AristoPower 4600c
DC Welding Power Sources
Instruction Manual
0558008884 03 / 2009
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
CAUTION
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/or inserts 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 be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends 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.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
2
TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions ....................................................................................5
1.1 Safety - English .................................................................................5
1.2 Safety - Spanish.................................................................................9
1.3 Safety - French.................................................................................13
2.0 Description ..........................................................................................17
2.1 Safety .........................................................................................19
2.2 Description....................................................................................19
2.3 Optional Accessories...........................................................................21
3.0 Installation.......................................................................................... 23
4.0 Operation ...........................................................................................27
5.0 Maintenance........................................................................................ 29
5.1 Cleaning....................................................................................... 29
5.2 Inspection and Service......................................................................... 29
5.2.1 Fan Motor.............................................................................. 29
5.2.2 Transformer ............................................................................29
5.2.3 Wire Feeder Control Circuits ............................................................29
5.2.4 Over Temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.0 Troubleshooting .....................................................................................31
7.0 Replacement Parts ...................................................................................33
7.1 General........................................................................................33
7.2 Ordering ......................................................................................33
3
TABLE OF CONTENTS
4
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
WARNING: These Safety Precautions are
for your protection. They summarize precautionary information from the references
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 equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield tted with the correct lter 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 not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy long-
sleeve shirt, cuess trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A ameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, 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-ammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
1.1 Safety - English
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective non-ammable 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 oors or wall openings and cause a hidden smoldering re or res on the oor 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 so that there
are no substances on the workpiece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a re hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
5
SECTION 1 SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on 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.
8. Put on dry, hole-free gloves before turning on the
power.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. 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.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommendations. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current owing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health eects which
are unknown.
1. Always provide 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 operations. 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 improve 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 specic ventilation recommendations.
6
SECTION 1 SAFETY PRECAUTIONS
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 & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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 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.
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 xtures where they may
become part of an electrical circuit.
3. When not in 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 ames.
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 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric 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,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
7
SECTION 1 SAFETY PRECAUTIONS
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used
throughout this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in immediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
8
SECCION 1 SEGURIDAD
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar 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 protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2. Use una careta que tenga el ltro correcto y lente
para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón 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 partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chis-
pas calientes con una cortina adecuada no-amable
como división.
6. Use careta protectora además de sus gafas de segu-
ridad cuando esté removiendo escoria o puliendo.
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases amables, solventes,
pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan
producir gases inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corri-
ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.
9
SECCION 1 SEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
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 eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas 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 - Son peligrosos. La corriente
eléctrica uye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos 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 sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique sub-
stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones especícas en la ventilación.
10
SECCION 1 SEGURIDAD
5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
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, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico 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 através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
SECCION 1 SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
12
SECTION 1 SÉCURITÉ
1.3 Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les ches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans la-
téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres ltrants et de
plaques protectrices appropriées an de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes an de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininammable an de vous protéger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininammable.
6. Portez des lunettes étanches par dessus vos lunettes
de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
L es p er so n ne s se tr o uv an t à p r ox im it é do ive n t é ga l e ment porter des lunettes étanches par dessus leur
lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ssures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-
telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
13
SECTION 1 SÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-
teur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des eets néfastes inconnus pour
la santé.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A. Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.
14
SECTION 1 SÉCURITÉ
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.
3. Maintenez les câbles, les ls de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.
6. Utilisez l'équipement conformément à son usage
prévu et n'eectuez aucune modication.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
15
SECTION 1 SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signie un danger qui peut entraîner des blessures
corporelles mineures.
