ESAB Aristo Mig 5000i 400 V Bedienungsanleitung

Valid for serial no. 620--xxx--xxxx0459 290 101 GB 060830

Mig 5000i

Aristot

400 V version

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................................................................

4 TECHNICAL DATA 5.................................................

5 INSTALLATION 6....................................................

5.1 Lifting instructions 7.........................................................

5.2 Placing 7...................................................................

5.3 Mains power supply 7........................................................

5.4 Terminating resistor 8........................................................

5.5 Connection of multiple wire feed units 8........................................

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 Mig 5000i 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).

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

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 Mig 5000i is a MIG/MAG welding power source, which can also be used for

MMA welding.

There are two variants of the power source:

SMig 5000i without cooling unit

SMig 5000i with cooling unit.

NB: These instructions describe an Mig 5000i 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 U8.

ESAB’s accessories for the product can be found on page 19.

3.1 Equipment

The power source is supplied complete with terminating resistor, 5 m return cable

and instruction manual.

4 TECHNICAL DATA

Mig 5000i

Mains voltage 400V, ±10%, 3∼50/60 Hz

Primary current

Imax MIG/MAG

Imax MMA 39 A

40 A

No--load power demand when in the energy--saving mode,

6.5 min. after welding 50 W

Voltage/current range

MIG/MAG

MIG/MAG, control panel M2

MMA

8--60 V / 16--500 A

8-- 42 V

16-- 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

Power factor at maximum current 0.85

Efficiency at maximum current 86 %

Open--circuit voltage

(MIG/MAG)

(MMA) 72 -- 88 V

68 -- 80 V

Operating temperature -- 1 0 t o + 4 0 ˚C

Dimensions, lxwxh

with cooling unit 625 x 394 x 496 mm

625 x 394 x 776 mm

Continual A--weighted sound pressure <70 db

Weight

with cooling unit 66 kg

86 kg

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Mig 5000i

Insulation class transformer H

Enclosure class IP 23

Application class

Cooling unit

Cooling power 2500 W at 40˚C temp. difference and

flow1.5l/min

Coolant 50 % water / 50% 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

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.

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 0.190 ohm or lower. If the

network impedance is higher, there is a risk of flicker in the illuminators.

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5.1 Lifting instructions

Power source Trolley and power source Trolley2 and power source

5.2 Placing

Position the welding power source such that its cooling air inlets and outlets are not

obstructed.

5.3 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

Mig 5000i 400 V 3μ50 Hz

Mains voltage 400 V

Mains cable area, mm24G6

Phase current, I RMS 31 A

Fuse

Anti--surge

Type C MCB 35 A

40 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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5.4 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.

5.5 Connection of multiple wire feed units

With control unit U8 and wire feed units without control panel (M0) 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 19.

Four wire feed units

Two connection kits and an extra cooling unit are required when connecting four wire

feed units, see accessories on page 19.

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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. Not used on

this model.

8White indicating lamp -- Power supply ON

2Connection for cooling water. Not used on

this model.

9Orange indicating lamp -- Overheating

3Cooling water filler 10 Fuse

4Connection for welding current cable (+)

(MMA welding) 11 Connection for control cable to the wire

feed unit or for the terminating resistor

5Connection for remote control 12 Connection for welding current to the wire

feed unit

6Connection for return cable (--) 13 Connection for cooling water to the wire

feed unit -- BLUE

7Main power supply switch, 0 / 1 / START 14 Connection for cooling water from the wire

feed unit -- RED

6.2 Turning on the power source

Turn on the mains power by turning switch (7) 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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