ESAB Tig 4000i Aristo Bedienungsanleitung

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).

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

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

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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