNICATIONS Inthe MIG process mode the digital displays will read preset wire feed speed in inches per minute and preset arc volts when the PRESET button is pressed Once welding begins the displays will show average welding current and volts in the top and bottom display respectively The displays have a HOLD circuit that retains the welding conditions After welding stops the display will continue to show the last average welding current and voltage sampled for 10 seconds then returns to 0 worked on Figure 4 1 Wire Feed Speed amp Volts Display C TIG and STICK WELDING In the TIG and STICK process mo
22. LDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone 800 ESAB 123 Fax 843 664 4452 Hours 7 30 AM to 5 00 PM EST or visit us on the web at http www esabna com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback amp Support E S AB ESAB Welding amp Cutting Products PO Box 100545 Florence SC 29501 0545 0558003748 03 2004
23. OTECTION INDIVIDUELLE Les br lures de la peau et des yeux dues au rayonnement de lectrique ou du m tal incandescent lors du soudage au plasma ou l lectrode ou lors du gougeage Parc peuvent s av rer plus graves que celles r sultant d une exposition prolong e au soleil Aussi convient il d observer les pr cautions suivantes a Portez un cran facial ad quat muni des plaques protectrices et des verres filtrants appropri s afin de vous prot ger les yeux le visage le cou et les oreilles des tincelles et du rayonnement de l arc lectrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l ex cution AVERTISSEZ les personnes se trouvant proximit de facon ce qu elles ne regardent pas et a ce qu elles ne s exposent pas son rayonnement ni celui du m tal incandescent b Portez des gants ignifug s crispins une tunique paisse manches longues des pantalons sans rebord des chaussures embout d acier et un casque de soudage ou une calotte de protection afin d viter d exposer la peau au rayonnement de l arc lectrique ou du m tal incandescent est galement souhaitable d utiliser un tablier ininflammable de facon se prot ger des tincelles et du rayonnement thermique Les tincelles ou les projections de m tal incandescent risquent de se loger dans des manches retrouss es des bords relev s de pantalons ou dans des poches Aussi conv
24. adas para usted 2 3 ANSI ASC 249 1 Safety in Welding and Cutting AWS C5 1 Recommended Practices for Plasma Arc Welding AWS C52 Recommended Practices for Plasma Arc Cutting AWS C5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting AWS C5 5 Recommended Practices for Gas Tungsten Arc Welding AWS C5 6 Recommended Practices for Gas Metal Arc Welding AWS SP Safe Practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Weld ing and Cutting of Containers That Have Held Hazardous Substances SIGNIFICADO DE LOS SIMBOLOS Seg n usted avanza en la lectura de este folleto Los S mbolos Significan Atenci n Est Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser A 158 er evadido puede resultar inmediatamente en serio da o personal o la muerte Significa el riesgo de un peligro potencial EL que puede resultar en serio da o per sonal o la muerte Significa el posible riesgo que puede CUIDADO resultar en menores da os a la persona SECTION 1 AVERTISSEMENT Ces r gles de s curit ont pour objet d assurer votre protection Veillez a lire et observer les pr cautions nonc es ci dessous avant de quipement ou commercer l utiliser Tout d faut d observation de ces pr cautions risque d entra ner des blessures graves ou mortelles 1 PR
25. cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs can start fires Hot slag or sparks can also cause fires and ex plosions Therefore 1 Remove all combustible materials well away from the work area or cover the materials with a protective non flammable covering Combustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal 3 Do not weld cut or perform other hot work until the workpiece has been completely cleaned sothatthere are no substances on the workpiece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use SAFETY PRECAUTIONS
26. de you must depress and HOLD the PRESET button while presetting the welding current in the top display Releasing the preset button causes the display to return to zero Once welding begins the display will show average welding current and volts in the top and bottom display respectively After welding stops the current display will again return to zero There is no HOLD circuit for the display meters when using the TIG and STICK process modes AQUI The chassis must be connected to an approved electrical ground Failure to do so may result in electrical shock severe burns or death WARNING Checkthe voltage links for proper volt age on the Input Terminal board before applying primary power Amra Before making any connections to the power source output terminals make sure that all primary input power to the machine is off _ LI m E E d 7 d 1 M _ AE E o 1 La 3 p E pu 4 Pra _ Figure 4 2 Overall Front View 20 SECTION 5 MAINTENANCE 5 1 CLEANING Periodically remove the cover from the power source and blow accumulated dust and dirt from the air passages and interior components by using clean low pressure air The frequency of cleaning required depends upon the environment in which the power
