ESAB AristoFeed 30- 4 User manual

Valid for serial no. 233--xxx--xxxx, 249--xxx--xxxx,

445--xxx--xxxx, 451--xxx--xxxx

0458 716 101 GB 051220

AristoFeed 30- 4

AristoFeed 48- 4

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................................................................

3.2 Control panel 5.............................................................

4 TECHNICAL DATA 6.................................................

5 INSTALLATION 6....................................................

5.1 Lifting instructions 7.........................................................

5.2 Terminating resistors 7.......................................................

5.3 Connection of multiple wire feed units 8........................................

6 OPERATION 8.......................................................

6.1 Connections and controls 9...................................................

6.2 Water connection 10..........................................................

6.3 Remote control unit 10........................................................

6.4 Wire feed pressure 11........................................................

6.5 Changing / loading wire AristoFeed 30 11........................................

6.6 Changing / loading wire AristoFeed 48 11........................................

6.7 Replacing the AristoFeed 30 feed rollers 12......................................

6.8 Replacing the AristoFeed 48 feed rollers 12......................................

7 MAINTENANCE 13....................................................

7.1 Inspection and cleaning 13....................................................

8 ORDERING OF SPARE PARTS 13......................................

DIAGRAM 14............................................................

ORDERING NUMBER 17.................................................

WEAR COMPONENTS 18.................................................

ACCESSORIES 22.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, declares that Wire feed unit AristoFeed

30/30W, AristoFeed 48/48W from serial number 105 onwards, conforms to standard EN 60974--5, in

accordance with the requirements of directive (73/23/EEC) and appendix (93/68/EEC) and standard

EN 50199 in accordance with the requirements of directive (89/336/EEC) and appendix (93/68/EEC).

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Joakim Cahlin

Vice President

ESAB Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2001--04--18

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.

This product is solely intended for arc welding.

3 INTRODUCTION

The AristoFeed 30--4 and AristoFeed 48--4 wire feed units are intended for use

with AristoMig power sources.

There are several variants available: see on page 17.

They are totally enclosed, containing four--wheel feeders and the necessary control

electronics.

They are suitable for use with wire on ESAB’s MarathonPact, or on standard

bobbins (standard Ø 300 mm, accessory Ø 440 mm).

The units can be positioned in a choice of ways: on the power source itself, hanging

above the working position, on a support arm or with a wheelset on the floor.

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ESAB’s accessories for the product can be found on page 22.

3.1 Equipment

The unit AristoFeed 30 is supplied with:

SInstruction manual for the wire feed unit.

SInstruction manual for control panel.

SStickers with recommended wear parts.

The unit AristoFeed 48 is supplied with:

SDistance washer (4 pieces).

SHexagon key (4 mm)

SInstruction manual for the wire feed unit.

SInstruction manual for the control panel.

SStickers with recommended wear parts.

3.2 Control panel

The units are supplied with one of the following control panels:

The M0 panel Empty panel for use with double wire feed units

or with use of control box AristoPendant U8.

The M2 panel With knobs for all settings/adjustments.

The MA4 panel

With knobs for setting the voltage and wire feed

speed / current. Other settings by pushbuttons,

with corresponding symbols on the display

panel.

The MA6 panel With knobs for setting the voltage and wire feed

speed / current. Other settings by pushbuttons,

with text indication on the display panel.

The U6 panel With knobs for setting the voltage and wire feed

speed / current. Other settings by pushbuttons,

with text indication on the display panel.

Detailed descriptions of the control panels can be found in separate Instruction

manuals.

