ESAB Aristo Mig U4000i User manual

Aristo®
Instruction manual
0459 419 401 GB 20171110 Valid for: serial no. 950-333-xxxx
Mig U4000i/4000iw

TABLE OF CONTENTS
0459 419 401 © ESAB AB 2017
1SAFETY ......................................................................................................... 4
1.1 Meaning of symbols ................................................................................. 4
1.2 Safety precautions ................................................................................... 4
2INTRODUCTION............................................................................................ 7
2.1 Equipment ................................................................................................. 7
3TECHNICAL DATA ........................................................................................ 8
4INSTALLATION.............................................................................................. 10
4.1 Lifting instructions ................................................................................... 10
4.2 Placing....................................................................................................... 10
4.3 Mains power supply ................................................................................. 11
4.4 Terminating resistor ................................................................................. 11
4.5 Connection of multiple wire feed units .................................................. 11
5OPERATION .................................................................................................. 13
5.1 Connections and control devices ........................................................... 13
5.2 Turning on the power source .................................................................. 13
5.3 Fan control ................................................................................................ 14
5.4 Overheating protection ............................................................................ 14
5.5 Cooling unit............................................................................................... 14
5.6 Remote control unit.................................................................................. 14
6MAINTENANCE............................................................................................. 16
6.1 Daily........................................................................................................... 16
6.2 If necessary............................................................................................... 16
6.3 Every year ................................................................................................. 16
7TROUBLESHOOTING ................................................................................... 17
8ORDERING SPARE PARTS .......................................................................... 18
DIAGRAM ............................................................................................................. 19
ORDERING NUMBERS........................................................................................ 22
SPARE PARTS LIST............................................................................................. 23
ACCESSORIES .................................................................................................... 24
Rights reserved to alter specifications without notice.

1 SAFETY
0459 419 401 -4- © ESAB AB 2017
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2 Safety precautions
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

1 SAFETY
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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
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0459 419 401 -6- © ESAB AB 2017
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
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.
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.
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.

2 INTRODUCTION
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2 INTRODUCTION
The Mig U4000i/4000iw are MIG/MAG / TIG welding power sources, which can also be used
for MMA welding.
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.
ESAB's accessories for the product can be found in chapter "ACCESSORIES".
2.1 Equipment
The power source is supplied complete with terminating resistor, 5 m return cable and
instruction manual.

3 TECHNICAL DATA
0459 419 401 -8- © ESAB AB 2017
3 TECHNICAL DATA
Mig U4000i/Mig 4000iw
Mains voltage 400 V ±10%, 3~ 50 Hz
Mains supply Sscmin 6.1 MVA
Primary current I max
MIG/MAG 27 A
MMA 28 A
TIG 22 A
No-load power demand when in energy-saving
mode 6.5 min. after welding 39 W
Voltage/current range
MIG/MAG 15.0 - 34.0 V / 20 - 400 A
MMA 20.6 - 36.0 V / 16 - 400 A
TIG 10 - 26 V / 4 - 400 A
Permissible load at MIG/MAG
35% duty cycle 400 A / 34 V
60% duty cycle 320 A / 30 V
100% duty cycle 250 A / 27 V
Permissible load at MMA
35% duty cycle 400 A / 36 V
60% duty cycle 320 A / 33 V
100% duty cycle 250 A / 30 V
Permissible load at TIG
35% duty cycle 400 A / 26 V
60% duty cycle 320 A / 23 V
100% duty cycle 250 A / 20 V
Power factor at maximum current 0.90
Efficiency at maximum current 82%
Open-circuit voltage U0max
MIG/MAG without VRD function 1) 60 V
MMA/TIG without VRD function 1) 60 V
U0L"Live TIG", VRD function deactivated 2) 60 V
VRD function activated 2) < 26 V
Operating temperature -10 to +40 °C (+14 to +104 °F)
Transportation temperature -20 to +55 °C (-4 to +131 °F)
Continual sound pressure at no-load <70 db (A)
Dimensions l × w × h 625 × 394 × 496 mm
(24.6×15.5×19.5in.)
with cooling unit 625 × 394 × 776 mm
(24.6×15.5×30.5in.)

3 TECHNICAL DATA
0459 419 401 -9- © ESAB AB 2017
Mig U4000i/Mig 4000iw
Weight 63.5 kg (139 lbs)
with cooling unit 84 kg (185 lbs)
Insulation class H
Enclosure class IP23
Application class
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.
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.
Cooling unit
Cooling power 50 Hz – 1.65 kW at 25 °C (77 °F) ambient
temperature and flow 1.0l/min (0.26 gal/min)
60 Hz – 1.55 kW at 25 °C (77 °F) ambient
temperature and flow 1.0l/min (0.26 gal/min)
Coolant ESAB's ready mixed coolant
Liquid quantity 5.5 l (1.45 gal)
Maximum water flow 2.0 l/min (0.53 gal/min)
Maximum number of water-cooled welding
torches that may be connected
One TIG torch and one MIG welding torch
Maximum pressure 50 Hz – 0.376 MPa (3.76 Bar)
60 Hz – 0.474 MPa (4.74 Bar)

4 INSTALLATION
0459 419 401 - 10 - © ESAB AB 2017
4 INSTALLATION
The installation must be carried out by a professional.
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit
power is greater than or equal to Sscmin at the interface point between the user's
supply and the public system. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply with a short-circuit
power greater than or equal to Sscmin. Refer to the technical data in the
TECHNICAL DATA chapter.
4.1 Lifting instructions
Power source Trolley and power source Trolley2 and power source
4.2 Placing
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.