16
SECTION 2 DESCRIPTION
Specifications:
Rated DC Output @ 100% Duty Cycle
50/60Hz, cv or cc .............................. .450 amps 38 vdc
Rated DC Output @ 60% Duty Cycle
50/60Hz, cv or cc ............................... 500 amps 39 vdc
Welding Range................................... 10A/12V to 500A/40V
Open Circuit Voltage Max. .......................................... 80vdc
Primary Input Voltage and Current @ 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:
W x L x H......... 18.8”(483mm), 32.5” (819mm), 25”(622mm)
Net Weight ................................................. 322 lbs.(146 Kg)
Shipping Weight ......................................... 375 lbs. (170Kg)
TM
Technology design, provides superior
Shown with AristoDrive 4 -30 wire feeder,
GM-400 Mig welding torch, TR-29 truck kit,
work cable, clamp and welding wire.
Build a Custom AristoPower Welding System
AristoPow er
T M
Pow er Source
AristoDrive 4
T M
Wire Feeder
Connection Cable
Gunmaster 400
NAS Connection
Options & Accessories
AristoDrive 4-30 *
0558003276 6ft. (2m)
AristoDrive 4-48 * 0456527880
12 ft. x .035-.045
0558003275 26ft. (8m)
0558001656
A
ristoPow er-460
A
ristoDrive 4- 48 * 0456527881
15 ft. x .035-.045
0558002668
Boom Sys tem
52ft.
(
16m
)
0558001659
0558003700 0456527882
12 ft. x .052-1/16
Balance Boom** 82ft. (25m) 0558001657
Balance Boom 12f t. 0456527883
15 ft. x .052-1/16
0558003442 114ft. (35m)
0558001660
Balance Boom 16f t. 0456527884
0558003365
* Includes M A -6 MM C
** See Boom Sales Sheets fo r co mplet e information
Complete Your Custom
System by Ordering
Components f rom the
Options & Accessories
List on the f ollow ing
page
AristoPower 4600c 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 & pulsed Mig and Stick welding
10 memory locations for user-dened 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
inverter like performance in the welding arc while providing SCR like reliability.
Energy and power ecient, the best in its class with a
92% eciency gure. 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 ne tuning of the arc characteris-
tics when short arc welding.
Adjustable arc force and hot start control for superior
stick electrode performance.
100% 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 energy savings.
Automatically turns the fan motor on and o.
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
TM
Technology design, provides superior
Shown with AristoDrive 4 -30 wire feeder, GM-
400 Mig welding torch, TR-29 truck kit, work
cable, clamp and welding wire.
Specications:
Rated DC Output @ 100% Duty Cycle
50/60Hz, cv or cc ..................................................450 amps 38 vdc
Rated DC Output @ 60% Duty Cycle
50/60Hz, cv or cc ..................................................500 amps 39 vdc
Welding Range ..................................................... 10A/12V to 500A/40V
Open Circuit Voltage Max. ............................................................... 80vdc
Primary Input Voltage and Current @ 100% DutyCycle
230/460/575vac, 60Hz 3ph .................................66/33/26 amps
Power Factor at Rated Output ...........................................................89%
Eciency at Rated Output ..................................................................92%
Auxiliary Output Power ............................. 115vac 50/60Hz, 10 amps
Physical Dimensions:
W x L x H ......................18.8”(483mm), 32.5” (819mm), 25”(622mm)
Net Weight .........................................................................322 lbs.(146 Kg)
Shipping Weight ..............................................................375 lbs. (170Kg)
17
SECTION 2 DESCRIPTION
MMA-6 MMC (Man/Machine Communications)
Easy to set weld parameters for MIG, MIG Pulse, Stick or Gouging. Choose
synergic weld parameters from one of 107 possibilities. Set the wire feed
speed and weld!
Internal Memory stores up to 10 dierent weld parameter set-ups. Recall
parameters with a simple push of a button. Programmable soft keys allow
direct access to exible functions, such as hot start, crater ll, 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 & post ow, inch or metric units, auto weld
schedule select, arc force, burnback and more. Update and change weld
data using optional ESAT software for maximum exibility.
Options & Accessories
AristoPower 4600c
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 cylinders, 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).
Aristo Control 5 Program Box ................................. 466801881
Use this option to access 5 dierent 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.
