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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.

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 be-
fore installing or operating this equipment.

This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions 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 imme-
diately. 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 ser-
vice facility designated by the manufacturer.



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

table of contents

section 1 safety precautions

1.0 Safety Precautions 1.1 Safety - English

WARNING: These Safety Precautions are FIRES AND EXPLOSIONS -- Heat from
for your protection. They summarize pre- flames and arcs can start fires. Hot
cautionary information from the references slag or sparks can also cause fires and
listed in Additional Safety Information sec- explosions. Therefore:
tion. Before performing any installation or operating
procedures, be sure to read and follow the safety precau- 1. Remove all combustible materials well away from
tions listed below as well as all other manuals, material the work area or cover the materials with a protec-
safety data sheets, labels, etc. Failure to observe Safety tive non-flammable covering. Combustible materials
Precautions can result in injury or death. include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
PROTECT YOURSELF AND OTHERS -- 2. Hot sparks or hot metal can fall through cracks or
Some welding, cutting, and gouging crevices in floors or wall openings and cause a hid-
processes are noisy and require ear den smoldering fire or fires on the floor below. Make
protection. The arc, like the sun, emits certain that such openings are protected from hot
ultraviolet (UV) and other radiation sparks and metal.
and can injure skin and eyes. Hot metal can cause 3. Do not weld, cut or perform other hot work until the
burns. Training in the proper use of the processes workpiece has been completely cleaned so that there
and equipment is essential to prevent accidents. are no substances on the workpiece which might
Therefore: produce flammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
1. Always wear safety glasses with side shields in any 4. Have fire extinguishing equipment handy for instant
work area, even if welding helmets, face shields, and use, such as a garden hose, water pail, sand bucket,
goggles are also required. or portable fire extinguisher. Be sure you are trained
2. Use a face shield fitted with the correct filter and in its use.
cover plates to protect your eyes, face, neck, and 5. Do not use equipment beyond its ratings. For ex-
ears from sparks and rays of the arc when operating ample, overloaded welding cable can overheat and
or observing operations. Warn bystanders not to create a fire hazard.
watch the arc and not to expose themselves to the 6. After completing operations, inspect the work area
rays of the electric-arc or hot metal. to make certain there are no hot sparks or hot metal
3. Wear flameproof gauntlet type gloves, heavy long- which could cause a later fire. Use fire watchers when
sleeve shirt, cuffless trousers, high-topped shoes, necessary.
and a welding helmet or cap for hair protection, to 7. For additional information, refer to NFPA Standard
protect against arc rays and hot sparks or hot metal. 51B, "Fire Prevention in Use of Cutting and Welding
A flameproof apron may also be desirable as protec- Processes", available from the National Fire Protec-
tion against radiated heat and sparks. tion Association, Batterymarch Park, Quincy, MA
4. Hot sparks or metal can lodge in rolled up sleeves, 02269.
trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing. ELECTRICAL SHOCK -- Contact with
5. Protect other personnel from arc rays and hot live electrical parts and ground can
sparks with a suitable non-flammable partition or cause severe injury or death. DO NOT
curtains. use AC welding current in damp areas,
6. Use goggles over safety glasses when chipping slag if movement is confined, or if there is
or grinding. Chipped slag may be hot and can fly far. danger of falling.
Bystanders should also wear goggles over safety

section 1 safety precautions

1. Be sure the power source frame (chassis) is con- 3. Welders should use the following procedures to
nected to the ground system of the input power. minimize exposure to EMF:

2. Connect the workpiece to a good electrical A. Route the electrode and work cables together.
ground. Secure them with tape when possible.

3. Connect the work cable to the workpiece. A poor B. Never coil the torch or work cable around your
or missing connection can expose you or others body.
to a fatal shock.
C. Do not place your body between the torch and
4. Use well-maintained equipment. Replace worn or work cables. Route cables on the same side of
damaged cables. your body.

5. Keep everything dry, including clothing, work D. Connect the work cable to the workpiece as close
area, cables, torch/electrode holder, and power as possible to the area being welded.
E. Keep welding power source and cables as far
6. Make sure that all parts of your body are insulated away from your body as possible.
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 FUMES AND GASES -- Fumes and
on dry boards or an insulating platform and wear gases, can cause discomfort or harm,
rubber-soled shoes. particularly in confined spaces. Do
not breathe fumes and gases. Shield-
8. Put on dry, hole-free gloves before turning on the ing gases can cause asphyxiation.
power. Therefore:

9. Turn off the power before removing your gloves. 1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
10. Refer to ANSI/ASC Standard Z49.1 (listed on gouge on materials such as galvanized steel, stain-
next page) for specific grounding recommenda- less steel, copper, zinc, lead, beryllium, or cadmium
tions. Do not mistake the work lead for a ground unless positive mechanical ventilation is provided.
cable. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

ELECTRIC AND MAGNETIC FIELDS tions. The heat or arc rays can react with chlorinated
May be dangerous. Electric cur- hydrocarbon vapors to form phosgene, a highly
rent flowing through any conduc- toxic gas, and other irritant gases.
tor causes localized Electric and
Magnetic Fields (EMF). Welding and 3. If you develop momentary eye, nose, or throat ir-
cutting current creates EMF around welding cables ritation while operating, this is an indication that
and welding machines. Therefore: ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
1. Welders having pacemakers should consult their area. Do not continue to operate if physical discom-
physician before welding. EMF may interfere with fort persists.
some pacemakers.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
2. Exposure to EMF may have other health effects which for specific ventilation recommendations.
are unknown.
section 1 safety precautions

5. WARNING: This product, when used for welding 1. Always have qualified personnel perform the instal-
or cutting, produces fumes or gases lation, troubleshooting, and maintenance work.
which contain chemicals known to Do not perform any electrical work unless you are
the State of California to cause birth qualified to perform such work.
defects and, in some cases, cancer.
(California Health & Safety Code 2. Before performing any maintenance work inside a
25249.5 et seq.) power source, disconnect the power source from
the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

CYLINDER HANDLING -- Cylinders, cord, and power supply in safe working order. Do
if mishandled, can rupture and vio- not operate any equipment in faulty condition.
lently release gas. Sudden rupture
of cylinder, valve, or relief device can 4. Do not abuse any equipment or accessories. Keep
injure or kill. Therefore: equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
1. Use the proper gas for the process and use the corrosive atmospheres and inclement weather.
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not 5. Keep all safety devices and cabinet covers in position
use adaptors. Maintain hoses and fittings in good and in good repair.
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas 6. Use equipment only for its intended purpose. Do
cylinder. not modify it in any manner.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure ADDITIONAL SAFETY INFORMATION -- For
cylinders to work tables or fixtures where they may more information on safe practices for
become part of an electrical circuit. electric arc welding and cutting equip-
ment, ask your supplier for a copy of
3. When not in use, keep cylinder valves closed. Have "Precautions and Safe Practices for Arc
valve protection cap in place if regulator is not con- Welding, Cutting and Gouging", Form
nected. Secure and move cylinders by using suitable 52-529.
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames. The following publications, which are available from
Never strike an arc on a cylinder. the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
in Cylinders", which is available from Compressed
Gas Association, 1235 Jefferson Davis Highway, 2. AWS C5.1 - "Recommended Practices for Plasma Arc
Arlington, VA 22202. Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

improperly maintained equipment can
cause injury or death. Therefore: 4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

section 1 safety precautions

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-


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 Atten-
tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-
mediate, 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.

