ESAB | Mig U5000i | Instruction manual | ESAB Mig U5000i User manual

ESAB Mig U5000i User manual
Aristo®
Mig U5000i,
Mig U5000i WeldCloud™
460 V
Instruction manual
0459 087 687 US 20171107
Valid for: 608-, 613-xxx-xxxx
TABLE OF CONTENTS
SAFETY .......................................................................................................
5
1.1
Meaning of symbols ...............................................................................
5
1.2
Safety precautions .................................................................................
5
1.3
User responsibility .................................................................................
9
INTRODUCTION ..........................................................................................
12
2.1
Equipment ...............................................................................................
12
3
TECHNICAL DATA ......................................................................................
13
4
INSTALLATION............................................................................................
15
4.1
Lifting instructions .................................................................................
15
4.2
Placing.....................................................................................................
15
4.3
Primary input ..........................................................................................
15
4.4
Terminating resistor ...............................................................................
16
4.5
Connection of multiple wire feed units ................................................
16
OPERATION ................................................................................................
18
5.1
Connections and control devices .........................................................
19
5.2
Turning on the power source ................................................................
20
5.3
Fan control ..............................................................................................
20
5.4
Overheating protection ..........................................................................
20
5.5
Cooling unit.............................................................................................
20
5.6
Remote control unit................................................................................
21
5.7
WeldCloud™ unit....................................................................................
21
MAINTENANCE ...........................................................................................
22
6.1
Daily .........................................................................................................
22
6.2
If necessary.............................................................................................
22
6.3
Every year ...............................................................................................
23
7
TROUBLESHOOTING .................................................................................
24
8
ORDERING SPARE PARTS ........................................................................
25
1
2
5
6
DIAGRAM .............................................................................................................
26
ORDERING NUMBERS ........................................................................................
27
SPARE PARTS LIST.............................................................................................
28
ACCESSORIES ....................................................................................................
29
Rights reserved to alter specifications without notice.
0459 087 687
© ESAB AB 2017
1 SAFETY
1
SAFETY
1.1
Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer's safety practices and Safety
Data Sheets (SDSs).
1.2
Safety precautions
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in the Additional Safety Information section.
Before performing any installation or operating procedures, be sure to read and
follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe the Safety Precautions could
result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require
hearing protection. The arc, like the sun, emits ultraviolet (UV) and
other radiation and can injure the skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes and equipment is
essential to prevent accidents. Therefore:
1.
2.
3.
Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
Always wear safety glasses with side shields in any work area, even if welding
helmets, face shields and goggles are also required.
Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to look at the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
0459 087 687
-5-
© ESAB AB 2017
1 SAFETY
4.
5.
6.
7.
Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
high-topped shoes, and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.
Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of the
clothing.
Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly for long distances. Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS
The heat from flames and arcs can start fires. Hot slag or sparks can
also cause fires and explosions. Therefore:
1.
2.
3.
4.
5.
6.
7.
Protect yourself and others from flying sparks and hot metal.
Move all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.
Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.
Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.
Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
After completing work, inspect the work area to make sure there are no hot sparks or
hot metal that could cause a fire later. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact between live electrical parts and earth can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:
1.
2.
3.
4.
5.
6.
7.
Be sure the power source frame (chassis) is connected to the earth system of the
input power.
Connect the workpiece to a good electrical earth.
Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
Use well-maintained equipment. Replace worn or damaged cables.
Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
Make sure that all parts of your body are insulated from both the work piece and from
the ground.
Do not stand directly on metal or the ground while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
0459 087 687
-6-
© ESAB AB 2017
1 SAFETY
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power, before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a earth cable.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor
causes localised Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:
1.
2.
3.
Welders with pacemakers fitted should consult their doctor before welding. EMF may
interfere with some pacemakers.
Exposure to EMF may have other health effects which are unknown.
Welders should use the following procedures to minimise exposure to EMF:
a) Route the electrode and work cables together. Secure them with tape when
possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on
the same side of your body.
d) Connect the work cable to the workpiece as close as possible to the area being
welded.
e) Keep the welding power source and cables as far away from your body as
possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therefore:
1.
2.
3.
4.
5.
6.
Keep your head out of the fumes. Do not breathe the fumes and gases.
Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe in the fumes from these materials.
Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other
irritant gases.
If you develop momentary eye, nose or throat irritation while operating, this is an
indication that the ventilation is not adequate. Stop work and take the necessary steps
to improve ventilation in the work area. Do not continue to operate if physical
discomfort persists.
Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
WARNING: This product when used for welding or cutting, produces fumes or gases
that contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:
0459 087 687
-7-
© ESAB AB 2017
1 SAFETY
1.
