0458 814 001 gb - esab · 0458 814 001 gb 050517 aristomig 400 ... 6.4 overheating protection 10...

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Page 1: 0458 814 001 GB - ESAB · 0458 814 001 GB 050517 AristoMig 400 ... 6.4 Overheating protection 10 ... With power source With trolley and power source With trolley2 and power source

GB

Valid for serial no. 050--xxx--xxxx, 105--xxx--xxxx,347--xxx--xxxx, 445--xxx--xxxx, 524--xxx--xxxx

0458 814 001 GB 050517

AristoMig 400

Instruction manual

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-- 2 --TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SAFETY 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 Electrical installation (with autotransformer) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Mains power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5 Terminating resistor 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Connections and control devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 Turning on the power source 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3 Fan control 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4 Overheating protection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 Cooling unit 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 Remote control unit 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 Cleaning the air filter 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 Topping up the coolant 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 FAULT TRACING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 ORDERING OF SPARE PARTS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ORDERING NUMBER 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPARE PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ACCESSORIES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 DIRECTIVE

DECLARATION OF CONFORMITYESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that weldingpower source AristoMig 400 from serial number 105 complies with standard IEC/EN 60974--1, in ac-cordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with stan-dard EN 50199 in accordance with the requirements of directive (89/336/EEC) and addendum(93/68/EEC).--------------------------------------------------------------------------------------------------------------------------------------

Joakim CahlinVice PresidentESAB Welding Equipment AB695 81 LAXÅSWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2001--04--18

2 SAFETYUsers of ESAB welding equipment have the ultimate responsibility for ensuring that anyone whoworks on or near the equipment observes all the relevant safety precautions. Safety precautionsmust 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 weldingequipment. Incorrect operation of the equipment may lead to hazardous situations which can resultin injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:S its operationS location of emergency stopsS its functionS relevant safety precautionsS welding

2. The operator must ensure that:S no unauthorized person is stationed within the working area of the equipment when it is

started up.S no--one is unprotected when the arc is struck

3. The workplace must:S be suitable for the purposeS be free from drafts

4. Personal safety equipmentS Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautionsS Make sure the return cable is connected securely.S Work on high voltage equipment may only be carried out by a qualified electrician.S Appropriate fire extinquishing equipment must be clearly marked and close at hand.S Lubrication and maintenance must not be carried out on the equipment during operation.

GB

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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 BEBASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can killS Install and earth the welding unit in accordance with applicable standards.S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.S Insulate yourself from earth and the workpiece.S Ensure your working stance is safe.FUMES AND GASES -- Can be dangerous to healthS Keep your head out of the fumes.S 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.S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.S Protect bystanders with suitable screens or curtains.

FIRE HAZARDS Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.NOISE -- Excessive noise can damage hearingS Protect your ears. Use earmuffs or other hearing protection.S Warn 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 installingor operating.

Do not use the power source for thawing frozen pipes.WARNING!

This product is solely intended for arc welding.

3 INTRODUCTIONThe AristoMig 400 is a MIG/MAG welding power source, which can also be used forMMA welding.

There are four variants of the power source:

S AristoMig 400 without cooling unit or autotransformerS AristoMig 400 with cooling unitS AristoMig 400 with autotransformerS AristoMig 400 with cooling unit and autotransformer

GB

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NB: These instructions describe an AristoMig 400 with cooling unit andautotransformer.

The power source is intended for use with the AristoFeed 30 or AristoFeed 48 wirefeed units.

ESAB’s accessories for the product can be found on page 19.

3.1 Equipment

The AristoMig 400 power source is supplied complete with terminating resistor,5m return cable and instruction manual.

4 TECHNICAL DATA

AristoMig 400not reconnectable

AristoMig 400reconnectable

Mains voltage 400V,±10%, 3∼ 50 Hz 208/230/400/460/475/500/575 V,±10%, 3∼ 50/60 Hz