1.2 Safety - Spanish La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas debern usar gafas
ADVERTENCIA: Estas Precauciones de Se- de seguridad y careta protectora.
guridad son para su proteccin. Ellas hacen
resumen de informacin proveniente de las FUEGO Y EXPLOSIONES -- El calor de
referencias listadas en la seccin "Informacin Adi- las flamas y el arco pueden ocacionar
cional Sobre La Seguridad". Antes de hacer cualquier fuegos. Escoria caliente y las chispas
instalacin o procedimiento de operacin , asegrese pueden causar fuegos y explosiones.
de leer y seguir las precauciones de seguridad listadas Por lo tanto:
a continuacin as como tambin todo manual, hoja
de datos de seguridad del material, calcomanias, etc. 1. Remueva todo material combustible lejos del rea
El no observar las Precauciones de Seguridad puede de trabajo o cubra los materiales con una cobija a
resultar en dao a la persona o muerte. prueba de fuego. Materiales combustibles incluyen
madera, ropa, lquidos y gases flamables, solventes,
PROTEJASE USTED Y A LOS DEMAS-- pinturas, papel, etc.
Algunos procesos de soldadura, corte 2. Chispas y partculas de metal pueden introducirse en
y ranurado son ruidosos y requiren las grietas y agujeros de pisos y paredes causando
proteccin para los odos. El arco, fuegos escondidos en otros niveles o espacios.
como el sol , emite rayos ultravioleta Asegrese de que toda grieta y agujero est cubierto
(UV) y otras radiaciones que pueden daar la piel para proteger lugares adyacentes contra fuegos.
y los ojos. El metal caliente causa quemaduras. EL 3. No corte, suelde o haga cualquier otro trabajo
entrenamiento en el uso propio de los equipos y relacionado hasta que la pieza de trabajo est to-
sus procesos es esencial para prevenir accidentes. talmente limpia y libre de substancias que puedan
Por lo tanto: producir gases inflamables o vapores txicos. No
trabaje dentro o fuera de contenedores o tanques
1. Utilice gafas de seguridad con proteccin a los lados cerrados. Estos pueden explotar si contienen vapores
siempre que est en el rea de trabajo, an cuando inflamables.
est usando careta de soldar, protector para su cara 4. Tenga siempre a la mano equipo extintor de fu-
u otro tipo de proteccin. ego para uso instantneo, como por ejemplo una
2. Use una careta que tenga el filtro correcto y lente manguera con agua, cubeta con agua, cubeta con
para proteger sus ojos, cara, cuello, y odos de las arena, o extintor porttil. Asegrese que usted esta
chispas y rayos del arco cuando se est operando y entrenado para su uso.
observando las operaciones. Alerte a todas las per- 5. No use el equipo fuera de su rango de operacin. Por
sonas cercanas de no mirar el arco y no exponerse ejemplo, el calor causado por cable sobrecarga en
a los rayos del arco elctrico o el metal fundido. los cables de soldar pueden ocasionar un fuego.
3. Use guantes de cuero a prueba de fuego, camisa 6. Despus de termirar la operacin del equipo, inspec-
pesada de mangas largas, pantaln de ruedo liso, cione el rea de trabajo para cerciorarse de que las
zapato alto al tobillo, y careta de soldar con capucha chispas o metal caliente ocasionen un fuego ms
para el pelo, para proteger el cuerpo de los rayos y tarde. Tenga personal asignado para vigilar si es
chispas calientes provenientes del metal fundido. necesario.
En ocaciones un delantal a prueba de fuego es 7. Para informacin adicional , haga referencia a la
necesario para protegerse del calor radiado y las publicacin NFPA Standard 51B, "Fire Prevention in
chispas. Use of Cutting and Welding Processes", disponible
4. Chispas y partculas de metal caliente puede alojarse a travs de la National Fire Protection Association,
en las mangas enrolladas de la camisa , el ruedo del Batterymarch Park, Quincy, MA 02269.
pantaln o los bolsillos. Mangas y cuellos debern
mantenerse abotonados, bolsillos al frente de la CHOQUE ELECTRICO -- El contacto
camisa debern ser cerrados o eliminados. con las partes elctricas energizadas
5. Proteja a otras personas de los rayos del arco y chis- y tierra puede causar dao severo o
pas calientes con una cortina adecuada no-flamable muerte. NO use soldadura de corri-
como divisin. ente alterna (AC) en reas hmedas,
6. Use careta protectora adems de sus gafas de segu- de movimiento confinado en lugares estrechos o
ridad cuando est removiendo escoria o puliendo. si hay posibilidad de caer al suelo.