2.
3.
4.
Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.
Always secure cylinders in an upright position, by chain or strap, to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause
injury. Therefore:
1.
2.
3.
4.
5.
6.
Keep all doors, panels, guards, and covers closed and securely in place.
Stop the engine or drive systems before installing or connecting a unit.
Have only qualified people remove covers for maintenance and troubleshooting as
necessary
To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
Keep hands, hair, loose clothing and tools away from moving parts.
Reinstall panels or covers and close doors when service is finished and before starting
engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or
any other accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend
beyond opposite side of unit.
• Keep cables and cords away from moving vehicles when working from
an aerial location.
0459 087 687
-8-
© ESAB AB 2017
1 SAFETY
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1.
2.
3.
4.
5.
6.
Always have qualified personnel perform the installation, troubleshooting
and maintenance work. Do not perform any electrical work unless you
are qualified to perform such work.
Before performing any maintenance work inside a power source,
disconnect the power source from the incoming electrical power.
Maintain cables, earthing wire, connections, power cord and power
supply in safe working order. Do not operate any equipment in faulty
condition.
Do not abuse any equipment or accessories. Keep equipment away from
heat sources such as furnaces, wet conditions such as water puddles, oil
or grease, corrosive atmospheres and inclement weather.
Keep all safety devices and cabinet covers in position and in good repair.
Use equipment only for its intended purpose. Do not modify it in any
manner.
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices
for Arc Welding, Cutting and Gouging.” Form 52-529.
The following publications are recommended to you:
1.
2.
3.
4.
5.
6.
7.
8.
9.
1
0.
1.3
ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding"
AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"
AWS SP - "Safe Practices" - Reprint, Welding Handbook
ANSI/AWS F4.1 - "Recommended Safe Practices for Welding and
Cutting of Containers That Have Held Hazardous Substances"
OSHA 29 CFR 1910 - "Safety and Health Standards"
CSA W117.2 - "Code for Safety in Welding and Cutting"
NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and
Other Hot Work"
CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”
ANSI Z87.1, "Occupational and Educational Personal Eye and Face
Protection Devices"
User responsibility
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
could result in injury to the operator and damage to the equipment.
0459 087 687
-9-
© ESAB AB 2017
1 SAFETY
1.
2.
3.
4.
5.
Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
The operator must ensure that:
○ no unauthorized person is 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
The workplace must:
○ be suitable for the purpose
○ be free from drafts
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
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
WARNING!
Arc welding and cutting may cause injury to yourself and others. Take
precautions when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves,
or wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Pose health risks
• Welders with pacemakers fitted should consult their doctor before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep the welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
0459 087 687
- 10 -
© ESAB AB 2017
1 SAFETY
FUMES AND GASES - Can be dangerous to your 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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use ear defenders or other hearing protection.
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause a fire. Make sure there are no inflammable
materials nearby.
• Do not use on closed containers.
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!
This product is solely intended for arc welding.
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.
0459 087 687
- 11 -
© ESAB AB 2017
2 INTRODUCTION
2
INTRODUCTION
The Mig U5000i is a GMAW/TIG welding power source, which can also be used for SMAW
(Shielded Metal Arc Welding).
There are four versions of the power source:
•
•
•
•
Mig U5000i without cooling unit
Mig U5000iw with cooling unit
Mig U5000i with WeldCloud™ unit
Mig U5000iw with cooling unit and WeldCloud™ unit
NOTE!
These instructions describe a Mig U5000iw with a cooling unit.
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.
The Mig U5000i WeldCloud™ power source is combined with U82 and 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 terminating resistor and instruction manual.