27. e replaced immediately Should such repair or replacement become necessary the manufacturer that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased This equipment or any of its parts should not be altered without the prior written approval of the manufacturer The user of this equipment shall have the sole responsibility for any malfunction which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer Copies of this manual can be obtained by any of the following Contacting your local ESAB supplier Downloading a copy from the ESAB web site at www esabna com Sending a written request to ESAB WELDING amp CUTTING PRODUCTS ATTN LITERATURE DEPT 411 S EBENEZER ROAD FLORENCE SC 29501 SECTION SECTION SECTION SECTION SECTION SECTION SECTION SECTION TABLE OF CONTENTS TITLE PAGE e 4 DESCRIPTIONS wA A 10 D Ip AS ue AA 16 OPERA TION 20 e a 21 TROUBLESHOOTING M 22 REPLACEMENT PARTS siria iii 27 SECTION 1 WARNING These Safety Precautions are for A your protection They summarize precaution ary information from the referenc
28. er Do not use adaptors Maintain hoses and fittings in good condition Follow manufacturer s operating instructions for mounting regu lator to a compressed gas cylinder 2 Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercarriages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit 3 When notin use keep cylinder valves closed Have valve protection cap in place if regulator is not connected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders 4 Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder 5 For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 SAFETY PRECAUTIONS EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power 3 Maintain cables grounding wire connections power cord and power supply in
29. es ci dessous avant de monter quipement ou commercer l utiliser Tout d faut d observation de ces pr cautions risque d entra ner des blessures graves ou mortelles 1 PROTECTION INDIVIDUELLE Les br lures de la peau et des yeux dues au rayonnement de l arc lectrique ou du m tal incandescent lors du soudage au plasma ou a l lectrode ou lors du gougeage l arc peuvent s av rer plus graves que celles r sultant d une exposition prolong e au soleil Aussi convient il d observer les pr cautions suivantes a Portez un cran facial ad quat muni des plaques protectrices et des verres filtrants appropri s afin de vous prot ger les yeux le visage le cou et les oreilles des tincelles et du rayonnement de l arc lectrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l ex cution AVERTISSEZ les personnes se trouvant proximit de facon ce qu elles ne regardent pas l arc et ce qu elles ne s exposent pas son rayonnement ni celui du m tal incandescent b Portez des gants ignifug s crispins une tunique paisse manches longues des pantalons sans rebord des chaussures embout d acier et un casque de soudage ou une calotte de protection afin d viter d exposer la peau au rayonnement de l arc lectrique ou du metal incandescent Il est galement souhaitable d utiliser un tablier ininflammable de fa on se prot ger des tincelles et du rayonnement therm
30. es listed in Additional Safety Information section Before performing any installation or operating procedures be sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in injury or death PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy and require ear protection The arc like the sun emits ultraviolet UV and other radiation and can injure skin and eyes Hot metal can cause burns Training in the proper use of the processes and equip ment is essential to prevent accidents Therefore EVA 1 Always wear safety glasses with side shields in any work area even if welding helmets face shields goggles are also required 2 Use a face shield fitted with the correct filter and cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observing operations Warn bystanders notto watch the arc and not to expose themselves to the rays the electric arc or hot metal 3 Wearflameproof gauntlettype gloves heavy long sleeve shirt cuffless trousers high topped shoes and a weld ing helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks 4 Hot sparks or metal can lodge in rolled up sleeves trouser
