ESAB AristoMig U500 User manual

Valid for serial no. 304--xxx--xxxx, 445--xxx--xxxx,

524--xxx--xxxx

0459 291 001 GB 050517

AristoMig U500

400 V version

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 4...................................................

3.1 Equipment 5................................................................

4 TECHNICAL DATA 5.................................................

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

5.1 Lifting instructions 6.........................................................

5.2 Placing 7...................................................................

5.3 Mains power supply 7........................................................

5.4 Terminating resistor 7........................................................

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

6.1 Connections and control devices 8............................................

6.2 Turning on the power source 9................................................

6.3 Fan control 9...............................................................

6.4 Overheating protection 9.....................................................

6.5 Cooling unit 9...............................................................

6.6 Remote control unit 10........................................................

7 MAINTENANCE 10....................................................

7.1 Cleaning the air filter 10.......................................................

7.2 Topping up the coolant 11.....................................................

8 FAULT TRACING 11...................................................

9 ORDERING OF SPARE PARTS 11......................................

DIAGRAM 12............................................................

ORDERING NUMBER 15.................................................

SPARE PARTS LIST 16...................................................

ACCESSORIES 17.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding

power source AristoMig U500 from serial number 304 complies with standard IEC/EN 60974--1, in

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

standard EN 50199 in accordance with the requirements of directive (89/336/EEC) and addendum

(93/68/EEC).

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Henry Selenius

Vice President

ESAB Welding Equipment AB

695 81 LAXÅ

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

Laxå 2003--04--07

2SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well--acquainted with the operation of the welding

equipment. Incorrect operation of the equipment may lead to hazardous situations which can result

in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorized person is stationed within the working area of the equipment when it is

started up.

Sno--one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from drafts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

SInstall and earth the welding unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

SKeep your head out of the fumes.

SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS -- Can injure eyes and burn skin.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

ESAB can provide you with all necessary welding protection and accessories.

WARNING!

Read and understand the instruction manual before installing

or operating.

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

3 INTRODUCTION

The AristoMig U500 is a MIG/MAG / TIG welding power source, which can also be

used for MMA welding.

There are two variants of the power source:

SAristoMig U500 without cooling unit

SAristoMig U500 with cooling unit

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NB: These instructions describe an AristoMig U500 with a cooling unit.

The power source is intended for use with the AristoFeed 30 or AristoFeed 48 wire

feed units.

All the settings are made from the wire feed unit or control box AristoPendant U8.

ESAB’s accessories for the product can be found on page 17.

3.1 Equipment

The AristoMig U500 power source is supplied complete with terminating resistor, 5m

return cable and instruction manual.

4 TECHNICAL DATA

AristoMig U500

Mains voltage 400V, ±10%, 3∼50/60 Hz

Primary current

Imax MIG/MAG

Imax MMA

Imax TIG

39 A

40 A

31 A

No--load power demand when in the energy--saving mode,

6.5 min. after welding 50 W

Voltage/current range

MIG/MAG

MMA

TIG

8--60 V / 16--500 A

16-- 500 A

4 -- 500 A

Permissible load at MIG/MAG

60 % duty cycle

100% duty cycle 500 A / 39 V

400 A / 34 V

Permissible load at MMA

60 % duty cycle

100% duty cycle 500 A / 40 V

400 A / 36 V

Permissible load at TIG

60 % duty cycle

100% duty cycle 500 A / 30 V

400 A / 26 V

Power factor at maximum current 0.85

Efficiency at maximum current 86 %

Open--circuit voltage

MIG/MAG

MMA

TIG

72 -- 88 V

68 -- 80 V

72 -- 88 V

Operating temperature -- 1 0 t o + 4 0 ˚C

Dimensions, lxwxh

with cooling unit 625 x 394 x 496 mm

625 x 394 x 776 mm

Continual A--weighted sound pressure <70 db

Weight

with cooling unit 69 kg

89 kg

Insulation class transformer H

Enclosure class IP 23

Application class

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Cooling unit

Cooling power 2500 W at 40˚C temp. difference and flow1.5

l/min

Coolant 50 % water / 50% glycol

Coolant quantity 5.5 l

Maximum water flow 2.0 l/min

Maximum number of water--cooled welding

guns/torches that may be connected two MIG welding guns or

one TIG torch and one MIG welding gun

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain load without overloading.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

5 INSTALLATION

The installation must be executed by a professional.

WARNING!

This product is intended for industrial use. In a domestic environment this product may cause radio

interference. It is the user’s responsibility to take adequate precautions.

5.1 Lifting instructions

Power source Trolley and power source Trolley2 and power source

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5.2 Placing

Position the welding power source such that its cooling air inlets and outlets are not

obstructed.