18
SECTION 2 DESCRIPTION
2.1. SAFETY
Before the AristoPower 4600c power source is put into operation, the safety section at the front of this manual should be
read completely. This will help avoid possible injury due to misuse or improper installation.
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 4600
equipment until you have read and fully understand these instructions. The information presented here should be given
careful consideration to ensure proper installation and optimum weld performance of this equipment.
Table 2-1. Rating Label for AristoPower 4600c
c power source. DO NOT attempt to install or operate this
The AristoPower 4600c 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 voltampere characteristics desired for conventional MIG (GMAW) and ux 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 specications.
19
SECTION 2 DESCRIPTION
FEATURES:
• Auto Fan - The AristoPower 4600c fan will run when the power source is rst 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 if 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 recongure with ESAT (ESAB Software Administration Tool) software.
A. VOLT AMPERE CHARACTERISTICS
The curves shown in Figure 2-1 represent the static volt-ampere characteristics for the power source. The slant of these
curves is referred to as the "slope" and is generally dened 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 of the power source. This switch energizes the main transformer,
control circuitry and illuminates the Power “ON” lamp.
2. FAULT/TEMPERATURE LAMP
The FAULT/TEMP lamp illuminates if an over temperature condition occurs within the AristoPower 4600c power source.
This condition may be caused by excessive duty cycle or over-current conditions. When an over temperature condition
occurs, the welding output is turned o and the unit must be allowed to cool. The machine will automatically reset when
the temperature falls to a safe level.
Constant Current (Max)
Constant Voltage (Max)
Constant Current (Min)
Constant Voltage (Min)
Figure 2-1 - AristoPower 4600c Volt-Ampere Curves
20
SECTION 2 DESCRIPTION
3. CONTROL RECEPTACLE
There are two 12-pin receptacles on the front panel and two 12-pin receptacles on the rear panel. Any of the four receptacles
accepts the control cable from the AristoDrive wire feeder and handles 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 CO2 regulator, or small hand
tools. The receptacle is rated 115 Vac / 10 amps with a oating neutral.
5. 42VAC AND 115 VAC CIRCUIT BREAKER (CB1 & CB2)
These resetable 10 amp circuit breakers (CB1 & 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 600A positive "twist lock" connector is mounted on
the rear panel.
2.3. OPTIONAL ACCESSORIES
A number of remote control units can be connected to the Aristo via the Remote Control Adaptor
A. REMOTE PROGRAM AND SYNERGIC CONTROLS
SEE OPTIONS & 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. When the adapter is connected, the power source and wire feed unit is 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.
Fault/Temperature
Lamp
Power “ON”
Lamp
Figure 2-2. Standard Control Panel
21
SECTION 2 DESCRIPTION
42Vac and
115 Vac
Circuit Breakers
Component
Connection
Receptacles
Weld Cable
Connection Lugs
115 Vac
10 Amp
Receptacle
Figure 2-3. Front View
OFF/ON
Switch
Component
Connection
Receptacles
(Secondary)
Positive Out-
put Receptacle
Input Cable
Strain Relief
Figure 2-4. Rear View
B. TR29 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. 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.
22
SECTION 3 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 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 Specications
for overall dimensions of the unit.
Do not use lters 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 ltering device is used.
CAUTION
For lifting purposes and for keeping dust, moisture, and other foreign material from entering the
power source, the lifting eyebolt must be fully tightened with a tool.
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 led by the purchaser with the
carrier. A copy of the 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. Check air passages at front and rear of cabinet, making sure that packing material has not obstructed air ow
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 completely under the base.
ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CONNECTIONS TO THE POWER
S O U R C E , " M A C H I N E R Y L O C K O U T P R O C E D U R E S " S H O U L D B E E M P L O Y E D . I F T H E C O N N E C T I O N S A R E
TO BE MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH IN THE OFF POSITION AND
WARNING
PADLOCK IT TO PREVENT INADVERTENT TRIPPING. IF THE CONNECTION IS MADE FROM A FUSE BOX,
REMOVE THE CORRESPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS NOT POSSIBLE TO
USE PADLOCKS, ATTACH A RED TAG TO THE LINE DISCONNECT SWITCH OR FUSE BOX WARNING
OTHERS THAT THE CIRCUIT IS BEING WORKED ON.