31. exposure to dust dirt moisture and corrosive vapors A minimum of 18 inches 46 cm is required between the side and rear panels of the power source and the nearest obstruction The selected site should also allow easy removal of the power source outer enclosure for maintenance See Specifications pg 10 for overall dimensions of the unit B RECEIVING UNPACKING AND PLACEMENT When requesting information concerning this equipment it is essential that Item number Serial number and Model number of the equipment be supplied 1 Upon receipt remove all packing material and carefully inspect for any damage that may have occurred during shipment Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier A copy ofthe bill of lading and freight bill will be furnished by the carrier on request 2 Remove the power source from the container Remove all packing materials Check the container for any loose parts 3 Checkair passages at front and rear of cabinet making sure that packing material has not obstructed air flow through the power source 4 Install the lifting bolt furnished with the power sources into the top of the unit 5 After selecting an installation site place the power source in the desired location The unit may be lifted either by using the lifting bolt or by forklift truck If a forklift is used for lifting the unit be sure that the lift forks are long enough to extend
32. f welding has not continued Stainless steel frame for envirornmental durability Durable composite side and top panels will not corrode 100 duty cycle at 450 amps output Upgrade and reconfigure with ESAT ESAB Software Administration Tool software VOLT AMPERE CHARACTERISTICS The curves shown in Figure 2 1 represent the static volt ampere character istics for the power source The slant of these curves is referred to as the slope and is generally defined as the voltage drop per 100 amperes of current use These curves show the output voltage available at any given output current from the minimum to the maximum setting of the voltage current control B FRONT AND REAR PANEL DESCRIPTION 1 POWER ON OFF SWITCH LAMP The main power switch is located on the right front panel ofthe power source This switch energizes the main transformer control circuitry and illuminates the Power ON lamp 90 O 2 5 30 20 Cohstant Current 10 Constant Voltage 0 0 100 200 300 400 500 600 Weld Current Amperes Figure 2 1 MultiPower 460 Volt Ampere Curves 13 SECTION 2 Fault Temperature Lamp DESCRIPTION 2 FAULT TEMPERATURE LAMP The FAULT TEMP lamp illuminates if an over temperature condition occurs Within the AristoPower 460 power source This condition may be ca
33. gujeros antes de energizar el equipo 9 Apage el equipo antes de quitarse sus guantes 10 Use como referencia la publicaci n ANSI ASC Standard Z49 1 listado en la pr xima p gina para recomendaciones espec ficas de como conectar el equipo a tierra No confunda el cable de soldar a la pieza de trabajo con el cable a tierra CAMPOS ELECTRICOS Y MAGNETICOS Sonpeligrosos La corriente el ctrica fluye atrav s de cualquier conductor causando a nivel lo cal Campos El ctricos y Magn ticos Las corrientes en el rea de corte y soldadura crean alrrededor de los ES cables de soldar y las maquinas Por lo tanto 1 Soldadores u Operadores que use marca pasos para el coraz n deber n consultar a su m dico antes de soldar El Campo Electromagn tico EMF puede interferir con algunos marca pasos 2 Exponerse a campos electromagn ticos EMF puede causar otros efectos de salud a n desconocidos 3 Los soldadores deber n usar los siguientes procedimientos para minimizar exponerse al EMF A Mantenga el electrodo y el cable a la pieza de trabajo juntos hasta llegar ala pieza que usted quiere soldar Aseg relos uno junto al otro con cinta adhesiva cuando sea posible B Nunca envuelva los cables de soldar alrededor de su cuerpo C Nunca ubique su cuerpo entre la antorcha y el cable a la pieza de trabajo Mantega los cables a un s lo lado de su cuerpo D Conecte el cable de trabajo a la pieza de traba
34. ide adequate ventilation in the work area by natural or mechanical means Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials 2 Do not operate near degreasing and spraying opera tions The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gases 3 If you develop momentary eye nose or throat irritation while operating this is an indication that ventilation is not adequate Stop work and take necessary steps to im prove ventilation in the work area Do not continue to operate if physical discomfort persists 4 Refer to ANSI ASC Standard Z49 1 see listing below for specific ventilation recommendations 5 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health 8 Safety Code 525249 5 et seq CYLINDER HANDLING Cylinders if 927 mishandled can rupture and violently 2 YA da E dE release gas Sudden rupture of cylin gt 7 der valve or relief device can injure 9 x kill Therefore 1 Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylind
