ESAB Aristo Mig 5000i User manual

GB
Valid for serial no. 802-xxx-xxxx, 803-xxx-xxxx,
950-xxx-xxxx
0459 290 301 GB 100112
Aristo™, Origo™
Mig 5000i
400 V version
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Lifting instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Placing 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Mains power supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Terminating resistor 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Connection of multiple wire feed units 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Connections and control devices 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Turning on the power source 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Fan control 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Overheating protection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Cooling unit 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Remote control unit 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Daily 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 If necessary 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Every year 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT TRACING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING OF SPARE PARTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE-695 81 Laxå, Sweden, gives its unreserved guarantee that weld
ing power source Mig 5000i, Mig 5000iw from serial number 802 (2008 w.02) are constructed and tes
ted in compliance with the standard EN 60974-1 /-2 and EN 60974-10 (Class A) in accordance with
the requirements of directive (2006/95/EC) and (2004/108/EEC).
---------------------------------------------------------------------------------------------------
Kent Eimbrodt
Global Director
Equipment and Automation
Laxå 2008-01-04
2 SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sno-one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves. Note! Do not use safety gloves when replacing wire.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
CAUTION!
This product is solely intended for arc welding.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer's safety practices which should be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
ESAB can provide you with all necessary welding protection and accessories.
WARNING!
Do not use the power source for thawing frozen pipes.
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.
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Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
3 INTRODUCTION
The Mig 5000i is a MIG/MAG welding power source, which can also be used for
MMA welding.
There are two variants of the power source:
SMig 5000i without cooling unit
SMig 5000i with cooling unit.
NB: These instructions describe an Mig 5000i with a cooling unit.
The power source is intended for use with the Feed 3004 or Feed 4804 wire feed
units.
All the settings are made from the wire feed unit or control box U8.
ESAB's accessories for the product can be found on page 19.
3.1 Equipment
The power source is supplied complete with terminating resistor, 5 m return cable
and instruction manual.
4 TECHNICAL DATA
Mig 5000i
Mains voltage 400V, $10%, 3∼50/60 Hz
Mains supply Ssc min 2.8 MVA
Zmax 0.21 Ω
Primary current
Imax MIG/MAG
Imax MMA
36 A
37 A
No-load power demand when in the energy-saving mode,
6.5 min. after welding 50 W
Voltage/current range
MIG/MAG
MIG/MAG, control panel M2
MMA
8-60 V / 16-500 A
8- 42 V
16- 500 A
Permissible load at MIG/MAG
60 % duty cycle
100% duty cycle
500 A / 39 V
400 A / 34 V
Permissible load at MMA
60 % duty cycle
100% duty cycle
500 A / 40 V
400 A / 36 V
Power factor at maximum current 0.91
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Mig 5000i
Efficiency at maximum current 87 %
Open-circuit voltage U0max
MIG/MAG without VRD function 1)
MMA without VRD function 1)
MIG/MAG, MMA, VRD function deactivated 2)
VRD function activated 2)
72 - 88 V
68 - 80 V
59 V
< 35 V
Operating temperature -10 to +40°C
Transportation temperature -20 to +55°C
Dimensions, lxwxh
with cooling unit
625 x 394 x 496 mm
625 x 394 x 776 mm
Continual sound pressure at no-load <70 db (A)
Weight
with cooling unit
68 kg
88 kg
Insulation class transformer H
Enclosure class IP 23
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 manuals for the control panel, if the panel has that function.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a cer
tain load without overloading. The duty cycle is valid for 40°C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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 temp. difference and
flow1.0 l/min
Coolant 50 % water / 50% mono-ethylen glycol
Coolant quantity 5.5 l
Maximum water flow 2.0 l/min
Maximum number of water-cooled welding
guns/torches that may be connected
two MIG welding guns or
one TIG torch and one MIG welding gun
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5 INSTALLATION
The installation must be executed by a professional.
Note!
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case it
is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distrubution network operator if necessary, that the equipment may be connected.
5.1 Lifting instructions
Power source Trolley and power source Trolley2 and power source
5.2 Placing
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
5.3 Mains power supply
Check that the unit is connected to the correct mains power
supply voltage, and that it is protected by the correct fuse sizes.
A protective earth connection must be made, in accordance
with regulations.
Rating plate with supply connection data
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Recommended fuse sizes and minimum cable areas
Mig 5000i 400 V 350 Hz
Mains voltage 400 V
Mains cable area, mm24G6
Phase current, I1eff 27 A
Fuse
Anti-surge
Type C MCB
25 A
32 A
NB:
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. They may not be applicable in other countries: make sure that
the cable area and fuse sizes comply with the relevant national regulations.
5.4 Terminating resistor
In order to avoid communication interference, the ends
of the CAN bus must be fitted with terminating resistors.
One end of the CAN bus is at the control panel, which has
an integral terminating resistor. The other end at the power
source must be fitted with the terminating resistor, as
shown on the right.
5.5 Connection of multiple wire feed units
With control unit U8 and wire feed units without control panel it is possible to manage
up to 4 wire feed units from one power source.
It is possible to choose between the following connections:
S1 TIG-torch and 1 MIG-gun (Universal power source required)
S2 MIG/MAG-guns
S1 TIG-torch and 3 MIG/-guns (Universal power source required)
S4 MIG/-guns
When welding with water-cooled MIG/-guns on all wire feed units, it is recommended
to connect a separate cooling unit for the 2 extra guns. We recommend connecting
the guns in parallel.
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Two wire feed units
A connection kit is required when connecting two wire feed units, see accessories on
page 19.
Four wire feed units
Two connection kits and an extra cooling unit are required when connecting four wire
feed units, see accessories on page 19.
