ESAB Aristo Tig 4000iw User manual

Aristo®
Instruction manual
0458 640 501 GB 20220103 Valid for: serial no. 950-406-xxxx
Tig 4000i / Tig 4000iw

TABLE OF CONTENTS
0458 640 501 © ESAB AB 2022
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 7
2.1 Equipment ............................................................................................... 7
2.2 The control panel.................................................................................... 7
3TECHNICAL DATA ...................................................................................... 8
4INSTALLATION............................................................................................ 10
4.1 Lifting instructions ................................................................................. 10
4.2 Positioning of the power source........................................................... 10
4.3 Mains power supply ............................................................................... 11
5OPERATION ................................................................................................ 12
5.1 Connections and control devices ......................................................... 12
5.2 Turning on the power source ................................................................ 12
5.3 Fan control .............................................................................................. 13
5.4 Overheating protection .......................................................................... 13
5.5 Cooling unit............................................................................................. 13
5.6 Remote control unit................................................................................ 13
6MAINTENANCE........................................................................................... 15
6.1 Daily......................................................................................................... 15
6.2 If necessary............................................................................................. 15
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
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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
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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 Tig 4000i/Tig 4000iw is a TIG welding power source, which can also be used for MMA
welding.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The Tig 4000i/Tig 4000iw is delivered with 5m return cable, instruction manual for power
source and one instruction manual for the control panel.
Instruction manuals in other languages can be downloaded from the Internet: www.esab.com
2.2 The control panel
The power source is supplied with one of the following control panels:
•TA4 panel

With a knob for adjusting the current. Other parameters are controlled by pushbuttons,
with symbols in the display panel.
•TA6 panel

With a knob for adjusting the current. Other parameters are controlled by pushbuttons,
with text in the display panel.
See the separate instruction manuals for detailed descriptions of the control panels.

3 TECHNICAL DATA
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3 TECHNICAL DATA
Tig 4000i/Tig 4000iw
Mains voltage 400 V ±10 %, 3 ~ 50 Hz
Mains supply Ssc min 6.1 MVA
Primary current
Imax TIG 22 A
Imax MMA 28 A
No-load power in energy-saving mode 6.5 min.
after welding
39 W
Voltage/current range
TIG 10 – 26 V / 4 – 400 A
MMA 20.6 – 36.0 V / 16 – 400 A
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
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
Power factor at maximum current 0.90
Efficiency at maximum current 81.2 %
Open-circuit voltage U0max
without VRD function 1) 78 – 90 V
U0L "Live TIG" , VRD function deactivated 2) 60 V
MMA, VRD function deactivated 2) 60 V
VRD function activated 2) < 26 V
Operating temperature range -10 to +40 °C (+14 to +104 °F)
Transportation temperature -20 to +55 °C (-4 to +131 °F)
Dimensions l × w × h 625 × 394 × 776 (24.6 × 15.5 × 30.5 in.)
Continual sound pressure at no-load < 70 db (A)
Weight 84 kg (185 lbs)
Insulation class H
Enclosure class 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 instructions for the control panel, if the panel has that function.

3 TECHNICAL DATA
0458 640 501 -9- © ESAB AB 2022
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.
Cooling unit (Tig 4000iw)
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
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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
With power source With trolley and power
source
With trolley2 and power
source






4.2 Positioning of the power source
Position the welding power source in such a way that its cooling air inlets and outlets are not
obstructed.

4 INSTALLATION
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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.
Recommended fuse sizes and minimum cable areas
Tig 4000i/Tig 4000iw 50 Hz
Mains voltage 400V
Mains cable area, mm24G4
Phase current, I1eff 16A
Fuse
Anti-surge
Type C MCB

20A
20A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. For other regions, supply cables must be suitable for the
application and meet local and national regulations.