35. ient il de garder boutonn s le col et les manches et de porter des v tements sans poches l avant d Prot gez des tincelles et du rayonnement de l arc lectrique les autres personnes travaillant proximit l aide d un cran ininflammable ad quat e Ne jamais omettre de porter des lunettes de s curit lorsque vous vous trouvez dans un secteur ou l on effectue des op rations de soudage ou de coupage l arc Utilisez des lunettes de s curit crans ou verres lat raux pour piquer ou me ler le laitier Les piquetures incandescentes de laitier peuvent tre projet es des distances consid rables Les personnes se trouvant proximit doivent galement porter des lunettes de protection f Le gougeage l arc et le soudage l arc au plasma produisent un niveau de bruit extr mement lev de 100 114 dB et exigent par cons quent l emploi de dispositifs appropri s de protection auditive 2 PREVENTION DES INCENDES Les projections de laitier incandescent ou d tincelles peuvent provoquer de graves incendies au contact de mat riaux com bustibles solides liquides ou gazeux Aussi faut il observer les pr cautions suivantes Th PR CAUTIONS DE S CURIT loigner suffisamment tous les mat riaux combustibles du secteur l on ex cute des soudures ou des coupes l arc moins de les recouvrir compl tement d une b che non inflammable Ce type de mat riaux comprend notamment le bois
36. ique Les tincelles ou les projections de m tal incandescent risquent de se loger dans des manches retrouss es des bords relev s de pantalons ou dans des poches Aussi convient il de garder boutonn s le col et les manches et de porter des v tements sans poches l avant d Prot gez des tincelles et du rayonnement de l arc lectrique les autres personnes travaillant proximit l aide d un cran ininflammable ad quat e Ne jamais omettre de porter des lunettes de s curit lorsque vous vous trouvez dans un secteur effectue des op rations de soudage ou de coupage l arc Utilisez des lunettes de s curit crans ou verres lat raux pour piquer ou me ler le laitier Les piquetures incandescentes de laitier peuvent tre projet es des distances consid rables Les personnes se trouvant proximit doivent galement porter des lunettes de protection f Le gougeage l arc et le soudage l arc au plasma produisent un niveau de bruit extr mement lev de 100 114 dB et exigent par cons quent l emploi de dispositifs appropri s de protection auditive 2 PREVENTION DES INCENDES Les projections de laitier incandescent ou d tincelles peuvent provoquer de graves incendies au contact de mat riaux com bustibles solides liquides ou gazeux Aussi faut il observer les pr cautions suivantes Th PR CAUTIONS DE S CURIT loigner suffisamment tous les mat riaux combustibles
37. jo lo m s cercano posible al rea de la soldadura E Mantenga la fuente de poder y los cables de soldar lo m s lejos posible de su cuerpo SECTION 1 HUMO Y GASES El humo y los gases pueden causar malestar da o particularmente en espacios sin ventilaci n No inhale el humo o gases El gas de protecci n puede causar falta de ox geno Por lo tanto Siempre provea ventilaci n adecuada en el rea de trabajo por medio natural o mec nico No solde corte o ranure materiales con hierro galvanizado acero inoxidable cobre zinc plomo ber lio o cadmio a menos que provea ventilaci n mec nica positiva No respire los gases producidos por estos materiales No opere cerca de lugares donde se aplique substancias qu micas en aerosol El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosf geno o gas t xico y otros irritant es 3 Si moment neamente desarrolla inrritaci n de ojos nariz ogarganta mientras est operando es indicaci n de que la ventilaci n no es apropiada Pare de trabajar y tome las medidas necesarias para mejorar la ventilaci n en el rea de trabajo No contin e operando si el malestar f sico persiste 4 Haga referencia a la publicaci n ANSI ASC Standard 249 1 Vea la lista a continuaci n para recomendaciones espec ficas en la ventilaci n 5 ADVERTENCIA Este producto cuando se utiliza para soldaduras o cortes
38. les ci risquent de causer des dommages corporels graves et m me mortels en cas d utilisation inad quate La gravit du choc lectrique recu d pend du chemin suivi par le courant travers le corps humain et de son intensit Ne laissez jamais de surfaces m talliques sous tension venir au contact direct de la peau ou de v tements humides Veillez porter des gants bien secs Si vous devez effectuer un travail sur une surface m tallique ou dans un secteur humide veillez assu rer votre isolation corporelle en portant des gants secs et des chaussures semelles de caoutchouc et en vous tenant sur une planche ou une plate forme s che Mettez toujours la terre le poste de soudage coupage en le reliant par un c ble une bonne prise de terre N utilisez jamais de c bles us s ou endommag s Ne surchargez jamais le cable Utilisez toujours un quipement correctement entretenu Mettez l quipement hors tension lorsqu il n est pas en service une mise la masse accidentelle peut en effet provoquer une surchauffe de l quipement et un danger d incendie Ne pas enrouler ou passer le cable autour d une partie quelconque du corps V rifiez si le c ble de masse est bien reli la pi ce en un point aussi proche que possible de la zone de travail Le branchement des c bles de masse du b timent ou en un point loign de la zone de travail augmente en effet le risque de passage d un coura