1. Asegrese de que el chasis de la fuente de poder 3. Los soldadores debern usar los siguientes proced-
est conectado a tierra atravs del sistema de imientos para minimizar exponerse al EMF:
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de A. Mantenga el electrodo y el cable a la pieza de
tierra fsica. trabajo juntos, hasta llegar a la pieza que usted
3. Conecte el cable de retorno a la pieza de trabajo. quiere soldar. Asegrelos uno junto al otro con
Cables y conductores expuestos o con malas cinta adhesiva cuando sea posible.
conexiones pueden exponer al operador u otras B. Nunca envuelva los cables de soldar alrededor
personas a un choque elctrico fatal. de su cuerpo.
4. Use el equipo solamente si est en buenas condi- C. Nunca ubique su cuerpo entre la antorcha y el
ciones. Reemplaze cables rotos, daados o con cable, a la pieza de trabajo. Mantega los cables a
conductores expuestos. un slo lado de su cuerpo.
5. Mantenga todo seco, incluyendo su ropa, el rea de D. Conecte el cable de trabajo a la pieza de trabajo
trabajo, los cables, antorchas, pinza del electrodo, lo ms cercano posible al rea de la soldadura.
y la fuente de poder. E. Mantenga la fuente de poder y los cables de soldar
6. Asegrese que todas las partes de su cuerpo estn lo ms lejos posible de su cuerpo.
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mien-
tras trabaja en lugares estrechos o reas hmedas; HUMO Y GASES -- El humo y los
trabaje sobre un pedazo de madera seco o una gases, pueden causar malestar o
plataforma insulada y use zapatos con suela de dao, particularmente en espacios
goma. sin ventilacin. No inhale el humo
8. Use guantes secos y sin agujeros antes de energizar o gases. El gas de proteccin puede
el equipo. causar falta de oxgeno.
9. Apage el equipo antes de quitarse sus guantes. Por lo tanto:
10. Use como referencia la publicacin ANSI/ASC
Standard Z49.1 (listado en la prxima pgina) para 1. Siempre provea ventilacin adecuada en el rea
recomendaciones especficas de como conectar el de trabajo por medio natural o mecnico. No solde,
equipo a tierra. No confunda el cable de soldar a corte, o ranure materiales con hierro galvanizado,
la pieza de trabajo con el cable a tierra. acero inoxidable, cobre, zinc, plomo, berlio, o cad-
mio a menos que provea ventilacin mecnica
CAMPOS ELECTRICOS Y MAGNETI- positiva . No respire los gases producidos por
COS - Son peligrosos. La corriente estos materiales.
elctrica fluye atravs de cualquier 2. No opere cerca de lugares donde se aplique sub-
conductor causando a nivel local stancias qumicas en aerosol. El calor de los rayos
Campos Elctricos y Magnticos del arco pueden reaccionar con los vapores de
(EMF). Las corrientes en el rea de corte y soldadura, hidrocarburo clorinado para formar un fosfgeno,
crean EMF alrrededor de los cables de soldar y las o gas txico, y otros irritant es.
maquinas. Por lo tanto: 3. Si momentneamente desarrolla inrritacin de
ojos, nariz o garganta mientras est operando, es
1. Soldadores u Operadores que use marca-pasos para indicacin de que la ventilacin no es apropiada.
el corazn debern consultar a su mdico antes de Pare de trabajar y tome las medidas necesarias
soldar. El Campo Electromagntico (EMF) puede para mejorar la ventilacin en el rea de trabajo.
interferir con algunos marca-pasos. No contine operando si el malestar fsico per-
2. Exponerse a campos electromagnticos (EMF) puede 4. Haga referencia a la publicacin ANSI/ASC Standard
causar otros efectos de salud an desconocidos. Z49.1 (Vea la lista a continuacin) para recomen-
daciones especficas en la ventilacin.


5. ADVERTENCIA-- Este producto cuando se uti- 1. Siempre tenga personal cualificado para efec-
liza para soldaduras o cortes, tuar l a instalacin, diagnstico, y mantenimiento
produce humos o gases, los del equipo. No ejecute ningn trabajo elctrico a
cuales contienen qumicos menos que usted est cualificado para hacer el
conocidos por el Estado de Cali- trabajo.
fornia de causar defectos en el 2. Antes de dar mantenimiento en el interior de la
nacimiento, o en algunos casos, fuente de poder, desconecte la fuente de poder
Cancer. (California Health & del suministro de electricidad primaria.
Safety Code 25249.5 et seq.) 3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
MANEJO DE CILINDROS-- Los en buen estado operacional. No opere ningn
cilindros, si no son manejados equipo en malas condiciones.
correctamente, pueden romp- 4. No abuse del equipo y sus accesorios. Mantenga
erse y liberar violentamente el equipo lejos de cosas que generen calor como
gases. Rotura repentina del hornos, tambin lugares hmedos como charcos
cilindro, vlvula, o vlvula de de agua , aceite o grasa, atmsferas corrosivas y
escape puede causar dao o las inclemencias del tiempo.
muerte. Por lo tanto: 5. Mantenga todos los artculos de seguridad y
coverturas del equipo en su posicin y en buenas
1. Utilize el gas apropiado para el proceso y utilize condiciones.
un regulador diseado para operar y reducir la 6. Use el equipo slo para el propsito que fue
presin del cilindro de gas . No utilice adapta- diseado. No modifique el equipo en ninguna
dores. Mantenga las mangueras y las conexiones manera.
en buenas condiciones. Observe las instrucciones
de operacin del manufacturero para montar el
regulador en el cilindro de gas comprimido. INFORMACION ADICIONAL DE SEGURI-
DAD -- Para ms informacin sobre las
2. Asegure siempre los cilindros en posicin vertical prcticas de seguridad de los equipos de
y amrrelos con una correa o cadena adecuada arco elctrico para soldar y cortar, pregunte
para asegurar el cilindro al carro, transportes, tablil- a su suplidor por una copia de "Precautions
leros, paredes, postes, o armazn. Nunca asegure and Safe Practices for Arc Welding, Cutting
los cilindros a la mesa de trabajo o las piezas que and Gouging-Form 52-529.
son parte del circuito de soldadura . Este puede ser
parte del circuito ellectrico.
Las siguientes publicaciones, disponibles atravs de
3. Cuando el cilindro no est en uso, mantenga la la American Welding Society, 550 N.W. LeJuene Road,
vlvula del cilindro cerrada. Ponga el capote de Miami, FL 33126, son recomendadas para usted:
proteccin sobre la vlvula si el regulador no
est conectado. Asegure y mueva los cilindros 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los 2. AWS C5.1 - "Recommended Practices for Plasma Arc

MANTENIMIENTO DEL EQUIPO -- Equipo 3. AWS C5.2 - "Recommended Practices for Plasma Arc
defectuoso o mal mantenido puede Cutting"
causar dao o muerte. Por lo tanto:
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"



-- Segn usted avanza en la lectura
de este folleto: Los Smbolos Sig-
nifican Atencin! Est Alerta! Se
trata de su seguridad.

Significa riesgo inmediato que,

de no ser evadido, puede resultar
inmediatamente en serio dao
personal o la muerte.

Significa el riesgo de un peligro

potencial que puede resultar en
serio dao personal o la muerte.

