ESAB Aristo Mig 5000i User manual

Aristo®

Instruction manual

0459 290 401 GB 20171107 Valid for: 608-, 613-xxx-xxxx

Mig5000i,

Mig5000iWeldCloud™

400 V

TABLE OF CONTENTS

0459 290 401 © ESAB AB 2017

1SAFETY ....................................................................................................... 5

2INTRODUCTION.......................................................................................... 8

2.1 Equipment ............................................................................................... 8

3TECHNICAL DATA ...................................................................................... 9

4INSTALLATION............................................................................................ 11

4.1 Lifting instructions ................................................................................. 11

4.2 Placing..................................................................................................... 11

4.3 Mains power supply ............................................................................... 12

4.4 Terminating resistor ............................................................................... 12

4.5 Connection of multiple wire feed units ................................................ 12

5OPERATION ................................................................................................ 15

5.1 Connections and control devices ......................................................... 15

5.2 Turning on the power source ................................................................ 16

5.3 Fan control .............................................................................................. 16

5.4 Overheating protection .......................................................................... 16

5.5 Cooling unit............................................................................................. 16

5.6 Remote control unit................................................................................ 16

5.7 WeldCloud™ unit.................................................................................... 17

6MAINTENANCE........................................................................................... 18

6.1 Daily......................................................................................................... 18

6.2 If necessary............................................................................................. 18

6.3 Every year ............................................................................................... 19

7FAULT TRACING......................................................................................... 20

8ORDERING OF SPARE PARTS .................................................................. 21

DIAGRAM ............................................................................................................. 22

ORDERING NUMBERS........................................................................................ 24

SPARE PARTS LIST............................................................................................. 25

ACCESSORIES .................................................................................................... 26

Rights reserved to alter specifications without notice.

1 SAFETY

0459 290 401 -5- © ESAB AB 2017

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:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

1 SAFETY

0459 290 401 -6- © ESAB AB 2017

WARNING!

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

• Install and earth the unit in accordance with applicable standards

• Do not touch live electrical parts or electrodes with bare skin, wet gloves

or wet clothing

• Insulate yourself from earth and the workpiece

• Ensure your working stance is safe

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes

• 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

• Protect your eyes and body. Use the correct welding screen and filter

lens and wear protective clothing

• Protect bystanders with suitable screens or curtains

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable materials nearby

NOISE - Excessive noise can damage hearing

• Protect your ears. Use earmuffs or other hearing protection.

• Warn bystanders of the risk

MALFUNCTION - Call for expert assistance in the event of malfunction.

Read and understand the instruction manual before installing or operating.

PROTECT YOURSELF AND OTHERS!

ESAB has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information contact your local ESAB dealer or visit us on

our website.

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.

CAUTION!

Read and understand the instruction manual before

installing or operating.

1 SAFETY

0459 290 401 -7- © ESAB AB 2017

NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/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.

2 INTRODUCTION

0459 290 401 -8- © ESAB AB 2017

2 INTRODUCTION

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

MMA welding.

There are several variants of the power source:

• Mig 5000i without cooling unit

• Mig 5000i with cooling unit

• Mig 5000i with WeldCloud™ unit

• Mig 5000i with cooling unit and WeldCloud™ unit

NOTE!

These instructions describe a Mig 5000i with a cooling unit.

The power source is intended for use with the Feed 3004 or Feed 4804 wire feed units.

The power source Mig 5000i WeldCloud™ is combined with U82and provides a control box

which enables wireless monitoring.

For more information about the feed units and WeldCloud™, refer to the Instruction manuals.

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of

this manual.

2.1 Equipment

The power source is supplied complete with:

• An instruction manual

• Terminating resistor

• 5 m return cable

Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

3 TECHNICAL DATA

0459 290 401 -9- © ESAB AB 2017

3 TECHNICAL DATA

Mig 5000i Mig 5000i WeldCloud™

Mains voltage 400 V ±10%, 3~ 50/60 Hz 400 V ±10%, 3~ 50/60 Hz

Mains supply Sscmin 14.54 MVA

Zmax 0.011 Ω

Sscmin 14.54 MVA

Zmax 0.011 Ω

Primary current

Imax MIG/MAG (GMAW) 37 A 37 A

Imax TIG (GTAW) 30 A 30 A

Imax MMA (SMAW) 38 A 38 A

No-load power demand when in the energy-saving mode 6.5 min. after welding

TIG/MIG (GTAW/GMAW) 36 W 36 W

MMA (SMAW) 43 W 43 W

Voltage/current range

MIG/MAG (GMAW) 8 - 60 V / 16 - 500 A 8 - 60 V / 16 - 500 A

MIG/MAG (GMAW), control

panel M2 8 - 42 V 8 - 42 V

MMA (SMAW) 16 - 500 A 16 - 500 A

Permissible load at MIG/MAG (GMAW)

60 % duty cycle 500 A / 39 V 500 A / 39 V

100% duty cycle 400 A / 34 V 400 A / 34 V

Permissible load at TIG

60 % duty cycle 500 A / 30 V 500 A / 30 V

100% duty cycle 400 A / 26 V 400 A / 26 V

Permissible load at MMA (SMAW)

60 % duty cycle 500 A / 40 V 500 A / 40 V

100% duty cycle 400 A / 36 V 400 A / 36 V

Power factor at maximum

current (I2) MMA/TIG/MIG 0.90 0.90

Efficiency at maximum current (I2)

MMA (SMAW) 85 % 85 %

TIG (GTAW) 82 % 82 %

MIG (GMAW) 84 % 84 %

Open-circuit voltage U0max

MIG/MAG (GMAW) without

VRD function 1) 72 - 88 V 72 - 88 V

MMA (SMAW) without VRD

function 1)

68 - 80 V 68 - 80 V

MIG/MAG (GMAW), MMA

(SMAW), VRD function

deactivated 2)

59 V 59 V

VRD function activated 2) < 35 V < 35 V

3 TECHNICAL DATA

0459 290 401 - 10 - © ESAB AB 2017

Mig 5000i Mig 5000i WeldCloud™

Operating temperature -10 to +40 °C

(14 to 104 °F)

-10 to +40 °C

(14 to 104 °F)

Transportation temperature -20 to +55 °C

(-4 to 131 °F)

-20 to +55 °C

(-4 to 131 °F)

Dimensions l × w × h

without cooling unit

with cooling unit

625 × 394 × 496 mm

(24.6 × 15.5 × 19.6in.)

625 × 394 × 496 mm

(24.6 × 15.5 × 19.6in.)

625 × 394 × 776 mm

(24.6 × 15.5 × 30.6in.)

625 × 394 × 776 mm

(24.6 × 15.5 × 30.6in.)

Continual sound pressure

at no-load

<70 db (A) <70 db (A)

Weight without cooling unit

with cooling unit

68 kg (150 lb) 79 kg (174 lb)

88 kg (194 lb) 99 kg (218 lb)

Insulation class transformer H H

Enclosure class IP23 IP23

Application class

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 manual for the control panel.

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/104°F, or below.

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 intended 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.

Mains supply, Zmax

Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

Cooling unit

Cooling power 2.0 kW at 40°C (104°F) temp. difference and flow

1.0 l/min (0.26 us gal/min)

Coolant 50 % water / 50 % mono-ethylen glycol

Coolant quantity 5.5 l (1.45 us gal)

Maximum water flow 2.0 l/min (0.53 us gal)

Maximum number of water-cooled

welding torches that may be connected

Two MIG welding torches or one TIG torch and one

MIG welding torch

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