39. llowing figures When ordering re placement parts order by part number and part name as illustrated on the figure Always provide the series or serial number of the unit on which the parts will be used The serial number is stamped on the unit nameplate 7 2 ORDERING To assure proper operation it is recommended that only genuine ESAB parts and products be used with this equipment The use of non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB distributor or from ESAB Welding amp Cutting Products Attn Customer Service Dept P O Box 100545 411 S Ebenezer Road Florence SC 29501 0545 Be sure to indicate any special shipping instructions when ordering replace ment parts To order parts by phone contact ESAB at 1 843 664 5540 Orders may also be faxed to 1 800 634 7548 Be sure to indicate any special shipping instructions when ordering replacement parts Refer to the Communication Guide located on the last page of this manual for a list of customer service phone numbers 27 SECTION 7 REPLACEMENT PARTS LLC TT amp pe ITEM CIRCUIT NO DESCRIPTION SYMBOL 0558002668 AristoPower Power 460 678025 Terminal Assembly 952219 Outlet 110V Square 950122 Breaker 10A 32VDC 250VAC 672786 Bolt Eye 75 10 X 2 00SL STL GR 0486958884 Control PC 456 680 880 Termination Resistor Plug not Shown 28 SECTION 7 REPLA
40. nformation may be used to locate the source of the trouble Check the problem against the symptoms in the following troubleshooting guide Table 6 1 The remedy for the problem may be quite simple If the cause cannot be quickly located open up the unit and perform a simple visual inspection of all the components and wiring Check for proper terminal connections loose or burned wiring or components blown fuses bulged or leaking capacitors or any other sign of damage or discoloration Table 6 1 Troubleshooting Table CONDITION ACTION Unit Inoperative No input power Check main line user s switch fuses replace if needed Poor or improper input terminal board connections Defective on off switch on rear panel replace Thermal light on Main transformer overheating Also check for proper cooling proper primary hookup or shorted turn on secondary Loss of primary phase Find amp replace defective fuse No Output Fan Poor or improper electrical input check input connections on TB Running Poor connections at output terminals work station check tighten or replace Main transformer overheating thermal switches tripped due to restricted cooling air Temperature light on front panel will be lit Let unit cool down PC board defective or loose PC board connector s if loose reinsert if defective replace Limited Output or Low Input voltage jumper links on terminal board improperly set check for
41. ns are correct and well insulated 16 SECTION 3 INSTALLATION Table 3 1 Recommended Sizes for Input Conductors and Line Fuses Rated Input 100 Duty Cycle Input GND Conductor Volts Amps CU AWG Sized per National Code for 80 rated copper conductors 30 ambient Not more than three conductors in raceway or cable Local codes should be followed if they specify sizes other than those listed above Connection Primary Cable Supplied by Customer Ground Fault Switch Bracket Ground Connection E A m AE Figure 3 1 Primary Power Leads L1 L2 L3 amp Ground 3 PRIMARY INPUT PRIMARY CONDUCTORS INPUT Earth Ground Figure 3 2 Recommended Cable Strip Lengths 17 SECTION 3 INSTALLATION 5 Figures 3 3 thru 3 5 illustrate the input voltage terminal board and the input voltage link connections The particular voltages from which this power source may be operated are stated on the rating plate The voltage links were factory set for highest voltage stated on the rating plate 575 If the power source is to be operated on another stated input voltage the links must be reset for that particular input voltage Always verify the input voltage and check the link arrangement regardless of factory setting The voltage links are set up by reconfiguring the copper link bars to the silk screened voltage designations for the desired voltage ONE 230 _
42. nt de sortie par des chaines de SECTION 2 AristoPower 460 Power Source Easy to use advanced technology Customizable MA 6 man machine communications Upgradable using ESAT software ESAB Software Administration Tools 107 preprogrammed synergic welding programs for standard amp pulsed Mig and Stick welding 10 memory locations for user defined welding parameter storage Digital preset of voltage amperage or wire speed on process slection Robust reliable energy saving 450 amp 100 Duty Cycle power source SuperSwitch Technology design provides superior inverter like performance in the welding arc while providing SCR like reliability Energy and power efficient the best in its class with a 92 efficiency figure Saves energy and reduces power costs Uses up to 50 less current than conventional SCR machines True Multi process three phase power source designed for heavy duty Industrial DC welding applications Use for High Performance Mig Pulse Mig Flux Cored wire Stick electrode welding and Air Carbon Arc Gouging Variable inductance for fine tuning of the arc charac teristics when short arc welding Adjustable arc force and hot start control for superior stick electrode performance 10096 Solid State no mechanical contactor Sheet metal parts and hardware made of stainless steel Top and side panel made of Kydex polymer for superior durability in harsh environments Auto Fan feature standard in the unit for