Primary currentImax MIG/MAGImax MMA

36 A38 A

61/54/36/28/28/25/19 A65/57/38/30/30/26/20 A

No--load power demand when in theenergy--saving mode, 6.5 min. afterwelding

60 W 235 W

Voltage/current rangeMIG/MAGMIG/MAG, M2MMA

8--60 V / 16--400 A8-- 42 A16-- 400 A

8--60 V / 16--400 A8-- 42 A16 -- 400 A

Permissible load at MIG/MAG35% duty cycle60 % duty cycle100% duty cycle

400 A / 34 V320 A / 30 V250 A / 27 V

400 A / 34 V320 A / 30 V250 A / 27 V

Permissible load at MMA35% duty cycle60 % duty cycle100% duty cycle

400 A / 36 V320 A / 33 V250 A / 30 V

400 A / 36 V320 A / 33 V250 A / 30 V

Power factor at maximum current 0.65 0.65

Efficiency at maximum current 85 % 85 %

Open--circuit voltageMIG/MAGMMA

55 -- 70 V78 -- 90 V

55 -- 70 V78 -- 90 V

Operating temperature --10 to +40˚C --10 to +40˚C

Dimensions, lxbxhwith cooling unit

625 x 394 x 496 mm625 x 394 x 776 mm

625 x 394 x 776 mm625 x 394 x 1056 mm

Continual A--weighted sound pres-sure

<70 db <70 db

Weightwith cooling unit

57 kg77 kg

114 kg134 kg

Insulation class H H

Enclosure class IP 23 IP 23

Application class

GB

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Cooling unit

Cooling power 2500 W at 40˚C temp. differencen and flow1,5l/min

Coolant 50 % water / 50% glycol

Coolant quantity 5.5 l

Maximum water flow 2.0 l/min

Maximum number of water--cooled weldingguns/torches that may be connected

two MIG welding guns orone TIG torch and one MIG welding gun

Duty cycleThe duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-tain load without overloading.

The duty cycle is valid for 40˚C.

Enclosure classThe IP code indicates the enclosure class, i. e. the degree of protection against penetration by solidobjects 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 increasedelectrical hazard.

5 INSTALLATIONThe installation must be executed by a professional.

WARNING!This product is intended for industrial use. In a domestic environment this product may cause radiointerference. It is the user’s responsibility to take adequate precautions.

5.1 Lifting instructions

With power source With trolley and power source With trolley2 and power source

GB

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5.2 Placing

Position the welding power source such that its cooling air inlets and outlets are notobstructed.

5.3 Electrical installation (with autotransformer)

GB

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5.4 Mains power supply

Check that the unit is connected to the correct mains powersupply voltage, and that it is protected by the correct fuse size.A protective earth connection must be made, in accordancewith regulations.

Rating plate with supply connection data

Recommended fuse sizes and minimum cable areasAristoMig 400 60 Hz 50/60

Hz50 Hz 60 Hz 60 Hz 50 Hz 60 Hz

Mains voltage 208 V 230 V 400 V 460 V 475 V 500 V 575 VMains cable area, mm2 4G6 4G6 4G4 4G4 4G4 4G4 4G4Phase current, I RMS 38 A 33 A 22 A 18 A 18 A 16 A 11 AFuseAnti--surgeType C MCB

50 A50 A

50 A50 A

25 A32 A

20 A--

20 A--

16 A--

16 A--

NB: The mains cable areas and fuse sizes as shown above are in accordance with Swedishregulations. They may not be applicable in other countries: make sure that the cable area and fusesizes comply with the relevant national regulations.

5.5 Terminating resistor

In order to avoid communication interference, the endsof the CAN bus must be fitted with terminatingresistors.

One end of the CAN bus is at the control panel, whichhas an integral terminating resistor. The other end atthe power source must be fitted with the terminatingresistor, as shown on the right.

GB

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6 OPERATION

General safety regulations for the handling of the equipment can be found onpage 3. Read through before you start using the equipment!

6.1 Connections and control devices

1 Connection for cooling water. Not used onthis model.

8 White indicating lamp -- Power supply ON

2 Connection for cooling water. Not used onthis model.

9 Orange indicating lamp -- Overheating

3 Cooling water filler 10 Fuse 4AT

4 Connection for welding current cable (+)(MMA welding)

11 Connection for control cable to the wirefeed unit or terminating resistor

5 Connection for remote control 12 Connection for welding current to the wirefeed unit

6 Connection for return cable (--) 13 Connection for cooling water to the wirefeed unit -- BLUE

7 Main power supply switch, 0 / 1 / START 14 Connection for cooling water from the wirefeed unit -- RED

6.2 Turning on the power source

Turn on the mains power by turning switch (7) to the ”START” position. Release theswitch, and it will return to the ”1” position.

If the mains power supply should be interrupted while welding is in progress, andthen be restored, the power source will remain de--energised until the switch is againturned manually to the ”START” position.

Turn the unit off by turning the switch to the ”0” position.

GB

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Whether in the event of a loss of power supply or of turning the power source off inthe normal manner, welding data will be stored so that it is available next time theunit 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 weldingrestarts.

The fans run at reduced speed for welding currents up to 144 A, and at full speed forhigher currents.

6.4 Overheating protection

The power source has two thermal overload trips which operate if the internaltemperature becomes too high, interrupting the welding current and lighting theorange indicating lamp on the front of the unit. They reset automatically when thetemperature has fallen.

6.5 Cooling unit

Function when welding

To start welding, the welder presses the welding gun trigger switch. The powersource 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 unitswitches 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 anaccessory.

6.6 Remote control unitThe program version in AristoPendant U8 should be 1.20 or higher. Aristo mchineswith intergral control panels should have program version 1.21 or higher, in order forthe remote control to function correctly.

When the remote control unit is connected, the power source and wire feed unit arein remote control mode; the buttons and knobs are blocked. The functions can onlybe adjusted via the remote unit.

If the remote control unit is not to be used, the remote control unit must bedisconnected from the power source / wire feed unit, as otherwise it will remain inremote control mode.

