ESAB Aristo Mig U4000i Bedienungsanleitung

Valid for serial no. 802-xxx-xxxx, 803-xxx-xxxx,

950-xxx-xxxx

0459 419 301 GB 20121105

Aristo

Mig U4000i

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 11............................................

5.2 Turning on the power source 12................................................

5.3 Fan control 12...............................................................

5.4 Overheating protection 12.....................................................

5.5 Cooling unit 12...............................................................

5.6 Remote control unit 13........................................................

6 MAINTENANCE 13....................................................

6.1 Daily 13.....................................................................

6.2 If necessary 14..............................................................

6.3 Every year 14................................................................

7 FAULT TRACING 15..................................................

8 ORDERING OF SPARE PARTS 15......................................

DIAGRAM 16............................................................

ORDERING NUMBER 19.................................................

SPARE PARTS LIST 20..................................................

ACCESSORIES 21.......................................................

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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

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:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding and cutting

2. The operator must ensure that:

Sno unauthorised 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 precautions 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!

WARNING

Do not use the power source for thawing frozen pipes.

CAUTION

Read and understand the instruction manual before

installing or operating.

CAUTION

This product is solely intended for arc welding.

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.

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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.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

The Mig U4000i is a MIG/MAG / TIG welding power source, which can also be used

for MMA welding.

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 21.

2.1 Equipment

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

and instruction manual.

3 TECHNICAL DATA

Mig U4000i

Mains voltage 400V, $10%, 350 Hz

Mains supply Ssc min 2.0 MVA

Primary current

Imax MIG/MAG

Imax MMA

Imax TIG

25 A

27 A

20 A

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

6.5 min. after welding 60 W

Voltage/current range

MIG/MAG

MMA

TIG

8-60 V / 20-400 A

16- 400 A

4 - 400 A

Permissible load at MIG/MAG

35% duty cycle

60 % duty cycle

100% duty cycle

400 A / 34 V

320 A / 30 V

250 A / 27 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

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

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Mig U4000i

Power factor at maximum current 0.90

Efficiency at maximum current 86 %

Open-circuit voltage U0max

MIG/MAG without VRD function 1)

MMA / TIG without VRD function 1)

U0L “Live TIG”, VRD function deactivated 2)

MIG/MAG, MMA, VRD function deactivated 2)

VRD function activated 2)

55 - 70 V

78 - 90 V

60 V

58 V

<35 V

Operating temperature -10 to +40°C

Transportation temperature -20 to +55°C

Continual sound pressure at no-load <70 db (A)

Dimensions, lxbxh

with cooling unit

625 x 394 x 496 mm

625 x 394 x 776 mm

Weight

with cooling unit

63.5 kg

83.5 kg

Insulation class 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

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 flow

1.0 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 carried out 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

distribution 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 U4000i 400 V 350 Hz

Mains voltage 400 V

Mains cable area, mm24G4

Phase current, I1eff 16 A

Fuse

Anti-surge

Type C MCB

20 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 21.

Four wire feed units

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

feed units, see accessories on page 21.

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