43. ntes de dar PRECAUCION DE SEGURIDAD MANTENIMIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede causar da o o muerte Por lo tanto a instalaci n diagn stico y mantenimiento del equipo No ejecute ning n trabajo el ctrico a menos que usted est cualificado para hacer el trabajo mantenimiento en el interior de la fuente de poder desconecte la fuente de poder del suministro de electricidad primaria Mantenga los cables cable a tierra conexciones cable primario y cualquier otra fuente de poder en buen estado operacional No opere ning n equipo en malas condiciones No abuse del equipo y sus accesorios Mantenga el equipo lejos de cosas que generen calor como hornos tambi n lugares h medos como charcos de agua aceite o grasa atm sferas corrosivas y las inclemencias del tiempo 5 Mantenga todos los art culos de seguridad y coverturas del equipo en su posici n y en buenas condiciones 6 Use el equipo s lo para el prop sito que fue dise ado No modifique el equipo en ninguna manera INFORMACION ADICIONAL DE SEGURIDAD Para m s informaci n sobre las pr cticas de seguridad de los equipos de arco el ctrico para soldar y cortar pregunte a su suplidor por una copia de Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Las siguientes publicaciones disponibles atrav s de la American Welding Society 550 N W LeJuene Road Miami FL 33126 son recomend
44. on dry hole free gloves before turning on the power Turn off the power before removing your gloves Referto ANSI ASC Standard Z49 1 listed on next page for specific grounding recommendations Do not mistake the work lead for a ground cable ELECTRIC AND MAGNETIC FIELDS be dangerous Electric current flow ing through any conductor causes lo calized Electric and Magnetic Fields Welding and cutting current cre E ates EMF around welding cables and welding machines Therefore 1 Welders having pacemakers should consult their physi Ci an before welding EMF may interfere with some pace makers 2 xposure to may have other health effects which are unknown 3 Welders should use the following procedures to minimize exposure to A B Route the electrode and work cables together Secure them with tape when possible Never coil the torch or work cable around your body C Do not place your body between the torch and work cables Route cables on the same side of your body D Connect the work cable to the workpiece as close as possible to the area being welded Keep welding power source and cables as far away from your body as possible SECTION 1 FUMES AND GASES Fumes 4 gases can cause discomfort or harm particularly in confined spaces Do not breathe fumes and gases Shield ing gases can cause asphyxiation Therefore 1 Always prov
45. produce humos o gases los cuales contienen qu micos conocidos por el Estado de California de causar defectos en el nacimiento o en algunos casos Cancer California Health 8 Safety Code 25249 5 et seq MANEJO DE CILINDROS Los cilindros si no son manejados correctamente pueden romperse y liberar violentamente gases Rotura repentina del cilindro v lvula o v lvula de escape puede causar da o o muerte Por lo tanto 1 Utilize el gas apropiado para el proceso y utilize un regulador dise ado para operar y reducir la presi n del cilindro de gas utilice adaptadores Mantenga las mangueras y las conexiones buenas condiciones Observe las instrucciones de operaci n del manufacturero para montar el regulador en el cilindro de gas comprimido 2 Asegure siempre los cilindros en posici n vertical y am rrelos con una correa o cadena adecuada para asegurar el cilindro al carro transportes tablilleros paredes postes o armaz n Nunca asegure los cilindros a la mesa de trabajo las piezas que son parte del circuito de soldadura Este puede ser parte del circuito el lectrico 3 Cuando el cilindro no est en uso mantenga la v lvula del cilindro cerrada Ponga el capote de protecci n sobre la v lvula si el regulador no est conectado Asegure y mueva los cilindros utilizando un carro o transporte adecuado Evite el manejo brusco de los Siempre tenga personal cualificado para efectuar A