0459 087 687
- 12 -
© ESAB AB 2017
3 TECHNICAL DATA
3
TECHNICAL DATA
Mig U5000i
Mig U5000i WeldCloud™
Main voltage
460 V ±10%, 3~ 50/60 Hz
460 V ±10%, 3~ 50/60 Hz
Main supply
Sscmin 8.7 MVA Zmax 0.018 Ω Sscmin 8.7 MVA Zmax 0.018 Ω
Primary current
Imax GMAW (MIG/MAG)
33 A
33 A
Imax SMAW (MMA)
34 A
34 A
Imax GTAW (TIG)
26 A
26 A
No-load power demand in energy-saving mode, 6.5 min. after welding
GTAW/GMAW (TIG/MIG)
45 W
45 W
SMAW (MMA)
55 W
55 W
GMAW (MIG/MAG)
8 - 60 V / 16 - 500 A
8 - 60 V / 16 - 500 A
SMAW (MMA)
16 - 500 A
16 - 500 A
GTAW (TIG)
4 - 500 A
4 - 500 A
Voltage/current range
Permissible load at GMAW (MIG/MAG)
60% duty cycle
500 A/39 V
500 A/39 V
100% duty cycle
400 A/34 V
400 A/34 V
Permissible load SMAW (MMA)
60% duty cycle
500 A/40 V
500 A/40 V
100% duty cycle
400 A/36 V
400 A/36 V
Permissible load at GTAW (TIG)
60% duty cycle
500 A/30 V
500 A/30 V
100% duty cycle
400 A/26 V
400 A/26 V
Power factor at maximum current (I2)
SMAW (MMA)
0.91
0.91
GTAW (TIG)
0.90
0.90
GMAW (MIG/MAG)
0.90
0.90
Efficiency at maximum current (I2)
SMAW (MMA)
87%
87%
GTAW (TIG)
82%
82%
GMAW (MIG/MAG)
83%
83%
Open-circuit voltage U0 max
GMAW (MIG/MAG), GTAW
(TIG) without VRD function 1) 72 - 88 V
SMAW (MMA) without VRD
function 1)
72 - 88 V
68 - 80 V
68 - 80 V
U0L "Live TIG", VRD function 79 V
deactivated
0459 087 687
79 V
2)
- 13 -
© ESAB AB 2017
3 TECHNICAL DATA
Mig U5000i
Mig U5000i WeldCloud™
GMAW (MIG/MAG), SMAW
(MMA), VRD function
deactivated 2)
59 V
59 V
VRD function activated 2)
< 35 V
< 35 V
Operating temperature
14 to 104°F
(-10 to +40°C)
14 to 104°F
(-10 to +40°C)
Transportation temperature -4 to 131°F
(-20 to +55°C)
-4 to 131°F
(-20 to +55°C)
Dimensions l × w × h
without cooling unit
24.6 × 15.5 × 19.5 in.
(625 × 394 × 496 mm)
24.6 × 15.5 × 19.5 in.
(625 × 394 × 496 mm)
with cooling unit
24.6 × 15.5 × 30.6 in.
(625 × 394 × 776 mm)
24.6 × 15.5 × 30.6 in.
(625 × 394 × 776 mm)
Continual sound pressure
at no-load
<70 dB (A)
<70 dB (A)
Weight
without cooling unit
158.7 lb (72 kg)
183 lb (83 kg)
202.8 lb (92 kg)
227 lb (103 kg)
with cooling unit
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 manuals for the control panel, if the panel has that function.
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 104 °F (40 °C) 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.
Cooling unit
Cooling power
2.0 kW at 104°F (40°C) temp. difference and flow
0.26 gal/min
Coolant
ESAB's ready mixed coolant
Coolant quantity
1.5 gal
Maximum water flow
0.6 gal/min
Maximum number of water-cooled
Two GMAW welding torches or
welding torches that may be connected one GTAW torch and one GMAW welding torch
0459 087 687
- 14 -
© ESAB AB 2017
4 INSTALLATION
4
INSTALLATION
The installation must be carried out by a professional.
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit
power is greater than or equal to Sscmin at the interface point between the user's
supply and the public system. 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 is connected only to a supply with a short-circuit
power greater than or equal to Sscmin. Refer to the technical data in the
TECHNICAL DATA chapter.
4.1
Lifting instructions
Power source
4.2
Trolley and power source
Trolley 2 and power source
Placing
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
4.3
Primary input
WARNING!
ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD BE
TAKEN TO PROVIDE MAXIMUM PROTECTION AGAINST ELECTRIC SHOCK.
BE SURE THAT ALL POWER IS OFF BY OPENING THE LINE (WALL)
DISCONNECT SWITCH WHEN PRIMARY ELECTRICAL CONNECTIONS ARE
MADE TO THE POWER SOURCE. BE SURE TO CHECK YOUR INPUT LEADS
WITH A VOLTMETER TO MAKE SURE ALL POWER IS OFF.
0459 087 687
- 15 -
© ESAB AB 2017
4 INSTALLATION
Check that the unit is connected to the correct main supply voltage,
and that it is protected by the correct fuse sizes. A protective ground
connection must be made, in accordance with regulations.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable areas
Mig U5000i
460 V 3~ 60 Hz
Main voltage
460 V
Main cable area, CU/AWG (mm2)
10(6)
Phase current, I RMS
24 A
Fuse, Time Delay
25 A
NOTE!