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 (exible 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.
23
Table 3-1. Recommended Sizes for Input
Conductors and Line Fuses
Rated Input
@ 100% Duty Cycle
Inp ut &
GND
Conductor*
CU/AW G
Fuse
Size
Amps
Volts Amps
220
230
400
460
575
68
66
37
33
26
No. 6
No. 6
No. 8
No. 8
No. 10
100
100
60
60
50
SECTION 3 INSTALLATION
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 connections are correct and well-insulated.
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 (575VAC). 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 reconguring the copper
link bars to the silk-screened voltage designations for the desired voltage.
TB-3
L1, L2, L3
Connection
Primary Cable
Ground Fault
Switch & Bracket
Ground
Connection
Table 3-1. Recommended Sizes for Input
Conductors and Line Fuses
*Sized per National Code for 80 °C rated copper conductors @ 30 °C ambi-
ent. Not more than three conductors in raceway or cable. Local codes
should be followed if they specify sizes other than those listed above.
Figure 3-1. Primary Power Leads L1,L2, L3 & Ground
Figure 3-2.
24
(3) PRIMARY
INPUT
CONDUCTORS
5"
24"
Green
(Earth Ground)
Recommended Cable Strip Lengths
SECTION 3 INSTALLATION
D. OUTPUT WELDING CONNECTIONS
(SECONDARY)
230 Vac Input 460 Vac Input 575 Vac Input
Figure 3-3. Input Terminal Board Conguration for 230/460/575 Model
(factory supplied in the 575 conguration)
230 Vac Input
Figure 3-4. Input Terminal Board Conguration 230/460
Model (factory supplied in the 460 conguration)
460 Vac Input
*
*
*
200 Vac Input
Figure 3-5. Input Terminal Board Conguration 200/400
Model (factory supplied in the 400 conguration)
400 Vac Input
25
SECTION 3 INSTALLATION
(SECONDARY)
Table 3-6. Output Cable Sizes (Secondary)
Welding
Current
Total Length (Feet) of
Cable in Weld Circuit*
50 100 150 200 250
100
150
200
250
300
400
500
6
4
3
2
1
2/0
3/0
4
3
1
1/0
2/0
3/0
3/0
3
1
1/0
2/0
3/0
4/0
4/0
2
1/0
2/0
3/0
4/0
4/0
2-2/0
1/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
WARNING
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 is located at 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 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
4600c. The secondary output cable connects (in most cases) between the positive output lug of the AristoPower 4600c 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 4600c 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.
BE SURE THAT THE BRANCH CIRCUIT OR MAIN DISCONNECT SWITCH IS OFF, OR ELECTRICAL
INPUT FUSES ARE REMOVED, BEFORE ATTEMPTING ANY INSPECTION OR WORK INSIDE THE
POWER SOURCE. PLACING THE POWER SWITCH IN THE OFF POSITION DOES NOT REMOVE ALL
POWER FROM INSIDE THE POWER SOURCE.
* 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.
Table 3-6. Output Cable Sizes (Secondary)
26
SECTION 4 OPERATION
ELECTRIC SHOCK 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 PREVENT INADVERTENT TRIPPING. IF THE
CONNECTION IS MADE FROM A FUSE BOX, REMOVE THE CORRESPONDING FUSES AND
PADLOCK THE BOX COVER. IF IT IS NOT POSSIBLE TO USE PADLOCKS, ATTACH A RED
TAG TO THE LINE DISCONNECT SWITCH OR FUSE BOX WARNING OTHERS THAT THE
CIRCUIT IS BEING WORKED ON.
WARNING
4.1. OPERATION
THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL GROUND. FAILURE
TO DO SO MAY RESULT IN ELECTRICAL SHOCK, SEVERE BURNS OR DEATH.