5.3 Mains power supply

Check that the unit is connected to the correct mains power

supply voltage, and that it is protected by the correct fuse sizes.

A protective earth connection must be made, in accordance

with regulations.

Rating plate with supply connection data

Recommended fuse sizes and minimum cable areas

AristoMig U500 400 V 3µ50 Hz

Mains voltage 400 V

Mains cable area, mm24G6

Phase current, I RMS 31 A

Fuse

Anti--surge

Type C MCB 35 A

40 A

NB: The mains cable areas and fuse sizes as shown above are in accordance with Swedish

regulations. They may not be applicable in other countries: make sure that the cable area and fuse

sizes comply with the relevant national regulations.

5.4 Terminating resistor

In order to avoid communication interference, the ends

of the CAN bus must be fitted with terminating

resistors.

One end of the CAN bus is at the control panel, which

has an integral terminating resistor. The other end at

the power source must be fitted with the terminating

resistor, as shown on the right.

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6OPERATION

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

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

6.1 Connections and control devices

1Connection for cooling water from the TIG

torch -- RED 10 White indicating lamp -- Power supply ON

2Connection with ELP* for cooling water to

the TIG torch -- BLUE 11 Orange indicating lamp -- Overheating

3Cooling water filler 12 Fuse

4Connection for welding current cable (+)

at MMA welding or for return cable at TIG

welding

13 Connection for control cable to the wire

feed unit or to the terminating resistor

5Connection for remote control 14 Connection for gas hose

6Connection for return cable (--) or for wel-

ding current cable at TIG welding 15 Connection for welding current to the wire

feed unit

7Connection for start signal from the torch. 16 Connection for cooling water to the wire

feed unit -- BLUE

8Connection for gas to the TIG torch 17 Connection for cooling water from the wire

feed unit -- RED

9Main power supply switch, 0 / 1 / START

* ELP = ESAB Logic Pump, see point 6.5

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6.2 Turning on the power source

Turn on the mains power by turning switch (7) to the ”START” position. Release the

switch, and it will return to the ”1” position.

If the mains power supply should be interrupted while welding is in progress, and

then be restored, the power source will remain de--energised until the switch is again

turned manually to the ”START” position.

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

Whether in the event of a loss of power supply or of turning the power source off in

the normal manner, welding data will be stored so that it is available next time the

unit is started.

6.3 Fan control

The power source fans continue to run for 6,5 minutes after welding has stopped,

and the unit switches to energy--saving mode. They start again when welding

restarts.

The fans run at reduced speed for welding currents up to 180 A, and at full speed for

higher currents.

6.4 Overheating protection

The power source has three thermal overload trips which operate if the internal

temperature becomes too high, interrupting the welding current and lighting the

orange indicating lamp on the front of the unit. They reset automatically when the

temperature has fallen.

6.5 Cooling unit

Water connection (TIG welding)

The cooling unit is equipped with a detection system ELP (ESAB Logic Pump)

which checks that the water hoses are connected.

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

water--cooled TIG torch.

If a water--cooled TIG torch is connected, the water pump starts automatically when

the main On/Off switch is turned to ”START” and/or when welding starts. After

welding, the pump continues to run for 6,5 minutes, and then switches to the

energy--saving mode.

Function when welding

To start welding, the welder presses the welding gun trigger switch. The power

source turns on and starts the wire feed and the cooling water pump.

To stop welding, the welder releases the welding gun trigger switch. Welding ceases,

but the cooling water pump continues to run for 6,5 minutes, after which the unit

switches to energy--saving mode.

Water flow guard

The water flow guard interrupts the welding current in the event of loss of coolant,

and displays an error message on the control panel. The water flow guard is an

accessory.

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6.6 Remote control unit

The program version in AristoPendant U8 should be 1.20 or higher. Aristo machines

with intergral control panels should have program version 1.21 or higher, in order for

the remote control to function correctly.

When the remote control unit is connected, the power source and wire feed unit are

in remote control mode; the buttons and knobs are blocked. The functions can only

be adjusted via the remote unit.

If the remote control unit is not to be used, the remote control unit must be

disconnected from the power source / wire feed unit, as otherwise it will remain in

remote control mode.

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

operating instructions for the control panel.

7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Maintenance must be executed by a professional.

Only those persons who have appropriate electrical knowledge (authorized

personnel) may remove the safety plates.

Note!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any

faults.

7.1 Cleaning the air filter

SRelease the cover plate with the dust

filter (1).

SSwing out the cover plate (2).

SRemove the dust filter (3).

SBlow it clean with compressed air at

reduced pressure.

SReplace the filter with the finer mesh

on the side against the cover plate (2).

SReplace the cover plate with the filter.

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