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
0458 640 501 -4- © ESAB AB 2022
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
0458 640 501 -5- © ESAB AB 2022
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
0458 640 501 -6- © ESAB AB 2022
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
0458 640 501 -7- © ESAB AB 2022
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
0458 640 501 -8- © ESAB AB 2022
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
0458 640 501 - 10 - © ESAB AB 2022
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.