CHECK THE VOLTAGE LINKS FOR PROPER VOLTAGE ON THE INPUT TERMINAL BOARD
BEFORE APPLYING PRIMARY POWER.
BEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUTPUT TERMINALS
MAKE SURE THAT ALL PRIMARY INPUT POWER TO THE MACHINE IS OFF.
A. WIRE FEEDER COMPATIBILITY
The AristoPower 4600c 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. MA6 MAN/MACHINE COMMUNICATIONS
In the 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”.
Figure 4-1 Wire Feed Speed & Volts Display
27
SECTION 4 OPERATION
4.1. OPERATION (con't.)
C. TIG and STICK WELDING
In the TIG and STICK process mode, 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.
Figure 4-2. Overall Front View
28
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 source is used.
It is imperative that all air passages be kept as clean as possible in order to allow adequate air ow 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 is 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
If the 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.
29
SECTION 5 MAINTENANCE
30
SECTION 6 TROUBLESHOOTING
CONDITION ACTION
Unit Inoperative A.
B.
C.
D.
E.
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 & replace defective fuse.
No Output -- Fan
Running
A.
B.
C.
D.
Poor or improper electrical input -- check input connections on TB.
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
Open-Circuit Voltage
A.
B.
C.
Input voltage jumper links on terminal board improperly set -- check for proper
voltage.
Poor output connections. Take apart, clean, and reassemble.
Panel-Remote switch in Remote position and remote voltage pot disabled.
Erratic Weld Current A.
B.
C.
D.
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 Outp ut, No
Voltage Control
A.B.PC board defective or loose -- reset and/or replace board.
Shorted I.G.B.T. - Replace I.G.B.T. and check driver PCB.
No 115 Volt ac Output A. Circuit breaker tripped. Check 115V CB2 -- Reset.
Line Fuse Blows When
Power Source is First
Turned On
A.B.Shorted SCR in Main Bridge -- replace.
Shorted capacitor in Capacitor Bank.
Wire Feeder is
Inoperative
A.B.Loose feeder control cable -- Check and tighten all connections.
A Circuit Breaker tripped -- Check 42V CB1 -- Reset.
Table 6-1 Troubleshooting Table
SECTION 6 TROUBLESHOOTING
6.0 TROUBLESHOOTING
If the power source is operating improperly, the following troubleshooting
information 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.
6.0 TROUBLESHOOTING
If the power source is operating improperly, the following troubleshooting information 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
31
SECTION 6 TROUBLESHOOTING
32
SECTION 7 REPLACEMENT PARTS
7.0 Replacement Parts
7.1 General
Always provide the 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 ensure 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.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
Note
Items listed in the following Bill of Materials that do not have a part number
shown are not available from ESAB as a replaceable item and cannot be
ordered. Descriptions are shown for reference only. Please use local retail
hardware outlets as a source for these items.
Note
All relevant Replacement Parts, Schematics and Wiring Dia-
grams are on 279.4mm x 431.8mm (11” x 17”) paper included
inside the back cover of this manual.
33
SECTION 7 REPLACEMENT PARTS
AristoPower 460 "Sleep" Option Kit
Bill-of-Material
PN-0558004579
Part Description Quantity
Number
0558004684 Control Transformer 1
0558038271 P. C. Board 1
(8)950840 Contactor 1
AristoPower 4600c "Sleep" Feature Replacement Parts
The “Sleep” feature reduces the power consumption (and cost of operation) during periods when the AristoPower 4600c power source is not welding. If the power source remains at idle (no welding being done) for a
period of 15 minutes, a pimary contactor will disconnect the main power transformer from the primary AC line.
The power source control circuits continued to be powered by a control transformer. The power source will immediately reconnect the primary to the main transformer and start welding when the gun trigger is pulled.
34
Original release - 03 / 2009
REVISION HISTORY
35
ESAB Welding & 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 Specications 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. WELDING 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) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
Manual # (Bck.) Mon./Yr.
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