ESAB Tig 4000i Aristo User manual

GB
Valid for serial no. 620--xxx--xxxx0458 640 101 GB 060523
Tig 4000i
Aristot
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
3.2 The control panel 5..........................................................
4 TECHNICAL DATA 6.................................................
5 INSTALLATION 7....................................................
5.1 Lifting instructions 7.........................................................
5.2 Placing 7...................................................................
5.3 Electrical installation (with autotransformer) 8...................................
5.4 Mains power supply 9........................................................
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 Cleaning the air filter 12.......................................................
7.2 Topping up the coolant 12.....................................................
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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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-
ing power source Tig 4000i from serial number 620 complies with standard IEC/EN 60974--1, in ac-
cordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with stan-
dard IEC/EN 60974--10 in accordance with the requirements of directive (89/336/EEC) and adden-
dum (93/68/EEC).
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Kent Eimbrodt
Global Director Equipment and Automation
ESAB AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2006--05--22
2SAFETY
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.
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 PRECAU-
TIONS 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!
Read and understand the instruction manual before installing
or operating.
Do not use the power source for thawing frozen pipes.
WARNING!
This product is solely intended for arc welding.
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!
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3 INTRODUCTION
The Tig 4000i is a TIG welding power source, which can also be used for MMA
welding.
There are eight variants of the power source:
STig 4000i with TA4 control panel
STig 4000i with TA6 control panel
STig 4000i with cooling unit and TA4 control panel
STig 4000i with cooling unit and TA6 control panel
STig 4000i with autotransformer and TA4 control panel
STig 4000i with autotransformer and TA6 control panel
STig 4000i with cooling unit, autotransformer and TA4 control panel
STig 4000i with cooling unit, autotransformer and TA6 control panel
NB: These instructions describe an Tig 4000i with cooling unit and autotransformer.
ESAB’s accessories for the product can be found on page 19.
3.1 Equipment
The Tig 4000i is delivered with 5m return cable, instructions for power source and
one instruction for the control panel.
3.2 The control panel
The power source is supplied with one of the following control panels:
STA4 panel
With a knob for adjusting the current. Other parameters are controlled by
pushbuttons, with symbols in the display panel.
STA6 panel
With a knob for adjusting the current. Other parameters are controlled by
pushbuttons, with text in the display panel.
See the separate instructions for detailed descriptions of the control panels.
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4 TECHNICAL DATA
Tig 4000i
not reconnectable Tig 4000i reconnectable
Mains voltage 400V, ±10%, 3∼50 Hz 208/230/400/460/475/500/575 V,
±10%, 3∼50/60 Hz
Primary current
Imax TIG
Imax MMA 29 A 38 A 50/44/29/23/23/20/15 A 65/57/38/30/30/20/20 A
No--load powerin the energy--
saving mode, 6,5 min. after wel-
ding
60 W 235 W
Voltage/current range
TIG
MMA 8--60 V / 4--400 A
16 -- 400 A 8--60 V / 4--400 A 16 -- 400 A
Permissible load at TIG
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 26 V
320 A / 23 V
250 A / 20 V
400 A / 26 V
320 A / 23 V
250 A / 20 V
Permissible load at MMA
35% duty cycle
60 % duty cycle
100% duty cycle
400 A / 36 V
320 A / 33 V
250 A / 30 V
400 A / 36 V
320 A / 33 V
250 A / 30 V
Power factor at maximum cur-
rent 0,65 0,65
Efficiency at maximum current 85 % 85 %
Open--circuit voltage 78 -- 90 V 78 -- 90 V
Operating temperature range -- 1 0 t o + 4 0 ˚C-- 1 0 t o + 4 0 ˚C
Dimensions, lxbxh
with cooling unit 625 x 394 x 496 625 x 394 x 776 625 x 394 x 776 625 x 394 x 1056
Continual A--weighted sound
pressure <70 db <70db
Weight
with cooling unit 59 kg 79 kg 116 kg 136 kg
Insulation class H H
Enclosure class IP 23 IP 23
Application class
Cooling unit
Cooling power 2500 W at 40˚C temperature difference and flow
1.5 l/min
Coolant 50 % water / 50% glykol
Liquid 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
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.
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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.
5 INSTALLATION
The installation must be executed by a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.
Note!
Connect the power source to the electricity mains with a network impedance of 0.200 ohm or lower. If the
network impedance is higher, there is a risk of flicker in the illuminators.
5.1 Lifting instructions
With power source With trolley and power source With trolley2 and power source
5.2 Placing
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
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5.3 Electrical installation (with autotransformer)
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5.4 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 60 Hz 50/60 Hz 50 Hz 60 Hz 60 Hz 50 Hz 60 Hz
Mains voltage 208 V 230 V 400 V 460 V 475 V 500 V 575 V
Mains cable area,
mm24G6 4G6 4G4 4G4 4G4 4G4 4G4
Phase current, I ef-
fective 38 A 33 A 22 A 18 A 18 A 16 A 11 A
Fuse
Anti--surge
Type C MCB 50 A
50 A 50 A 50 A 25 A 32 A 20 A -- 20 A -- 16 A -- 16 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.
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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 from the TIG
torch -- RED 9Main power supply switch, 0 / 1 / START
2Connection with water lock for cooling wa-
ter 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 Fuse4AT
6Connection for welding cable (--) 14 Connection for gas hose
7Connection for start signal from the wel-
ding torch 15 Connection for cooling water. Not used on this model.
8Connection for gas to the TIG torch 16 Connection for cooling water. Not used on
this model.
6.2 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
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 144 A, and at full speed for
higher currents.
6.4 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.
6.5 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
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
Aristo 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.
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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.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
Note!
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 Cleaning the air filter
SRelease the cover plate with the dust
filter (1).
SSwing out the cover plate (2).
SRemove the dust filter (3).
SBlow it clean with compressed air at
reduced pressure
SReplace the filter with the finer mesh
on the side against the cover plate (2)
SRefit the cover plate with the filter.
7.2 Topping up the coolant
We recommend a 50/50 % mixture of water and
ethylene glycol.
Top up with coolant until it is up to the level of
the filling hole.
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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.
SCheck fuse.
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 ope-
rate 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 electrodes are being used.
SCheck the main power supply fuses.
9 ORDERING OF SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Tig 4000i is designed and tested in accordance with the international an European
standards IEC/EN 60974--1 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.
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