Significa el posible riesgo que

puede resultar en menores daos
a la persona.

section 1 sCURIT
1.3 Safety - French INCENDIES ET EXPLOSIONS -- La
AVERTISSEMENT : Ces rgles de scurit chaleur provenant des flammes ou de
ont pour but d'assurer votre protection. Ils l'arc peut provoquer un incendie. Le
rcapitulent les informations de prcaution laitier incandescent ou les tincelles
provenant des rfrences dans la section peuvent galement provoquer un
des Informations de scurit supplmentaires. Avant incendie ou une explosion. Par consquent :
de procder l'installation ou d'utiliser l'unit, assurez-
vous de lire et de suivre les prcautions de scurit ci- 1. loignez suffisamment tous les matriaux combus-
dessous, dans les manuels, les fiches d'information sur la tibles de l'aire de travail et recouvrez les matriaux
scurit du matriel et sur les tiquettes, etc. Tout dfaut
d'observer ces prcautions de scurit peut entraner avec un revtement protecteur ininflammable. Les
des blessures graves ou mortelles. matriaux combustibles incluent le bois, les vte-
ments, la sciure, le gaz et les liquides combustibles,
PROTGEZ-VOUS -- Les processus de les solvants, les peintures et les revtements, le
soudage, de coupage et de gougeage papier, etc.
produisent un niveau de bruit lev et 2. Les tincelles et les projections de mtal incan-
exige l'emploi d'une protection auditive. L'arc, tout descent peuvent tomber dans les fissures dans
comme le soleil, met des rayons ultraviolets en plus les planchers ou dans les ouvertures des murs et
d'autre rayons qui peuvent causer des blessures la dclencher un incendie couvant l'tage infrieur
peau et les yeux. Le mtal incandescent peut causer Assurez-vous que ces ouvertures sont bien protges
des brlures. Une formation relie l'usage des des tincelles et du mtal incandescent.
processus et de l'quipement est essentielle pour
3. N'excutez pas de soudure, de coupe ou autre tra-
prvenir les accidents. Par consquent:
vail chaud avant d'avoir compltement nettoy la
1. Portez des lunettes protectrices munies d'crans la- surface de la pice traiter de faon ce qu'il n'ait
traux lorsque vous tes dans l'aire de travail, mme aucune substance prsente qui pourrait produire
si vous devez porter un casque de soudeur, un cran des vapeurs inflammables ou toxiques. N'excutez
facial ou des lunettes tanches. pas de travail chaud sur des contenants ferms
2. Portez un cran facial muni de verres filtrants et de car ces derniers pourraient exploser.
plaques protectrices appropries afin de protger 4. Assurez-vous qu'un quipement d'extinction
vos yeux, votre visage, votre cou et vos oreilles des
tincelles et des rayons de l'arc lors d'une opration d'incendie est disponible et prt servir, tel qu'un
ou lorsque vous observez une opration. Avertissez tuyau d'arrosage, un seau d'eau, un seau de sable
les personnes se trouvant proximit de ne pas re- ou un extincteur portatif. Assurez-vous d'tre bien
garder l'arc et de ne pas s'exposer aux rayons de l'arc instruit par rapport l'usage de cet quipement.
lectrique ou le mtal incandescent. 5. Assurez-vous de ne pas excder la capacit de
3. Portez des gants ignifugis crispin, une chemise l'quipement. Par exemple, un cble de soudage
paisse manches longues, des pantalons sans rebord surcharg peut surchauffer et provoquer un in-
et des chaussures montantes afin de vous protger des cendie.
rayons de l'arc, des tincelles et du mtal incandescent,
en plus d'un casque de soudeur ou casquette pour 6. Une fois les oprations termines, inspectez l'aire de
protger vos cheveux. Il est galement recommand travail pour assurer qu'aucune tincelle ou projec-
de porter un tablier ininflammable afin de vous prot- tion de mtal incandescent ne risque de provoquer
ger des tincelles et de la chaleur par rayonnement. un incendie ultrieurement. Employez des guetteurs
4. Les tincelles et les projections de mtal incandescent d'incendie au besoin.
risquent de se loger dans les manches retrousses, 7. Pour obtenir des informations supplmentaires,
les rebords de pantalons ou les poches. Il est recom- consultez le NFPA Standard 51B, "Fire Prevention in
mand de garder boutonns le col et les manches et
de porter des vtements sans poches en avant. Use of Cutting and Welding Processes", disponible au
5. Protgez toute personne se trouvant proximit des National Fire Protection Association, Batterymarch
tincelles et des rayons de l'arc l'aide d'un rideau ou Park, Quincy, MA 02269.
d'une cloison ininflammable.
6. Portez des lunettes tanches par dessus vos lunettes CHOC LECTRIQUE -- Le contact avec
de scurit lors des oprations d'caillage ou de des pices lectriques ou les pices
meulage du laitier. Les cailles de laitier incandescent de mise la terre sous tension peut
peuvent tre projetes des distances considrables. causer des blessures graves ou mor-
Les personnes se trouvant proximit doivent gale-
ment porter des lunettes tanches par dessus leur telles. NE PAS utiliser un courant de
lunettes de scurit. soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
section 1 sCURIT

1. Assurez-vous que le chssis de la source 3. Les soudeurs doivent suivre les procdures suivantes
d'alimentation est branch au systme de mise pour minimiser l'exposition aux champs lectriques
la terre de l'alimentation d'entre. et magntiques :
2. Branchez la pice traiter une bonne mise de A. Acheminez l'lectrode et les cbles de masse
terre lectrique. ensemble. Fixez-les l'aide d'une bande adhsive
3. Branchez le cble de masse la pice traiter et lorsque possible.
assurez une bonne connexion afin d'viter le risque B. Ne jamais enrouler la torche ou le cble de masse
de choc lectrique mortel. autour de votre corps.
4. Utilisez toujours un quipement correctement C. Ne jamais vous placer entre la torche et les cbles
entretenu. Remplacez les cbles uss ou endom- de masse. Acheminez tous les cbles sur le mme
mags. ct de votre corps.
5. Veillez garder votre environnement sec, incluant D. Branchez le cble de masse la pice traiter le
les vtements, l'aire de travail, les cbles, le porte- plus prs possible de la section souder.
lectrode/torche et la source d'alimentation. E. Veillez garder la source d'alimentation pour le
6. Assurez-vous que tout votre corps est bien isol soudage et les cbles une distance approprie
de la pice traiter et des pices de la mise la de votre corps.
7. Si vous devez effectuer votre travail dans un espace LES VAPEURS ET LES GAZ -- peuvent
restreint ou humide, ne tenez vous pas directe- causer un malaise ou des dommages
ment sur le mtal ou sur la terre; tenez-vous sur corporels, plus particulirement
des planches sches ou une plate-forme isole et dans les espaces restreints. Ne re-
portez des chaussures semelles de caoutchouc. spirez pas les vapeurs et les gaz. Le
8. Avant de mettre l'quipement sous tension, isolez gaz de protection risque de causer
vos mains avec des gants secs et sans trous. l'asphyxie. Par consquent :
9. Mettez l'quipement hors tension avant d'enlever
vos gants. 1. Assurez en permanence une ventilation adquate
10. Consultez ANSI/ASC Standard Z49.1 (list dans l'aire de travail en maintenant une ventila-
la page suivante) pour des recommandations tion naturelle ou l'aide de moyens mcanique.
spcifiques concernant les procdures de mise N'effectuez jamais de travaux de soudage, de
la terre. Ne pas confondre le cble de masse avec coupage ou de gougeage sur des matriaux tels que
le cble de mise la terre. l'acier galvanis, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
CHAMPS LECTRIQUES ET MAGN- de moyens mcaniques de ventilation efficaces. Ne
TIQUES comportent un risque de respirez pas les vapeurs de ces matriaux.
danger. Le courant lectrique qui 2. N'effectuez jamais de travaux proximit d'une
passe dans n'importe quel conduc- opration de dgraissage ou de pulvrisation. Lor-
teur produit des champs lectriques sque la chaleur
et magntiques localiss. Le soudage et le cou- ou le rayonnement de l'arc entre en contact avec les
rant de coupage crent des champs lectriques vapeurs d'hydrocarbure chlor, ceci peut dclencher
et magntiques autour des cbles de soudage et la formation de phosgne ou d'autres gaz irritants,
l'quipement. Par consquent : tous extrmement toxiques.
3. Une irritation momentane des yeux, du nez ou de la
1. Un soudeur ayant un stimulateur cardiaque doit gorge au cours d'une opration indique que la ven-
consulter son mdecin avant d'entreprendre une tilation n'est pas adquate. Cessez votre travail afin
opration de soudage. Les champs lectriques et de prendre les mesures ncessaires pour amliorer
magntiques peuvent causer des ennuis pour cer- la ventilation dans l'aire de travail. Ne poursuivez
tains stimulateurs cardiaques. pas l'opration si le malaise persiste.
2. L'exposition des champs lectriques et magn- 4. Consultez ANSI/ASC Standard Z49.1 ( la page
tiques peut avoir des effets nfastes inconnus pour suivante) pour des recommandations spcifiques
la sant. concernant la ventilation.
section 1 sCURIT