Sizes per National Electric Code for 90°C rated copper conductors @ 30°C
ambient. Not more than three conductors in raceway or cable. Local codes
should be followed if they specify larger sizes other than those listed above.
4.4
Terminating resistor
In order to avoid communication interference, the ends of the
CAN bus must have 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 have a 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 (M0), you can manage up to 4 wire
feed units from one power source.
You can choose between the following connections:
•
•
•
•
1 GTAW (TIG) torch and 1 GMAW (MIG/MAG) gun (Universal power source required)
2 GMAW (MIG/MAG) guns
1 GTAW (TIG) torch and 3 GMAW (MIG/MAG) guns (Universal power source required)
4 GMAW (MIG/MAG) guns
When welding with water-cooled GMAW guns on all wire feed units, it is recommended to
connect a separate cooling unit for the two extra guns.
We recommend connecting the guns in parallel.
0459 087 687
- 16 -
© ESAB AB 2017
4 INSTALLATION
Two wire feed units
A connection kit is required when connecting two wire feed units, see "ACCESSORIES"
chapter.
A. Water connection
B. Welding current connection
C. Control box connection
Four wire feed units
Two connection kits and an extra cooling unit are required when connecting four wire feed
units, see "ACCESSORIES" chapter.
A. Water connection
B. Welding current connection
C. Control box connection
0459 087 687
- 17 -
© ESAB AB 2017
5 OPERATION
5
OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
0459 087 687
- 18 -
© ESAB AB 2017
5 OPERATION
5.1
Connections and control devices
1
Orange indicating lamp - Overheating
14* *Only on WeldCloud™ version: Red
indicating lamp - Wi-Fi Connectivity
2
White indicating lamp - Power supply ON 15 Fuse for supply voltage for feeder unit,
42 V
3
Main power supply switch, 0 / 1 / START 16* *Only on WeldCloud™ version:
Connection for Ethernet
4
Connection for start signal from the torch 17 Measure outlet screw terminal Red (+)
5
Connection for gas to the TIG torch
6
Connection (-) for return cable at SMAW 19 Connection for control cable to the wire
and GMAW or for welding current cable
feed unit or to the terminating resistor
at TIG (GTAW)
7
Connection for remote control
8
Connection (+) for welding current cable 21 Connection for gas hose
at SMAW (MMA) welding or for return
cable at TIG (GTAW) welding
9
Cooling water filler
18 Measure outlet screw terminal Black (-)
20 Connection for control cable to the wire
feed unit or for the terminating resistor
22 Connection (+) for welding current cable
to the wire feed unit
10 Connection with ELP1 for cooling water
to the TIG torch - BLUE
23 Connection (-) for the return cable wire
feeder unit
11 Connection for cooling water from the
TIG torch - RED
24 Connection for cooling water to the wire
feed unit - BLUE
12* *Only on WeldCloud™ version: Antenna 25 Connection for cooling water from the
wire feed unit - RED
13* *Only on WeldCloud™ version: USB
Connectivity
1)
ELP = ESAB Logic Pump, see "Cooling unit" section in this chapter.
0459 087 687
- 19 -
© ESAB AB 2017
5 OPERATION
5.2
Turning on the power source
Turn on the main power by turning switch (7) to the “START” position. Release the switch,
and it will return to the “1” position.
If the main power supply is interrupted while welding is in progress, and then is restored, the
power source will remain de-energized until the switch is again turned manually to the
“START” position.
Turn the unit off by turning the switch to the “0” position.
If the supply power fails or the power source is turned off in the normal manner, the welding
data will be stored so that it is available next time the unit is started.
5.3
Fan control
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 resumes.
The fans run at reduced speed for welding currents up to 180 A, and at full speed for higher
currents.
5.4
Overheating 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. They reset automatically when the temperature has fallen.
5.5
Cooling unit
To ensure problem-free operation, the installation height from the cooling unit to the welding
torch must be max. 7 m. Heights in excess of this can cause problems, such as long starting
times, air bubbles, vacuums, etc.
If an installation height in excess of 7 m is required, we recommend an installation kit
comprising a non-return valve and a solenoid valve, refer to accessories in the
"ACCESSORIES" chapter. Once these valves have been installed, the hose package must
be horizontal during the initial startup so that everything fills with water. Then raise the wire
feed unit and hose package to the high height. Continued safe operation at installation
heights of up to 12 m can now begin.
Water connection (GTAW)
The cooling unit is equipped with an ELP (ESAB Logic Pump) detection system, which
checks that the water hoses are connected.
The power source On/Off switch must be in the “0” position (Off) when connecting a
water-cooled GTA torch.