Tig 4000i
Edition 060523
Ordering number
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1.
Ordering no. Denomination Type Notes
0458 630 880 Welding power source AristotTig 4000i, TA4
0458 630 881 Welding power source AristotTig 4000i, TA4 with cooling unit
0458 630 882 Welding power source AristotTig 4000i, TA4 with auto transformer
0458 630 883 Welding power source AristotTig 4000i, TA4 with cooling unit and auto
transformer
0458 630 884 Welding power source AristotTig 4000i, TA6
0458 630 885 Welding power source AristotTig 4000i, TA6 with cooling unit
0458 630 886 Welding power source AristotTig 4000i, TA6 with auto transformer
0458 630 887 Welding power source AristotTig 4000i, TA6 with cooling unit and auto
transformer
0458 640 990 Spare part list AristotTig 4000i
0458 819 xxx Instruction manual AristotTA4
0458 855 xxx Instruction manual AristotTA6
The instruction manuals and the spare parts list are available on the Internet at www.esab.com
Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page where you can
both search for and download instructions and spare parts lists.

Tig 4000i
Edition 060523
Spare parts list
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Item Ordering no. Denomination
10458 398 001 Filter
20458 383 001 Front grill

Edition 060523
Tig 4000i
Accessories
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Trolley ................................. 0458 530 881
Remote control adapter RA12 12pole ....
For analogue remote controls to CAN based
equipment.
0459 491 910
RemotecontrolunitMTA1CAN ..........
MIG/MAG: wire feed speed and voltage
MMA: current and arc force
TIG: current, pulse and background current
0459 491 880
RemotecontrolunitM110ProgCAN......
Choice of on of 10 programs
MIG/MAG: voltage deviation
TIG and MMA: current deviation
0459 491 882
RemotecontrolunitAT1CAN ............
MMA and TIG: current
0459 491 883
RemotecontrolunitAT1CFCAN .........
MMA and TIG: rough and fine setting of
current.
0459 491 884
Remote cable CAN 4 pole -- 12 pole
5m.....................................
10m....................................
15m....................................
25m....................................
0.25m ..................................
0459 544 880
0459 554 881
0459 554 882
0459 554 883
0459 554 884

Edition 060523
Tig 4000i
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Return cable 5m70mm
2................ 0700 006 895
Water flow guard 0.7l/min................ 0456 855 880