ESAB Aristo Mig U4000iw User manual

GB
Valid for serial no. 802-xxx-xxxx, 803-xxx-xxxx,
950-xxx-xxxx
0459 291 301 GB 110509
Aristo®
Mig U5000i
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Lifting instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Placing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Mains power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Terminating resistor 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Connection of multiple wire feed units 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Connections and control devices 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Turning on the power source 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Fan control 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Overheating protection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Cooling unit 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Remote control unit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 MAINTENANCE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Daily 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 If necessary 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Every year 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 FAULT TRACING 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING OF SPARE PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
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.
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.
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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 and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the 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
This product is solely intended for arc welding.
CAUTION
Read and understand the instruction manual before
installing or operating.
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Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/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
The Mig U5000i is a MIG/MAG / TIG welding power source, which can also be used
for MMA welding.
There are two variants of the power source:
SMig U5000i without cooling unit
SMig U5000i with cooling unit.
NB: These instructions describe a Mig U5000i 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.
ESAB's accessories for the product can be found on page 23.
2.1 Equipment
The power source is supplied complete with terminating resistor, 5m return cable
and instruction manual.
3 TECHNICAL DATA
Mig U5000i
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
Imax TIG
36 A
37 A
29 A
No-load power demand when in the energy-saving mode,
6.5 min. after welding 50 W
Voltage/current range
MIG/MAG
MMA
TIG
8-60 V / 16-500 A
16- 500 A
4 - 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
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Mig U5000i
Permissible load at TIG
60 % duty cycle
100% duty cycle
500 A / 30 V
400 A / 26 V
Power factor at maximum current 0.91
Efficiency at maximum current 87 %
Open-circuit voltage U0max
MIG/MAG, TIG without VRD function 1)
MMA without VRD function 1)
U0L “Live TIG”, VRD function deactivated 2)
MIG/MAG, MMA, VRD function deactivated 2)
VRD function activated 2)
72 - 88 V
68 - 80 V
79 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
71 kg
91 kg
Insulation class transformer H
Enclosure class IP 23
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.
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.
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 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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4 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.
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.
4.3 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 U5000i 400 V 350 Hz
Mains voltage 400 V
Mains cable area, mm24G6
Phase current, I1eff 28 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.
4.4 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.
4.5 Connection of multiple wire feed units
With control unit 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 23.
Four wire feed units
Two connection kits and an extra cooling unit are required when connecting four wire
feed units, see accessories on page 23.
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