ESAB Aristo Mig 5000i User manual

Aristo®
Instruction manual
0459 290 401 GB 20171107 Valid for: 608-, 613-xxx-xxxx
Mig5000i,
Mig5000iWeldCloud™
400 V

TABLE OF CONTENTS
0459 290 401 © ESAB AB 2017
1SAFETY ....................................................................................................... 5
2INTRODUCTION.......................................................................................... 8
2.1 Equipment ............................................................................................... 8
3TECHNICAL DATA ...................................................................................... 9
4INSTALLATION............................................................................................ 11
4.1 Lifting instructions ................................................................................. 11
4.2 Placing..................................................................................................... 11
4.3 Mains power supply ............................................................................... 12
4.4 Terminating resistor ............................................................................... 12
4.5 Connection of multiple wire feed units ................................................ 12
5OPERATION ................................................................................................ 15
5.1 Connections and control devices ......................................................... 15
5.2 Turning on the power source ................................................................ 16
5.3 Fan control .............................................................................................. 16
5.4 Overheating protection .......................................................................... 16
5.5 Cooling unit............................................................................................. 16
5.6 Remote control unit................................................................................ 16
5.7 WeldCloud™ unit.................................................................................... 17
6MAINTENANCE........................................................................................... 18
6.1 Daily......................................................................................................... 18
6.2 If necessary............................................................................................. 18
6.3 Every year ............................................................................................... 19
7FAULT TRACING......................................................................................... 20
8ORDERING OF SPARE PARTS .................................................................. 21
DIAGRAM ............................................................................................................. 22
ORDERING NUMBERS........................................................................................ 24
SPARE PARTS LIST............................................................................................. 25
ACCESSORIES .................................................................................................... 26
Rights reserved to alter specifications without notice.

1 SAFETY
0459 290 401 -5- © ESAB AB 2017
1 SAFETY
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation

1 SAFETY
0459 290 401 -6- © ESAB AB 2017
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the unit in accordance with applicable standards
• Do not touch live electrical parts or electrodes with bare skin, wet gloves
or wet clothing
• Insulate yourself from earth and the workpiece
• Ensure your working stance is safe
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter
lens and wear protective clothing
• Protect bystanders with suitable screens or curtains
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
CAUTION!
Read and understand the instruction manual before
installing or operating.

1 SAFETY
0459 290 401 -7- © ESAB AB 2017
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.

2 INTRODUCTION
0459 290 401 -8- © ESAB AB 2017
2 INTRODUCTION
The Mig 5000i is a MIG/MAG welding power source, which can also be used for TIG and
MMA welding.
There are several variants of the power source:
• Mig 5000i without cooling unit
• Mig 5000i with cooling unit
• Mig 5000i with WeldCloud™ unit
• Mig 5000i with cooling unit and WeldCloud™ unit
NOTE!
These instructions describe a Mig 5000i with a cooling unit.
The power source is intended for use with the Feed 3004 or Feed 4804 wire feed units.
The power source Mig 5000i WeldCloud™ is combined with U82and provides a control box
which enables wireless monitoring.
For more information about the feed units and WeldCloud™, refer to the Instruction manuals.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The power source is supplied complete with:
• An instruction manual
• Terminating resistor
• 5 m return cable
Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

3 TECHNICAL DATA
0459 290 401 -9- © ESAB AB 2017
3 TECHNICAL DATA
Mig 5000i Mig 5000i WeldCloud™
Mains voltage 400 V ±10%, 3~ 50/60 Hz 400 V ±10%, 3~ 50/60 Hz
Mains supply Sscmin 14.54 MVA
Zmax 0.011 Ω
Sscmin 14.54 MVA
Zmax 0.011 Ω
Primary current
Imax MIG/MAG (GMAW) 37 A 37 A
Imax TIG (GTAW) 30 A 30 A
Imax MMA (SMAW) 38 A 38 A
No-load power demand when in the energy-saving mode 6.5 min. after welding
TIG/MIG (GTAW/GMAW) 36 W 36 W
MMA (SMAW) 43 W 43 W
Voltage/current range
MIG/MAG (GMAW) 8 - 60 V / 16 - 500 A 8 - 60 V / 16 - 500 A
MIG/MAG (GMAW), control
panel M2 8 - 42 V 8 - 42 V
MMA (SMAW) 16 - 500 A 16 - 500 A
Permissible load at MIG/MAG (GMAW)
60 % duty cycle 500 A / 39 V 500 A / 39 V
100% duty cycle 400 A / 34 V 400 A / 34 V
Permissible load at TIG
60 % duty cycle 500 A / 30 V 500 A / 30 V
100% duty cycle 400 A / 26 V 400 A / 26 V
Permissible load at MMA (SMAW)
60 % duty cycle 500 A / 40 V 500 A / 40 V
100% duty cycle 400 A / 36 V 400 A / 36 V
Power factor at maximum
current (I2) MMA/TIG/MIG 0.90 0.90
Efficiency at maximum current (I2)
MMA (SMAW) 85 % 85 %
TIG (GTAW) 82 % 82 %
MIG (GMAW) 84 % 84 %
Open-circuit voltage U0max
MIG/MAG (GMAW) without
VRD function 1) 72 - 88 V 72 - 88 V
MMA (SMAW) without VRD
function 1)
68 - 80 V 68 - 80 V
MIG/MAG (GMAW), MMA
(SMAW), VRD function
deactivated 2)
59 V 59 V
VRD function activated 2) < 35 V < 35 V

3 TECHNICAL DATA
0459 290 401 - 10 - © ESAB AB 2017
Mig 5000i Mig 5000i WeldCloud™
Operating temperature -10 to +40 °C
(14 to 104 °F)
-10 to +40 °C
(14 to 104 °F)
Transportation temperature -20 to +55 °C
(-4 to 131 °F)
-20 to +55 °C
(-4 to 131 °F)
Dimensions l × w × h
without cooling unit
with cooling unit
625 × 394 × 496 mm
(24.6 × 15.5 × 19.6in.)
625 × 394 × 496 mm
(24.6 × 15.5 × 19.6in.)
625 × 394 × 776 mm
(24.6 × 15.5 × 30.6in.)
625 × 394 × 776 mm
(24.6 × 15.5 × 30.6in.)
Continual sound pressure
at no-load
<70 db (A) <70 db (A)
Weight without cooling unit
with cooling unit
68 kg (150 lb) 79 kg (174 lb)
88 kg (194 lb) 99 kg (218 lb)
Insulation class transformer H H
Enclosure class IP23 IP23
Application class
1) Valid for power sources without VRD specification on the rating plate.
2) Valid for power sources with VRD specification on the rating plate. The VRD function is
explained in the instruction manual for the control panel.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
Mains supply, Zmax
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
Cooling unit
Cooling power 2.0 kW at 40°C (104°F) temp. difference and flow
1.0 l/min (0.26 us gal/min)
Coolant 50 % water / 50 % mono-ethylen glycol
Coolant quantity 5.5 l (1.45 us gal)
Maximum water flow 2.0 l/min (0.53 us gal)
Maximum number of water-cooled
welding torches that may be connected
Two MIG welding torches or one TIG torch and one
MIG welding torch