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilis ENTRETIEN DE L'QUIPEMENT -- Un quipe-

dans une opration de soudage ou de ment entretenu de faon dfectueuse ou
coupage, dgage des vapeurs ou des inadquate peut causer des blessures
gaz contenant des chimiques consid- graves ou mortelles. Par consquent :
res par l'tat de la Californie comme
1. Efforcez-vous de toujours confier les tches
tant une cause des malformations
d'installation, de dpannage et d'entretien un
congnitales et dans certains cas, du
personnel qualifi. N'effectuez aucune rparation
cancer. (California Health & Safety
lectrique moins d'tre qualifi cet effet.
Code 25249.5 et seq.)
2. Avant de procder une tche d'entretien
l'intrieur de la source d'alimentation, dbranchez
l'alimentation lectrique.
La manipulation d'un cylindre, sans
3. Maintenez les cbles, les fils de mise la terre,
observer les prcautions ncessaires,
les branchements, le cordon d'alimentation et la
peut produire des fissures et un
source d'alimentation en bon tat. N'utilisez ja-
chappement dangereux des gaz.
mais un quipement s'il prsente une dfectuosit
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles-
4. N'utilisez pas l'quipement de faon abusive. Gardez
sures graves ou mortelles. Par consquent :
l'quipement l'cart de toute source de chaleur,
notamment des fours, de l'humidit, des flaques
1. Utilisez toujours le gaz prvu pour une opration
d'eau, de l'huile ou de la graisse, des atmosphres
et le dtendeur appropri conu pour utilisation
corrosives et des intempries.
sur les cylindres de gaz comprim. N'utilisez jamais
5. Laissez en place tous les dispositifs de scurit et
d'adaptateur. Maintenez en bon tat les tuyaux et
tous les panneaux de la console et maintenez-les
les raccords. Observez les instructions d'opration
en bon tat.
du fabricant pour assembler le dtendeur sur un
6. Utilisez l'quipement conformment son usage
cylindre de gaz comprim.
prvu et n'effectuez aucune modification.
2. Fixez les cylindres dans une position verticale,
l'aide d'une chane ou une sangle, sur un chariot
manuel, un chssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
TIVES LA SCURIT -- Pour obtenir de
jamais un cylindre un poste de travail ou toute autre
l'information supplmentaire sur les rgles
dispositif faisant partie d'un circuit lectrique.
de scurit observer pour l'quipement
3. Lorsque les cylindres ne servent pas, gardez les
de soudage l'arc lectrique et le coupage,
soupapes fermes. Si le dtendeur n'est pas bran-
demandez un exemplaire du livret "Precau-
ch, assurez-vous que le bouchon de protection de
tions and Safe Practices for Arc Welding,
la soupape est bien en place. Fixez et dplacez les
Cutting and Gouging", Form 52-529.
cylindres l'aide d'un chariot manuel appropri.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres une distance approprie
Les publications suivantes sont galement recomman-
de toute source de chaleur, des tincelles et des
des et mises votre disposition par l'American Welding
flammes. Ne jamais amorcer l'arc sur un cylindre.
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
5. Pour de l'information supplmentaire, consultez
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
CGA Standard P-1, "Precautions for Safe Handling
2. AWS C5.1 - "Recommended Practices for Plasma Arc
of Compressed Gases in Cylinders", mis votre dis-
position par le Compressed Gas Association, 1235
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Jefferson Davis Highway, Arlington, VA 22202.
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

section 1 sCURIT


Ce symbole, utilis partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
scurit est en jeu.

Signifie un danger immdiat. La situation peut
entraner des blessures graves ou mortelles.

Signifie un danger potentiel qui peut entraner des
blessures graves ou mortelles.

Signifie un danger qui peut entraner des blessures
corporelles mineures.


460Power Source
Power Source

Easy-to-use advanced
Easy-to-use technology
advanced technology

CustomizableMA-6 man/machine
MA-6 communications.
man/machine communications.
Upgradable using ESATESAT
using software (ESAB (ESAB
software SoftwareSoftware
Administration Tools).
preprogrammed synergic
synergic weldingwelding programs
programs for for
standard & pulsed
& pulsed Mig Stick
Mig and and Stick
10 10
memory locations
locations for user-defined
for user-defined weldingwelding
storage storage
Digital preset
preset of voltage,
of voltage, amperage
amperage or wireorspeed
wire speed
on on
process slection.
Robust, reliable, energy saving 450 amp/100% Duty
Robust, reliable, energy saving 450 amp/100% Duty Cycle
Cycle power source
power source TM
SuperSwitch Technology design, provides superior
SuperSwitch TM
Technology design, provides superior
inverter like performance in the welding arc while
inverter like performance
providing in the welding arc while provid-
SCR like reliability.
ing SCR like reliability.
Energy and power efficient, the best in its class with a
92%and power efficient,
efficiency the best
figure. Saves in its class
energy and with a
92% efficiency figure. Saves energy
power costs. Uses up to 50% less current than and reduces power
costs. Uses up to 50%
conventional SCRless current than conventional SCR
True Multi-process, three phase power source Shown with AristoDrive 4 -30 wire feeder,
True Multi-process,
designed for heavythreeduty
phase power source
Industrial designed
DC welding GM-400 Mig AristoDrive
welding torch,
Shown with 4 -30TR-29 truck kit,
wire feeder, GM-
heavy duty Industrial DC welding applications. work
400 Migcable, clamp
welding and
torch, welding
TR-29 truckwire.
kit, work
UseUse for High
for High Performance
Performance Mig, Mig,
Mig, Pulse Pulse Mig,
Flux Fluxwire,
Cored Cored

Stick Stick electrode
electrode welding, and welding, and Air
Air Carbon Arc Carbon
cable, clamp and welding wire.

