Arc 4000i
GB
Arc 4000i
Aristot / Origot
Instruction manual
0458 636 301 GB 080105
Valid for serial no. 802--xxx--xxxx, 803--xxx--xxxx
1 DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
5
3.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
4 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
5.1 Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
6.1
6.2
6.3
6.4
6.5
Connections and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main voltage connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan control timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
9
9
7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
7.1 Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
8 FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
12
14
15
16
Rights reserved to alter specifications without notice.
TOCe
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GB
1
DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that welding power source Arc 4000i from serial number 802 (2008 w.02) are constructed and tested in compliance with the standard EN 60974--1 and EN 60974--10 (Class A) in accordance with the requirements of directive (2006/95/EC) and (2004/108/EEC).
--------------------------------------------------------------------------------------------------------------------------------------
Laxå 2008--01--04
Kent Eimbrodt
Global Director
Equipment and Automation
2
SAFETY
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
Arc welding and cutting can be injurious to yourself and others. Take precausions 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.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
CAUTION!
Read and understand the instruction manual before
installing or operating.
WARNING!
Do not use the power source for thawing frozen pipes.
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 electromagnic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
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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!
ESAB can provide you with all necessary welding protection and accessories.
3
INTRODUCTION
The Arc 4000i is a welding current power source intended for use with coated
electrodes (MMA welding).
It is available in two variants:
S
Arc 4000i with the A2 control panel
S
Arc 4000i with the A4 control panel.
See page 16 for details of ESAB’s accessories for the power unit.
3.1
Equipment
The Arc 4000i is supplied with instruction manuals for power source and for the
control panel.
3.2
Control panels
The power source is supplied with one of the following control panels:
S
A2
With knobs for all control settings.
S
A4
With a knob for setting the welding current. Other functions controlled by
pushbuttons and symbols in the display panel.
See the separate instruction manuals for detailed descriptions of the control panels.
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4
TECHNICAL DATA
Arc 4000i
Mains voltage
Mains supply
Primary current Imax
No--load power in energy--saving mode 6.5 min. after welding
Setting range
Maximum permissible load at
35% duty cycle
60 % duty cycle
100 % duty cycle
Power factor at maximum current
Efficiency at maximum current
Open--circuit voltage
Temperature range
Dimensions, l x b x h
Continual A--weighted sound pressure
Weight
Insulation class
Enclosure class
Application class
400 V, ±10%, 3∼ 50 Hz
Ssc min 2.0 MVA
27 A
50 W
16 A -- 400 A
400 A / 36 V
320 A / 33 V
250 A / 30 V
0,90
86%
78 -- 90 V
--10 till + 40˚C
625 x 294 x 492 mm
<70 db
47,5 kg
H
IP 23
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 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
5
INSTALLATION
The installation must be executed 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
distrubution network operator if necessary, that the equipment may be connected.
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5.1
Lifting instructions
5.2
Placing
Place the power source so that its cooling air inlets and outlets are not obstructed.
5.3
Mains power supply
Make sure that the unit is connected to the correct supply voltage, and that it is
protected by the correct fuse rating. Make protective earth connections in
accordance with the requirements of applicable regulations.
Rating plate with supply data.
Recommended fuse rating and minimum cable size
Arc 4000i
Supply voltage
Mains cable size, mm2
Phase current, I1eff
Fuse
anti--surge
Type C, MCB
400 V, 3~50 Hz
400 V
4G4
16 A
20 A
20 A
Note!
Cable size and fuse ratingcomplies to Swedish electrical regulations. Connect the power supply in
conformance with local 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
1
Welding current cable connector (+)
5
White indicating lamp, mains power supply
ON
2
Connector for remote control
6
Orange indicating lamp, overheating
3
Return welding current cable connector
(--)
7
Control panel (see respective instruction
manual)
4
Main power supply switch, 0 / 1 /
START
6.2
Main voltage connection
Turn on the power supply by turning switch (4) against the spring to the “START”
position. The switch returns to the “1” position when it is released.
If the mains power supply is interrupted, and then restored, the power source
remains off until the switch is again turned to the “START” position and released.
Turn the power 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.