5 OPERATION
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5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
5.1 Connections and control devices
1Connection for cooling water from the TIG
torch - RED
9Main power supply switch, 0 / 1 / START
2Connection with water lock for cooling
water to the TIG torch - BLUE
10 White indicating lamp - Power supply ON
3Cooling water filler 11 Orange indicating lamp - Overheating
4Connection for return cable (+) 12 Control panel (see the respective
instructions)
5Connection for remote control 13 Connection for gas hose
6Connection for welding cable (-) 14 Connection for cooling water. Not used on
this model.
7Connection for start signal from the
welding torch
15 Connection for cooling water. Not used on
this model.
8Connection for gas to the TIG torch
5.2 Turning on the power source
Turn on the mains power by turning switch (9) 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

5 OPERATION
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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.
5.3 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 144 A, and at full speed for higher
currents.
5.4 Overheating protection
The power source has two 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.
5.5 Cooling unit
Water lock
The cooling unit has a water lock that senses whether the cooling water hoses are
connected.
The power source On/Off switch must be in the "0" position (Off) when connecting a
water-cooled TIG torch.
If a water-cooled TIG torch is connected, the water pump starts automatically when the main
On/Off switch is turned to "START" and/or when welding starts. After welding, the pump
continues to run for 6.5 minutes, and then switches to the energy-saving mode.
Function when welding
To start welding, the welder presses the torch trigger switch. The power source energises the
torch and starts wire feed and the cooling water pump.
To stop welding, the welder releases the torch trigger switch. The welding current is
interrupted, but the cooling water pump continues to run for 6.5 minutes, after which the unit
switches to energy-saving mode.
Water flow guard (optional)
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.
5.6 Remote control unit
Aristo power sources with integral 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.
When carrying out TIG welding, the value for the pulse current can be changed with the
remote control.
For more information about the operation of the remote control unit, see the relevant
operating instructions for the control panel.

5 OPERATION
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6 MAINTENANCE
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6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.
6.1 Daily
Carry out the following maintenance every day.
• Check that all cables and connections are fault free. Tighten if necessary and replace
any defective parts.
• Check the water level and water flow, top up with coolant if necessary.
6.2 If necessary
• Regularly check that the power source is not clogged with dirt.
Clogged or blocked air inlets and outlets result in overheating
• Clean the dust filter
○ Remove the fan grille with the dust filter (1).
○ Swing out the grille (2).
○ Release the dust filter (3).
○ Blow the filter clean with compressed air
(reduced pressure).
○ Replace the filter with the finer mesh on the
side
against the grille (2) (out from the power
source).
○ Replace the fan grille with the dust filter.
• Top up with coolant
ESAB's ready mixed coolant is recommended for
use.
See "ACCESSORIES" chapter.
○ Top up with coolant until it covers half the inlet
pipe.
CAUTION!
The coolant must be handled as chemical waste.

6 MAINTENANCE
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6.3 Every year
Carry out the following maintenance at least once a year.
• Clean off any dirt and dust. Blow the power source clean with dry compressed air
(reduced pressure).
• Change the coolant and clean the hoses and water reservoir with clean water.
• Check seals, cables and connections. Tighten if necessary and replace any defective
parts.

7 TROUBLESHOOTING
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7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorised service
technician.
Type of fault Action
No arc • Check that the mains power supply switch is turned on.
• Check that the welding current supply and return cables
are correctly connected.
• Check that the correct current value is set.
Welding current is
interrupted during welding
• Check whether the thermal overload trips have operated
(indicated by the orange lamp on the front panel).
• Check the main power supply fuses.
The thermal overload trips
operate frequently.
• Check to see whether the air filters are clogged.
• Make 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. • Check that the welding current supply and return cables
are correctly connected.
• Check that the correct current value is set.
• Check that the correct electrodes are being used.
• Check the main power supply fuses.

8 ORDERING SPARE PARTS
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8 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Tig 4000i/Tig 4000iw is designed and tested in accordance with the international and
European standards IEC-/EN 60974-1, /-2, /-3 and IEC-/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 mentioned standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.

DIAGRAM
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DIAGRAM

DIAGRAM
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