Gouging Specifications:
Rated DC Output @ 100% Duty Cycle
Variable inductance for fine tuning of the arc characteris- Rated DC50/60Hz,
Output @cv100% or ccDuty Cycle
.............................. .450 amps 38 vdc
when short inductance
arc welding.for fine tuning of the arc charac-
Rated DC cv
50/60Hz, Output
or cc..@ 60% Duty Cycle
.................................................450 amps 38 vdc
Adjustable arc force and hot welding.
teristics when short arc start control for superior Rated DC50/60Hz,
Output @cv60% or cc Duty...............................
Cycle 500 amps 39 vdc
stick arc force and hot start control for superior
electrode performance. Welding
cv or cc. ................................... 10A/12Vamps
..................................................500 to 500A/40V
39 vdc
stick electrode performance. OpenRange.
Welding Circuit Voltage Max. ..........................................
..................................................... 10A/12V to 500A/40V 80vdc
100% Solid State, no mechanical contactor
100% Solid State, no mechanical contactor Open Primary
Voltage Voltage and Current @ 100% DutyCycle
Max................................................................. 80vdc
Sheet metal parts and hardware made of stainless steel.
Sheet metal parts and hardware made of stainless 230/460/575vac,
Primary Input Voltage and60Hz Current 3ph @....................
100% DutyCycle 66/33/26 amps
Top and side panel made of Kydex polymer for superior
steel. Top and side panel made of Kydex polymer for
durability in harsh environments. Power Factor at Rated
230/460/575vac, 60Hz Output ......................................
3ph.................................. 66/33/26 amps 89%
superior durability in harsh environments. PowerEfficiency
Factor atatRated
Output ............................................ 92%
Auto Fan feature
Auto Fan feature standard
standardin theinunit
thefor energy
unit savings.
for energy Auxiliary Output Power ................ 115vac 50/60Hz, 10 amps
Efficiency at Rated Output...................................................................92%
Automatically turns the fan motor on and
savings. Automatically turns the fan motor on and off. off.
Auxiliary Output Power.............................. 115vac 50/60Hz, 10 amps
Convenient 115vac auxiliary power receptacle. Physical Dimensions:
Convenient 115vac auxiliary power receptacle.
W x L x H ......... 18.8(483mm), 32.5 (819mm), 25(622mm)
Compatible withwithAristoDrive
and AristoDrive 4-48 4-48
and AristoDrive Physical Dimensions:
Net Weight ................................................. 322 lbs.(146 Kg)
wire feeders.
wire feeders. W x Shipping
L x H.......................
Weight 18.8(483mm), 32.5 (819mm),
......................................... 37525(622mm)
lbs. (170Kg)
NAS(Tweco) style style
(Tweco) QuickQuick
Disconnect gun-to-feeder
Disconnect gun-to-feeder Net Weight..........................................................................322 lbs.(146 Kg)
connection is standard
is standard Shipping Weight...............................................................375 lbs. (170Kg)

Build a Custom AristoPower Welding System

AristoPow er TM AristoDrive 4TM Gunmaster 400
Connection Cable Options & Accessories
Pow er Source Wire Feeder NAS Connection

AristoDrive 4-30 *
0558003276 6ft. (2m)
AristoDrive 4-48 * 0456527880 12 ft. x .035-.045
0558003275 26ft. (8m) 0558001656 Complete Your Custom
AristoPow er-460 AristoDrive 4-48 * 0456527881 15 ft. x .035-.045 System by Ordering
0558002668 Boom System 52ft. (16m) 0558001659 Components from the
0558003700 0456527882 12 ft. x .052-1/16 Options & Accessories
Balance Boom** 82ft. (25m) 0558001657 List on the follow ing
Balance Boom 12ft. 0456527883 15 ft. x .052-1/16 page
0558003442 114ft. (35m) 0558001660
Balance Boom 16ft. 0456527884
0558003365 * Includes M A -6 M M C
** See Bo o m Sales Sheets fo r co mplete info rmatio n

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 different weld parameter set-ups. Recall
parameters with a simple push of a button. Programmable soft keys allow
direct access to flexible functions, such as hot start, crater fill, 2/4 stroke
trigger, wire inch, gas purge, etc.
Large display gives real time readout of voltage, current, and wire speed.
Preset inductance, gas pre & post flow, inch or metric units, auto weld
schedule select, arc force, burnback and more. Update and change weld
data using optional ESAT software for maximum flexibility.

Options & Accessories Aristo Control 5 Program Box.................................. 466801881

AristoPower 4600c Use this option to access 5 different weld schedules saved to
TR-29 Truck.........................................................................37924 memory locations 1 through 5. Arc trim is remotely controlled
This truck kit provides complete mobility of the power source. The from the box.
kit consists of front casters, rear cylinder rack for two cylinders, gas Aristo Control 5 Program, Bar...........................................466515881
cylinder bracket and chain, and pull handle. The option has the same function as the 5 Program Box yet is
Wire Feeder Swivel Mount Kit...........................................36172 more compact and mobile.
This kit allows the wire feeder to be placed on an insulated swivel Aristo Synergic Control Box...............................................466801880
post on top of the power source. The feeder can freely rotate, Provides remote control for synergic wire feed speed and volt-
minimizing potential wire feed problems. age trim.
ESAT PC Software Package.................................... 0458847880 Aristo Synergic Control Bar................................................466515880
PC software for service, diaignostics, troubleshooting, and The option has the same function as the Synergic Box yet is
upgrading (PC is not included). more compact and mobile.


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.


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 4600c power source. DO NOT attempt to install or operate this
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

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 volt-
ampere characteristics desired for conventional MIG (GMAW) and flux core (FCAW) arc welding in the CV (constant voltage)
mode, Mig Pulse (GMAW-P) arc or stick (SMAW) welding and air carbon arc cutting/gouging (CAC-A) in the CC (constant cur-
rent) mode. Table 2-1 outlines the electrical and physical specifications.