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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
6.1 Connections and control devices
1Connection for cooling water. Not used on
this model.
8White indicating lamp - Power supply ON
2Connection for cooling water. Not used on
this model.
9Orange indicating lamp - Overheating
3Cooling water filler 10 Connection for control cable to the wire
feed unit or for the terminating resistor
4Connection for welding current cable (+)
(MMA welding)
11 Connection for welding current to the wire
feed unit
5Connection for remote control 12 Connection for cooling water to the wire
feed unit - BLUE
6Connection for return cable (-) 13 Connection for cooling water from the wire
feed unit - RED
7Main power supply switch, 0 / 1 / START 14 Fuse for supply voltage for feeder unit,
42 V
6.2 Turning on the power source
Turn on the mains power by turning switch (7) to the ”START” position. Release the
switch, and it will return to the ”1” position.
If the mains power supply should be interrupted while welding is in progress, and
then be restored, the power source will remain de-energised until the switch is again
turned manually to the ”START” position.
Turn the unit off by turning the switch to the ”0” position.
Whether in the event of a loss of power supply or of turning the power source off in
the normal manner, welding data will be stored so that it is available next time the
unit is started.
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6.3 Fan control
The power source fans continue to run for 6,5 minutes after welding has stopped,
and the unit switches to energy-saving mode. They start again when welding
restarts.
The fans run at reduced speed for welding currents up to 180 A, and at full speed for
higher currents.
6.4 Overheating protection
The power source has three thermal overload trips which operate if the internal
temperature becomes too high, interrupting the welding current and lighting the
orange indicating lamp on the front of the unit. They reset automatically when the
temperature has fallen.
6.5 Cooling unit
To ensure problem-free operation, the installation height from the cooling unit to the
welding gun must be max. 7 m. Heights in excess of this can cause problems, such
as long starting times, air bubbles, vacuums, etc.
If an installation height in excess of 7 m is required, we recommend an installation kit
comprising a non-return valve and a solenoid valve, refer to accessories on page 19.
Once these valves have been installed, the hose package must be horizontal during
the initial startup so that everything fills with water. Then raise the wire feed unit and
hose package to the high height. Continued safe operation at installation heights of
up to 12 m can now commence.
Function when welding
To start welding, the welder presses the welding gun trigger switch. The power
source turns on and starts the wire feed and the cooling water pump.
To stop welding, the welder releases the welding gun trigger switch. Welding ceases,
but the cooling water pump continues to run for 6,5 minutes, after which the unit
switches to energy-saving mode.
Water flow guard
The water flow guard interrupts the welding current in the event of loss of coolant,
and displays an error message on the control panel. The water flow guard is an
accessory.
6.6 Remote control unit
The program version in U8 should be 1.20 or higher. Machines with intergral control
panels should have program version 1.21 or higher, in order for the remote control to
function correctly.
When the remote control unit is connected, the power source and wire feed unit are
in remote control mode; the buttons and knobs are blocked. The functions can only
be adjusted via the remote unit.
If the remote control unit is not to be used, the remote control unit must be
disconnected from the power source / wire feed unit, as otherwise it will remain in
remote control mode.
For more information about the operation of the remote control unit, see the
operating instructions for the control panel.
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7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only personnel with the appropriate electrical skills (authorised electricians) may
remove safety plates.
CAUTION!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
7.1 Daily
Carry out the following maintenance every day.
SCheck that all cables and connections are fault free. Tighten if necessary and
replace any defective parts.
SCheck the water level and water flow, top up with coolant if necessary.
7.2 If necessary
SRegularly check that the power source is not clogged with dirt.
Clogged or blocked air inlets and outlets result in overheating
SClean the dust filter
SRemove the fan grille with the dust
filter (1).
SSwing out the grille (2).
SRelease the dust filter (3).
SBlow the filter clean with compressed
air (reduced pressure).
SReplace the filter with the finer mesh
on the side against the grille (2) (out
from the power source).
SReplace the fan grille with the dust
filter.
STop up with coolant
ESAB's ready mixed coolant is recommended for use.
See accessories on page 19.
STop up with coolant until it covers half the inlet pipe.
Note! Coolant must be topped up if connecting a welding torch or
connection cables that are 5 meters in length or longer. When
adjusting the water level by topping up, the coolant hose does not
need to be disconnected.
CAUTION!
The coolant must be handled as chemical waste.
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7.3 Every year
Carry out the following maintenance at least once a year.
SClean off any dirt and dust. Blow the power source clean with dry compressed
air (reduced pressure).
SChange the coolant and clean the hoses and water reservoir with clean water.
SCheck seals, cables and connections. Tighten if necessary and replace any
defective parts.
8 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised
service technician.
Type of fault Action
No arc. SCheck that the mains power supply switch is
turned on.
SCheck that the welding current supply and
return cables are correctly connected.
SCheck that the correct current value is set.
Welding current is interrupted during welding SCheck whether the thermal overload trips
have operated (indicated by the orange
lamp on the front panel).
SCheck the main power supply fuses.
The thermal overload trips operate frequently. SCheck to see whether the air filters are
clogged.
SMake sure that you are not exceeding the
rated data for the power source (i.e. that the
unit is not being overloaded).
Poor welding performance. SCheck that the welding current supply and
return cables are correctly connected.
SCheck that the correct current value is set.
SCheck that the correct wire is being used.
SCheck the main power supply fuses.
9 ORDERING OF SPARE PARTS
Mig 5000i is designed and tested in accordance with the international an European
standards IEC/EN 60974-1/-2 and EN 60974-10.
It is the obligation of the service unit which has carried out the service or repair work
to make sure that the product still conforms to the said standard.
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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Diagram
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Cooling unit