For more information about the operation of the remote control unit, see theoperating instructions for the control panel.

GB

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7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Only those persons who have appropriate electrical knowledge (authorizedpersonnel) may remove the safety plates to connect or carry out service,maintenance or repair work on welding equipment.

Note!All guarantee undertakings from the supplier cease to apply if the customer himselfattempts any work in the product during the guarantee period in order to rectify anyfaults.

7.1 Cleaning the air filter

S Release the cover plate with the dustfilter (1).

S Swing out the cover plate (2).

S Remove the dust filter (3).

S Blow it clean with compressed air atreduced pressure.

S Replace the filter with the finer meshon the side against the cover plate (2).

S Replace the cover plate with the filter.

7.2 Topping up the coolant

We recommend a 50/50 % mixture of water and ethyleneglycol.

Top up with coolant until it is up to the level of the filling hole.

GB

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8 FAULT TRACING

Try these recommended checks and inspections before sending for an authorisedservice technician.

Type of fault Action

No arc. S Check that the mains power supply switch isturned on.

S Check that the welding current supply andreturn cables are correctly connected.

S Check that the correct current value is set.S Check the fuse.

Welding current is interrupted during welding S Check whether the thermal overload tripshave operated (indicated by the orangelamp on the front panel).

S Check the main power supply fuses.

The thermal overload trips operate frequently. S Check to see whether the air filters areclogged.

S Make sure that you are not exceeding therated data for the power source (i.e. that theunit is not being overloaded).

Poor welding performance. S Check that the welding current supply andreturn cables are correctly connected.

S Check that the correct current value is set.S Check that the correct electrodes are being

used.S Check the main power supply fuses.

9 ORDERING OF SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman.Use only ESAB original spare and wear parts.

AristoMig 400 is designed and tested in accordance with the international an Europeanstandards IEC/EN 60974--1 and EN 50199.It is the obligation of the service unit which has carried out the service or repair workto make sure that the product still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page ofthis publication.

GB

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Diagram

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AristoMig 400

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AristoMig 400

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Cooling unit

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AristoMig 400

Edition 050517

Ordering number

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1.

Ordering no. Denomination Type Notes

0458 625 880 Welding power source AristoMig 4000458 625 881 Welding power source AristoMig 400 with cooling unit0458 625 882 Welding power source AristoMig 400 with auto transformer0458 625 883 Welding power source AristoMig 400 with cooling unit and auto transformer

0458 814 990 Spare part list AristoMig 400

The spare parts list is available on the Internet at www.esab.comUnder ”Products” and ”Welding & cutting equipment”, you will find a link to the page where you canboth search for and download instruction manuals and spare parts lists.

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AristoMig 400

Edition 050517

Spare parts list

-- 18 --ba37s

Item Qty Ordering no. Denomination

1 0458 398 001 Filter

2 0458 383 001 Front grill

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Edition 050517

AristoMig 400

Accessories

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Trolley for AristoMig . . . . . . . . . . . . . . . . . . . . . . 0458 530 880

Trolley 2 for AristoMig (for feeder withcounterbalance device and/or 2 gas bottles) . 0458 603 880

Feeder stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0458 522 880

Turning piece . . . . . . . . . . . . . . . . . . . . . . . . . . . 0458 703 880

Remote control adapter RA12 12 pole . . . .For analogue remote controls to CAN basedequipment.

0459 491 910

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Edition 050517

AristoMig 400

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Remote control unit MTA1 CAN . . . . . . . . . .For setting of wire feed speed, current andarc force.

0459 491 880

Remote control unit M1 10Prog CAN . . . . . .For setting of voltage and current. Choice ofon of 10 programs.

0459 491 882

Remote control unit AT1 CAN . . . . . . . . . . . .For setting of current.

0459 491 883

Remote control unit AT1 CF CAN . . . . . . . . .For rough and fine setting of current.

0459 491 884

Remote control cable 12 pole -- 4 pole5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.25m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0459 554 8800459 554 8810459 554 8820459 554 8830459 554 884

Connection set1.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connection set, water1.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0456 528 8800456 528 8900456 528 8810456 528 8820456 528 8830456 528 884

0456 528 8850456 528 8950456 528 8860456 528 8870456 528 8880456 528 889

Return cable 5 m 70 mm2 . . . . . . . . . . . . . . . . 0156 743 881

Page 21: 0458 814 001 GB - ESAB · 0458 814 001 GB 050517 AristoMig 400 ... 6.4 Overheating protection 10 ... With power source With trolley and power source With trolley2 and power source

Edition 050517

AristoMig 400

-- 21 --ba34a11a

Water flow guard 0.7 l/min . . . . . . . . . . . . . . . . 0456 855 880

MMC kit AristoMig . . . . . . . . . . . . . . . . . . . . . . . 0459 579 880

Page 22: 0458 814 001 GB - ESAB · 0458 814 001 GB 050517 AristoMig 400 ... 6.4 Overheating protection 10 ... With power source With trolley and power source With trolley2 and power source

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