6.3
Fan control timer
The power source fans continue to run for 6,5 minutes after welding has stopped,
and the unit switches to energy--saving mode. They start again when welding
restarts.
The fans run at reduced speed for welding currents up to 144 A, and at full speed for
higher currents.
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6.4
Thermal overload protection
The power source has two thermal overload trips which operate if the internal
temperature becomes too high, interrupting the welding current and lighting the
orange indicating lamp on the front of the unit. The trips reset automatically when
the temperature has fallen.
6.5
Remote control unit
Aristo machines with intergral control panels should have program version 1.21 or
higher, in order for the remote control to function correctly.
When the remote control unit is connected, the power source is in remote control
mode; the buttons and knobs are blocked. The functions can only be adjusted via the
remote control unit.
If the remote control unit is not to be used, the remote control unit must be
disconnected from the power source as otherwise it will remain in remote control
mode.
For more information about the operation of the remote control unit, see the relevant
operating instructions for the control panel.
7
MAINTENANCE
Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
7.1
Cleaning the air filter
S
Release the cover plate with the dust
filter (1).
S
Swing out the cover plate (2).
S
Remove the dust filter (3).
S
Blow it clean with compressed air at
reduced pressure.
S
Replace the filter with the finer mesh on
the side against the cover plate (2).
S
Replace the cover plate with the filter.
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8
FAULT TRACING
Try these recommended checks and inspections before sending for an authorised
service technician.
Type of fault
No arc.
Action
S
S
S
Welding current is interrupted
during welding.
S
S
Check that the mains power supply switch is turned on.
Check that the welding current supply and return cables are
correctly connected.
Check that the correct current value is set.
Check whether the thermal overload trips have operated
(indicated by the orange lamp on the front panel).
Check the main power supply fuses.
The thermal overload trips
operate frequently.
S
S
Check to see whether the air filters are clogged.
Make sure that you are not exceeding the rated data for the
power source (i.e. that the unit is not being overloaded).
Poor welding performance.
S
Check that the welding current supply and return cables are
correctly connected.
Check that the correct current value is set.
Check that the correct electrodes are being used.
Check the main power supply fuses.
S
S
S
9
ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Arc 4000i is designed and tested in accordance with the international an European
standards IEC/EN 60974--1 and EN 60974--10.
It is the obligation of the service unit which has carried out the service or repair work to
make sure that the product still conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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p
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Diagram
Arc 4000i
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Arc 4000i
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Arc 4000i
Ordering number
1.
Ordering no.
Denomination
0458 635 880 Welding power source
0458 635 881 Welding power source
Type
Origot Arc 4000i, A2
Aristot Arc 4000i, A4
0458 636 990 Spare part list
0458 817
0458 856
Instruction manual
Instruction manual
Control panel A2
Control panel A4
Instruction manuals and the spare parts list are available on the Internet at www.esab.com
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Edition 080105
Arc 4000i
Spare parts list
Item
Qty
Ordering no.
1
1
0458 397 001
Filter
2
1
0458 382 001
Front grill
bh27s
Denomination
-- 15 --
Edition 080105
Arc 4000i
Accessories
0458 525 880
Trolley
Remote control adapter RA12 12 pole . . . . . . 0459 491 910
For analogue remote controls to CAN based
equipment.
Remote control unit MTA1 CAN . . . . . . . . . . . . 0459 491 880
For setting of wire feed speed, current and arc
force.
Remote control unit AT1 CAN . . . . . . . . . . . . . . 0459 491 883
For setting of current.
Remote control unit AT1 CF CAN . . . . . . . . . . . 0459 491 884
For rough and fine setting of current.
Remote control cable 12 pole -- 4 pole
5m .......................................
10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.25m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0459 554 880
0459 554 881
0459 554 882
0459 554 883
0459 554 884
Return cable 5 m 70 mm2 . . . . . . . . . . . . . . . . . . 0700 006 895
ESAB 400 electrode holder with 6 m cable . . . 0349 501 060
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R0458 636/E080105/P20
p
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p
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ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 5308 9922
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 3 5296 7371
Fax: +81 3 5296 8080
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 8027 9869
Fax: +60 3 8027 4754
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
070514
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