46. proper Open Circuit Voltage voltage Poor output connections Take apart clean and reassemble Panel Remote switch in Remote position and remote voltage pot disabled Erratic Weld Current Welding cable size too small use correct cables Loose welding cable connection will usually get hot tighten all connections Improper wire feeder setup PC board defective replace High Output No Voltage Control PC board defective or loose reset and or replace board _ 2 gt ms gt Shorted 1 G B T Replace and check driver PCB No 115 Volt ac Output Circuit breaker tripped Check 115V CB2 Reset Line Fuse Blows When Power Source is First Turned On Shorted SCR in Main Bridge replace Shorted capacitor in Capacitor Bank Wire Feeder is Inoperative Loose feeder control cable Check and tighten all connections A Circuit Breaker tripped Check 42V CB1 Reset 22 TROUBLESHOOTING SECTION 6 lt Nv2 Z NN lt 1 9 lt k AZL 6 1 0 9 8 1 1604 lt lt NVO L lt lt 1 9 lt lt NV 47156 lt lt A0 9 V NV LXAN NO 626 097 062 5 pie GM gt mig O 001 Mg IS gt zs gt ES gt S gt 2 HS 19 gt 157
47. recommended secondary cable output sizes 1 CONNECTIONS FROM THE WIRE FEEDER The wire feeder control cable connects to the 12 pin J1 receptacle on the lower front or the rear panel of the AristoPower 460 The secondary output cable connects in most cases between the positive output lug the AristoPower 460 and the power connection block of the wire feeder See the wire feeder installation instructions for other connections such as shield gas water remote controls Mig guns and wire feeder operation 2 CONNECTIONS FOR STICK AND TIG WELDING The Tig torch and stick electrode holder connect directly to the appropriate AristoPower 460 output lugs on the lower front panel The choice of the Positive or Negative terminal depends on the welding process and electrode type being used In most cases the Tig torch will connect to the negative lug and work cable will connect to the positive lug The stick electrode holder usually connects to the positive lug and the work cable to the negative lug Table 3 6 Output Cable Sizes Secondary Total Length Feet of Cable in Weld Circuit Total cable length includes work and electrode cables Cable size is based on direct current insulated copper conductors 100 percent duty cycle and a voltage drop of 4 or less volts The welding cable insulator must have a voltage rating that is high enough to withstand the open circuit voltage of the power source 19 SECTION 4 WARNING ELECTRIC S
48. s Por lo tanto 1 Remueva todo material combustible lejos del rea de trabajo o cubra los materiales con una cobija a prueba de fuego Materiales combustibles incluyen madera ropa l quidos y gases flamables solventes pinturas papel etc 2 Chispas y part culas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios Aseg rese de que toda grieta y agujero est cubierto para proteger lugares adyacentes contra fuegos 3 No corte suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo est totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores t xicos No trabaje dentro o fuera de contenedores o tanques cerrados Estos pueden explotar si contienen vapores inflamables 4 Tenga siempre a la mano equipo extintor de fuego para uso instant neo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor port til Aseg rese que usted esta entrenado para su uso 5 No use el equipo fuera de su rango de operaci n Por ejemplo PRECAUCION DE SEGURIDAD el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego 6 Despu s de termirar la operaci n del equipo inspeccione el rea de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego m s tarde Tenga personal asignado para vigilar si es necesario 7 Para informaci
49. safe working order Do not operate any equipment in faulty condition 4 Do not abuse any equipment or accessories Keep equipment away from heat sources such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather 5 Keep all safety devices and cabinet covers in position and in good repair 6 Use equipment only for its intended purpose Do not modify it in any manner ADDITIONAL SAFETY INFORMATION For more information on safe practices for elec A tric arc welding and cutting equipment ask your supplier for a copy of Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 The following publications which are available from the American Welding Society 550 N W LeJuene Road Mi ami FL 33126 are recommended to you 1 ANSI ASC 249 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Welding 3 AWS C52 Recommended Practices for Plasma Arc Cutting 4 AWS C5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting 5 AWS 5 5 Recommended Practices for Gas Tungsten Arc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding AWS SP Safe Practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances 00 Y MEANING OF SYMBOLS As used through out this manual Means Attention
