ESAB Tig 4000i Aristo Instruction 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 1 1.....................................................
6.5 Cooling unit 11...............................................................
6.6 Remote control unit 1 1........................................................
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 welding power source Tig 4000i from serial number 620 complies with standard IEC/EN 60974--1, in accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with standard IEC/EN 60974--10 in accordance with the requirements of directive (89/336/EEC) and addendum (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 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 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:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from drafts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication 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. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S 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.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn 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:
S Tig 4000i with TA4 control panel
S Tig 4000i with TA6 control panel
S Tig 4000i with cooling unit and TA4 control panel
S Tig 4000i with cooling unit and TA6 control panel
S Tig 4000i with autotransformer and TA4 control panel
S Tig 4000i with autotransformer and TA6 control panel
S Tig 4000i with cooling unit, autotransformer and TA4 control panel
S Tig 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:
S TA4 panel
With a knob for adjusting the current. Other parameters are controlled by
pushbuttons, with symbols in the display panel.
S TA6 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
I
max
TIG
I
max
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 welding
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 current
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 certain load without overloading.
The duty cycle is valid f or 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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