Auto Fan - The AristoPower 4600c fan will run when the power source is first powered up and will remain running for
30 seconds then shut down. The fan will start again when welding begins. The fan will remain running for 6.5 minutes
after welding stops and then shut down automatically 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 reconfigure with ESAT (ESAB Software Administration Tool) software.


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 defined as the voltage drop per 100 amperes of current use. These curves
show the output voltage available at any given output current from the minimum to the maximum setting of the voltage/
current control.



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.

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 off 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


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.


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 floating 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.


A number of remote control units can be connected to the Aristo via the Remote Control Adaptor


(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.

Power ON

Figure 2-2. Standard Control Panel

115 Vac
42Vac and 10 Amp
115 Vac OFF/ON
Circuit Breakers Switch

Connection Positive Out- Input Cable
Component Receptacles put Receptacle Strain Relief
Connection (Secondary)

Weld Cable Figure 2-3. Front View

Connection Lugs

Figure 2-4. Rear View

B. TR-29 TRUCK KIT (PN - 37924)

This truck kit provides complete mobility of the power source. The kit consists of front castors, rear cylinder rack and wheels,
gas cylinder bracket, cylinder chain and pull handle.


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.



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 mini-
mum of 18 inches (46 cm) is required between the side and rear panels of the power source and the nearest obstruction.

The selected site should also allow easy removal of the power source outer enclosure for maintenance. See Specifications
for overall dimensions of the unit.

Do not use filters on this unit as they would restrict the volume of intake air required for proper
cooling. Output ratings on this unit are based on an unobstructed supply of cooling air drawn over

CAUTION its internal components. Warranty is void if any type of filtering device is used.

For lifting purposes and for keeping dust, moisture, and other foreign material from entering the
power source, the lifting eyebolt must be fully tightened with a tool.


When requesting information concerning this equipment, it is essential that Item number, Serial number and Model number
of the equipment be supplied.

1. Upon receipt, remove all packing material and carefully inspect for any damage that may have occurred during
shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the
carrier. A copy 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
3. Check air passages at front and rear of cabinet, making sure that packing material has not obstructed air flow
through the power source.
4. Install the lifting bolt furnished with the power sources into the top of the unit.
5. After selecting an installation site, place the power source in the desired location. The unit may be lifted either
by using the lifting bolt or by forklift truck. If a forklift is used for lifting the unit, be sure that the lift forks are long
enough to extend completely under the base.

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.


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 re-
quired. Either rubber covered cable or conduit (flexible or solid) may be used. Table 3-1 provides recommended
input conductors and line fuse sizes.
2. Remove the top cover. Identify primary power input connection block, chassis ground lug on the fan shroud frame,
and primary input terminal board. Refer to Figures 3-1 thru 3-5.

3. When using the provided strain relief, refer to Figure 3-2 for proper cable strip lengths. It is important to follow the
cable strip guide to ensure that if the primary input cable is ever pulled from the strain relief, the input conductors
will be pulled from the Terminal Block before the ground lead is pulled from the ground lug. Once stripped, thread
the input and ground conductors through the large strain-relief in the rear panel of the power source. Connect the
ground wire to the terminal lug located on the fan shroud frame. Connect the primary power leads to terminals
L1, L2 and L3 on the input power block. Secure the strain relief on the input cable.
4. Check all connections for proper tightness. Ensure all 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 fac-
tory 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 reconfiguring the copper
link bars to the silk-screened voltage designations for the desired voltage.

L1, L2, L3

Primary Cable

Ground Fault
Switch & Bracket


3-1. Primary Power Leads L1,L2, L3 & Ground

Table 3-1. Recommended Sizes for Input

Table 3-1. Recommended
Conductors andSizes for Input
Line Fuses
Conductors and Line Fuses
Rated Input
@ 100% Duty Cycle Fuse
GND 5"
Volts Amps CU/AWG

220 68 No. 6 100

230 66 No. 6 100
400 37 No. 8 60 24"
460 33 No. 8 60 Green
575 26 No. 10 50 (Earth Ground)

ized per National CodeperforNational Codecopper
80 C rated for 80 C rated copper
conductors @ 30conductors
C ambient.@ 30 C more
Not ambi-than three
nductors in racewayent.orNot more
cable. thancodes
Local three conductors in raceway
should be followed or cable.
if they Local
specify codes
sizes other than those
Figure 3-2. Recommended Cable Strip Lengths
should be followed if theylisted above.
specify sizes other than those listed above.




230 Vac Input 460 Vac Input 575 Vac Input

Figure 3-3. Input Terminal Board Configuration for 230/460/575 Model

(factory supplied in the 575 configuration)

230 Vac Input 460 Vac Input 200 Vac Input 400 Vac Input
Figure 3-4. Input Terminal Board Configuration 230/460 Figure 3-5. Input Terminal Board Configuration 200/400
Model (factory supplied in the 460 configuration) Model (factory supplied in the 400 configuration)


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.
WELDING Placing the power switch in the off position does not remove all
power from inside the power source.
that the branch circuit or main
nect switch is off, or electrical The output connections are located on the front panel (Figure 2-3). The positive
The output connections
uses are removed, before at-
are located on the front panel (Figure 2-3). The positive connection is located at the bottom left
connection is located at the bottom left corner and the negative connection is
g any inspection andinside
or work the negative connection is located at the bottom right corner. An additional (+) twist lock connect is available
wer source. Placing
located at the bottom right corner. An additional (+) twist lock connect is available
on the the
panel. In most instances, the work cable is connected to the negative output terminal lug. Table 3-6 provides
in the off position does not on the rear panel. In most instances, the work cable is connected to the negative
the recommended secondary
all power from inside the power
cable output
output terminal sizes. 3-6 provides the recommended secondary cable
lug. Table
output sizes.
The wire feeder control
1. cable connects toFROM
pin J1WIRE
FEEDER on the lower front or the rear panel of the AristoPower
4600c. The secondaryThe output
feeder connects (in most
control cable cases) between
connects to the 12the
pin positive outputon
J1 receptacle lug oflower
the the AristoPower 4600c and
the power connection block
front or of
thethe wire
rear feeder.
panel SeeAristoPower
of the the wire feeder installation
460. instructions
The secondary forcable
output other connections such as
shield gas, water, remote controls,
connects Mig guns
(in most and
cases) wire feeder
between operation.
the positive output lug of the AristoPower 460
and the power connection block of the wire feeder. See the wire feeder
2. CONNECTIONS FOR installation
STICK AND instructions for other connections such as shield gas, water, remote
The Tig torch and stick Migholder
electrode guns and wire feeder
connect directlyoperation.
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
2. Tig
used. In most cases the CONNECTIONS FORtoSTICK
torch will connect AND TIG
the negative lugWELDING
and work cable will connect to the positive lug. The stick
The Tig torch and stick electrode holder
electrode holder usually connects to the positive lug and the work connect directly
cable to to the appropriate
the negative lug.
AristoPower 460 output lugs on the lower front panel. The choice of the Positive
or Negative terminal depends on the welding process and electrode type being
used. In most cases the Tig torch will connect to the negative lug and work cable
will connect to the positive lug. The stick electrode holder usually connects to the
positive lug and the work cable to the negative lug.