50. source 1 used It is imperative that all air passages be kept as clean as possible in order to allow adequate air flow to provide proper cooling After cleaning with low pressure air check for and tighten any loose hardware including all electrical connections Check for frayed and or cracked insulation on all power cables and replace if necessary 5 2 INSPECTION AND SERVICE Keep the power source dry free of oil and grease and protected at all times from damage by hot metal and sparks 5 2 1 FAN MOTOR Keep the fan motor free of accumulated dust and lint 5 2 2 TRANSFORMER Other than periodically cleaning the dust and dirt from the transformer no maintenance is required Ensure that only clean dry low pressure air 1 used 5 2 3 WIRE FEEDER CONTROL CIRCUITS These circuits are protected by two 10 amp circuit breakers mounted in the front panel If these open the contactor and wire feeder will not operate 5 2 4 OVER TEMPERATURE PROTECTION Ifthe power source reaches an abnormally high internal temperature the thermal protection will deenergize the contactor circuit shutting down the power source but leaving the cooling fan on After the power source has cooled to a safe level the thermal protection will automatically reset While de energized the contactor and wire feeder cannot be operated 21 SECTION 6 TROUBLESHOOTING 6 0 TROUBLESHOOTING If the power source is operating improperly the following troubleshooting i
51. tro tipo de protecci n 2 Use una careta que tenga el filtro correcto y lente para proteger sus ojos cara cuello y o dos de las chispas y rayos del arco cuando se est operando y observando las operaciones Alerte atodas las personas cercanas de no mirar el arco y no exponerse alos rayos del arco el ctrico o el metal fundido 3 Use guantes de cuero a prueba de fuego camisa pesada de mangas largas pantal n de ruedo liso zapato alto al tobillo y careta de soldar con capucha para el pelo para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas 4 Chispas y part culas de metal caliente puede alojarse en las mangas enrolladas de la camisa el ruedo del pantal n o los bolsillos Mangas y cuellos deber n mantenerse abotonados bolsillos al frente de la camisa deber n ser cerrados o eliminados 5 Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no flamable como divisi n 6 Usecareta protectora adem s de sus gafas de seguridad cuando est removiendo escoria o puliendo La escoria puede estar caliente y desprenderse con velocidad Personas cercanas deber n usar gafas de seguridad y careta protectora FUEGO Y EXPLOSIONES El calor de las flamas y el arco pueden ocacionar 3 fuegos Escoria caliente y las chispas p pueden causar fuegos y explosione
52. used by excessive duty cycle or over current conditions When an over temperature condition occurs the welding outputis turned off and the unit must be allowed to cool The machine will automatically reset when the temperature falls to a safe level 3 CONTROL RECEPTACLE There are two 12 pin receptacles on the front panel and two 12 pin recep tacles onthe rear panel Any ofthe four receptacles accepts the control cable from the AristoDrive wire feeder and all the control signals needed for operation The remaining receptacles are use for remote controls service and trouble shooting accessories 4 AUXILIARY 115 VAC RECEPTACLE A 115 Vac receptacle is provided to supply power to accessories such as a water cooler heated CO regulator or small hand tools The receptacle is rated 115 Vac 10 amps with a floating neutral 5 42VAC AND 115 CIRCUIT BREAKER CB1 amp CB2 These resetable 10 amp circuit breakers CB 1 8 CB2 protect the 42 volt wire feeder control and 115 volt auxiliary receptacle circuitry against over current 6 COMPONENT CONNECTION RECEPTACLES There are 2 receptacles on the front panel and 2 on the rear panel for connection of wire feeders accessories and service monitoring equipment 7 WELD CABLE CONNECTION LUGS A positive and negative lug connector is provided on the front and a 600 positive twist lock connector is mounted on the rear panel 2 3 OPTIONAL ACCESSORIES A number of remote control
53. vers le corps humain et de son intensit Ne laissez jamais de surfaces m talliques sous tension venir au contact direct de la peau ou de v tements humides Veillez porter des gants bien secs Si vous devez effectuer un travail sur une surface m tallique ou dans un secteur humide veillez assu rer votre isolation corporelle en portant des gants secs et des chaussures semelles de caoutchouc et en vous tenant sur une planche ou une plate forme s che Mettez toujours la terre le poste de soudage coupage en le reliant par un c ble une bonne prise de terre N utilisez jamais de c bles us s ou endommag s Ne surchargez jamais le cable Utilisez toujours un quipement correctement entretenu Mettez l quipement hors tension lorsqu il n est pas en service une mise la masse accidentelle peut en effet provoquer une surchauffe de l quipement et un danger d incendie Ne pas enrouler ou passer le c ble autour d une partie quelconque du corps V rifiez si le c ble de masse est bien reli la pi ce en un point aussi proche que possible de la zone de travail Le branchement des c bles de masse du b timent ou en un point loign de la zone de travail augmente en effet le risque de passage d un courant de sortie par des chaines de SECTION 1 AVERTISSEMENT Ces regles de s curit ont pour objet d assurer votre protection Veillez lire et observer les pr cautions nonc
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