Mig 5000i
Edition 100112
Ordering number
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1.
Ordering no. Denomination Type Notes
0459 230 880 Welding power source Mig 5000i
0459 230 881 Welding power source Mig 5000i with cooling unit
0459 230 896 Welding power source Mig 5000i with cooling unit and flow guard
0459 839 018 Spare parts list Mig 5000i
The spare parts list is available on the Internet at www.esab.com

Mig 5000i
Edition 100112
Spare parts list
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Item Ordering no. Denomination
10458 398 001 Filter
20458 383 991 Front grill

Mig 5000i
R0459 290/E100112/P24
Accessories
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Trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0458 530 880
Trolley 2 (for feeder with counterbalance
device and/or 2 gas bottles) . . . . . . . . . . . . . . . . 0458 603 880
Guide pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0458 731 880
Insulating bushing for guide pin, included in
trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0278 300 401
Autotransformer TUA2 . . . . . . . . . . . . . . . . . . . 0459 145 880

Mig 5000i
R0459 290/E100112/P24
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Handle (1 piece) with mounting screws . . 0459 307 881
Remote control adapter RA12 12 pole . . . .
For analogue remote controls to CAN based
equipment.
0459 491 910
Remote control unit MTA1 CAN . . . . . . . . . .
MIG/MAG: wire feed speed and voltage
MMA: current and arc force
TIG: current, pulse and background current
0459 491 880
Remote control unit M1 10Prog CAN . . . . . .
Choice of on of 10 programs
MIG/MAG: voltage deviation
TIG and MMA: current deviation
0459 491 882
Remote control unit AT1 CAN . . . . . . . . . . . .
MMA and TIG: current
0459 491 883
Remote control unit AT1 CF CAN . . . . . . . . .
MMA and TIG: rough and fine setting of
current.
0459 491 884