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4 TECHNICAL DATA

AristoFeed 30--4 AristoFeed 48--4

Power supply 42 V 50 -- 60 Hz 42 V 50 -- 60 Hz

Power requirement 336 VA 378 VA

Motor current 8A 9A

Wire feed speed 0.8 -- 25 m/min 0.8 -- 25 m/min

Welding gun connection EURO EURO

Max. diameter of wire bobbin 300 mm (*440 mm) 300 mm (*440 mm)

Wire dimension 0.6 -- 1.6 mm 0.6 -- 2.4 mm

Weight

basic unit

with bobbin carrier

with enclosed bobbin carrier

13 kg

16 kg

17.5 kg

18 kg

21 kg

22.5 kg

Dimensions (l x w x h)

basic unit

with bobbin carrier

with enclosed bobbin carrier

380 x 265 x 340 mm

560 x 265 x 350 mm

690 x 285 x 420 mm

380 x 265 x 340 mm

560 x 265 x 350 mm

690 x 285 x 420 mm

Shielding gas

max pressure

All types intended for

MIG/MAG welding

5 bar

All types intended for

MIG/MAG welding

5 bar

Coolant

max pressure

50% water / 50% glycol

5 bar

50% water / 50% glycol

5 bar

Permissible load at

60% duty cycle 500 A 500 A

Enclosure class

basic unit

with bobbin carrier

with enclosed bobbin carrier

IP23

IP2X

IP23

IP2X

IP23

* Accessory, see page 22.

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.

Equipment marked IP2X is designed for indoor use.

5 INSTALLATION

The installation must be executed by a professional.

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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.

WARNING!

When welding in an environment with increased electrical danger, only power sources intended

for this environment may be used. These power sources are marked with the symbol .

5.1 Lifting instructions

Ordering number for the lifting eye can be found on page 22.

Note! If another mounting device is used, this should be insulated from the wire feed

unit.

5.2 Terminating resistors

In order to avoid communication interference, the

ends of the CAN bus must be terminated by resistive

loads.

One end of the CAN bus is at the wire feed unit control panel,

which incorporates a terminating resistor. The other end is in

the power source and it must be fitted with a terminating resistor,

as shown in the diagram to the right.

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5.3 Connection of multiple wire feed units

When connecting multiple wire feed units (maximum 4), use wire feed units without

control panel (M0) and with control box AristoPendant U8.

Two feed units are to be connected according to the picture.

When connecting more than two feed units, an authorised ESAB service technican

must perform the installation.

6OPERATION

General safety regulations for the handling of the equipment can be found on

page 3. Read through before you start using the equipment!

WARNING!

Assure that the side panels are closed during operation.

To prevent the reel from sliding off the hub: Lock the reel in place by

turning the red knob as shown on the warning label attached next to

the hub.

WARNING!

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WARNING!

Rotating parts can cause injury, take great care.

WARNING!

There is a risk of tipping if the wire feed unit is fitted with a counterbalance arm. Secure the

equipment, especially if used on an uneven or sloping surface.

When moving the equipment use intended handle. NOTE! Never pull on the gun.

6.1 Connections and controls

1Control panel

(see respective instruction manual) 6Connection for welding current from the

power source (OKC)

Connection for remote control adapter

Connection for AristoPendant U8.

7Connection for the control cable from the

power source

3Connection with ELP* for cooling water to

the welding gun-- BLUE 8Connection for cooling water to the power

source (cooling unit) -- RED

4Connection for cooling water from the wel-

ding gun -- RED 9Connection for cooling water from the po-

wer source (cooling unit) -- BLUE

5Connection for the welding gun 10 Connection for protection gas

NOTE! Cooling water connections only available on certain models.

* ELP = ESAB Logic Pump, see point 6.2.

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6.2 Water connection

The wire feed unit with water connection is equipped with a detection system ELP

(ESAB Logic Pump) which checks that the water hoses are connected.

AristoMig 400 and 500

The power unit On/Off switch must be in the “0” position (Off) when connecting a

water--cooled welding gun.

If a water--cooled welding gun 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.

AristoMig 320 and 450

The power unit On/Off switch for cooling unit must be in the “I” position (ON) when

connecting a water--cooled welding gun.

6.3 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.

When a remote control unit is used to set the voltage, the function will be changed to

the setting of current during MMA welding.

For more information about the operation of the remote control unit, see the

operating instructions for the control panel.

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