Table 3-6. Output Cable Sizes (Secondary)

Table 3-6. Output Cable Sizes (Secondary)
Total Length (Feet) of
Welding Cable in Weld Circuit*
50 100 150 200 250

100 6 4 3 2 1/0

150 4 3 1 1/0 2/0

200 3 1 1/0 2/0 3/0

250 2 1/0 2/0 3/0 4/0

300 1 2/0 3/0 4/0 4/0

400 2/0 3/0 4/0 4/0 2-2/0

500 3/0 3/0 4/0 2-2/0 2-3/0

* Total cable length includes work and electrode cables. Cable size is based on direct
* Total cable length includes work and electrode cables. Cable size is based on direct
current, insulated
insulated copper
copper conductors,
conductors, 100-percent
100-percent duty
duty cycle
cycle and
and a avoltage
dropofof4 4ororless
less The
volts. volts.welding
The welding
cable cable insulator
insulator must ahave
must have a voltage
voltage ratingrating
that isthat is enough
high high enough
to to
withstand thethe open
open circuit
circuit voltage
voltage of the
of the power
power source.


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 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.



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. MA-6 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


4.1. OPERATION (con't.)


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



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 flow to provide proper cool-

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.


Keep the power source dry, free of oil and grease, and protected at all times from damage by hot metal and sparks.


Keep the fan motor free of accumulated dust and lint.

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.


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.


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.


6.0 TROUBLESHOOTING If the power source is operating improperly, the following troubleshooting
information may be used to locate the source of the trouble.
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
Check the problem against the symptoms be in the following
quickly located, troubleshooting guide
open up the unit and (Table a6-1.)
perform simpleThevisual
remedy for the problem
inspection of all
may be quite simple. If the cause cannotthe
quickly located,
andopen up the
wiring. unitfor
Check andproper
perform a simple
terminal visual inspection
connections, of all
loose or
the components and wiring. Check for burned wiring or connections,
proper terminal components,loose
blownorfuses, bulged
burned wiringor or
leaking capacitors,
components, or any
blown fuses,
bulged or leaking capacitors, or any other signsign of damage
of damage or discoloration.
or discoloration.

Table6-1 Troubleshooting
6-1 Table
Troubleshooting Table


Unit Inoperative A. No input power. Check main line (user's) switch fuses -- replace if needed.
B. Poor or improper input (terminal board) connections.
C. Defective on/off switch on rear panel -- replace.
D. Thermal light on. Main transformer overheating. Also check for proper cooling,
proper primary hookup, or shorted turn on secondary.
E. Loss of primary phase. Find & replace defective fuse.

No Output -- Fan A. Poor or improper electrical input -- check input connections on TB.
Running B. Poor connections at output terminals/work station -- check, tighten or replace.
C. Main transformer overheating -- thermal switches tripped due to restricted cooling
air. Temperature light on front panel will be lit. Let unit cool down.
D. PC board defective or loose PC board connector(s) -- if loose, reinsert; if
defective, replace.

Limited Output or Low A. Input voltage jumper links on terminal board improperly set -- check for proper
Open-Circuit Voltage voltage.
B. Poor output connections. Take apart, clean, and reassemble.
C. Panel-Remote switch in Remote position and remote voltage pot disabled.

Erratic Weld Current A. Welding cable size too small -- use correct cables.
B. Loose welding cable connection (will usually get hot) -- tighten all connections.
C. Improper wire feeder setup.
D. PC board defective -- replace.

High Output, No A. PC board defective or loose -- reset and/or replace board.

Voltage Control B. 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 A. Shorted SCR in Main Bridge -- replace.

Power Source is First B. Shorted capacitor in Capacitor Bank.
Turned On

Wire Feeder is A. Loose feeder control cable -- Check and tighten all connections.
Inoperative B. A Circuit Breaker tripped -- Check 42V CB1 -- Reset.


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

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.

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.

Section 7
SECTION 6 Replacement partsPARTS

AristoPower 4600c "Sleep" Feature Replacement Parts

The Sleep feature reduces the power consumption (and cost of operation) during periods when the Aristo-
AristoPower 460 "Sleep" Option Kit
Power 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 im-
mediately reconnect the primary to the main transformer and start welding when the gun trigger is pulled.

Part Description Quantity

0558004684 Control Transformer 1
0558038271 P. C. Board 1
(8)950840 Contactor 1
0558004686 Control Transformer Bracket 1
0558004687 P. C. Board Bracket 1
0558004685 Contactor Bracket 1
0558004689 Wire Kit 1
#10 x 24 x .500-inch Self-tapping
61325902 2
63300916 #10 x 24 Hex Nuts 11
64307004 #10 External Tooth Lock Washer 15
61319087 x 20 x .500-inch Self-tapping Screw 1
64307996 -inch External Tooth Lock Washer 1
61325880 #8 x 32 x .500-inch Self-tapping Screw 2
64307887 #8 External Tooth Lock Washer 2
61325854 #6 x 32 x .750-inch Self-tapping Screw 3

61304090 x 20 x 1. 00-inch Self-tapping Screw 2

0558002017 .750 Spacers 2
950906 F.M. Fast-on terminal 2
634736 Wire Caps (Small) 10
99512659 Wire Caps (Large) 5
9950440 Tywrap Sticky-down 5
99511578 Tywrap Push-mount 2
180W68 Tywrap (Small) 10
950995 Tywrap (Large) 2
0558001379 Fuse 2 Amp 2
952136 Fuse Holder 2
0558004690 "Sleep" Option Installation Instructions 1
3-1/2" Floopy Disk with Software
0558004691 1


revision history

Original release - 03 / 2009

ESAB Welding & Cutting Products, Florence, SC Welding Equipment


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

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

Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specifications Equipment Recommendations

Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST


Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status


Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations


Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST


Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST


Telephone: (800) ESAB-123

Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
visit us on the web at http://www.esabna.com
The ESAB web site offers
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Warranty Registration
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