If a water-cooled GTA torch is connected, the water pump starts automatically when the main
On/Off switch is turned to “START” and/or when welding starts. After welding, the pump
continues to run for 6.5 minutes, and then switches to the energy-saving mode.
Function when welding
To start welding, the welder presses the welding torch trigger switch. The power source turns
on and starts the wire feed and the cooling water pump.
To stop welding, the welder releases the welding torch trigger switch. Welding ceases, but
the cooling water pump continues to run for 6.5 minutes, after which the unit switches to
energy-saving mode.
Water flow guard
The water flow guard interrupts the welding current in the event of loss of coolant, and
displays an error message on the control panel. The water flow guard is an accessory.
0459 087 687
- 20 -
© ESAB AB 2017
5 OPERATION
5.6
Remote control unit
When the remote control unit is connected, the power source and wire feed unit are in
remote control mode; the buttons and knobs are blocked. The functions can only be adjusted
via the remote unit.
If the remote control unit is not to be used, the remote control unit must be disconnected from
the power source/wire feed unit, as otherwise it will remain in remote control mode.
For more information about the operation of the remote control unit, see the operating
instructions for the control panel.
5.7
WeldCloud™ unit
The WeldCloud™ unit connects the welding power source with a local WeldCloud™ server
through Wi-Fi, Wired LAN or 3G. The WeldCloud™ unit is equipped with GPS to track the
location of the welding power source. It also has Bluetooth connectivity to enable connection
with 3rd party input devices, for example a Bluetooth enabled barcode/QR scanner.
The WeldCloud™ unit Wi-Fi is enabled at power up of the power source. It will start as a
hotspot that appears as an available Wi-Fi network. After establishing connection, it is
possible to access the web interface of the power source for a one-time set-up. After set-up
and restart, the power source will be visible in WeldCloud™. For more information about the
WeldCloud™ unit and features, see the WeldCloud™ instruction manual.
0459 087 687
- 21 -
© ESAB AB 2017
6 MAINTENANCE
6
MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
Only individuals with the appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1
Daily
Carry out the following maintenance every day.
•
•
Check that all cables and connections are fault-free. Tighten if necessary and replace
any defective parts.
Check the water level and water flow, top up with coolant if necessary.
6.2
•
•
If necessary
Regularly check that the power source is not clogged with dirt.
Clogged or blocked air inlets and outlets result in overheating.
Clean the dust filter.
• Remove the fan grille with the dust
filter (1).
• Swing out the grille (2).
• Release the dust filter (3).
• Blow the filter clean with compressed
air (reduced pressure).
• Reinstall the filter with the finer mesh
on the side against the grille (2) (out
from the power source).
• Reinstall the fan grille with the dust
filter.
• Top up with coolant
ESAB's ready mixed coolant is recommended for use. See
"ACCESSORIES" chapter.
• Top up with coolant until it covers half the inlet pipe.
NOTE!
Coolant must be topped up if connecting a welding torch or
connection cables that are 5 m in length or longer. When
adjusting the water level by topping up, the coolant hose
does not need to be disconnected.
CAUTION!
The coolant must be handled as chemical waste.
0459 087 687
- 22 -
© ESAB AB 2017
6 MAINTENANCE
6.3
Every year
Carry out the following maintenance at least once a year.
•
•
•
Clean off any dirt and dust. Blow the power source clean with dry compressed air
(reduced pressure).
Change the coolant and clean the hoses and water reservoir with clean water.
Check seals, cables and connections. Tighten if necessary and replace any defective
parts.
0459 087 687
- 23 -
© ESAB AB 2017
7 TROUBLESHOOTING
7
TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault
Action
No arc.
• Check that the main 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.
Welding current is interrupted during welding.
• 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. • 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.
0459 087 687
• 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.
- 24 -
© ESAB AB 2017
8 ORDERING SPARE PARTS
8
ORDERING SPARE PARTS
Mig U5000i, Mig U5000iw, Mig U5000i WeldCloud™ and Mig U5000iw WeldCloud™ are
designed and tested in accordance with the international and European standards IEC/EN
60974-1/-2/-3 and EN 60974-10.
It is the obligation of the service unit which carried out the service or repair work to make
sure that the product still conforms to these standards.
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.
0459 087 687
- 25 -
© ESAB AB 2017
DIAGRAM
DIAGRAM
0459 087 687
- 26 -
© ESAB AB 2017
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
Product
Notes
0459 230 885
Welding power source
Mig U5000i
0459 230 886
Welding power source
Mig U5000iw
With cooling unit
0445 400 885
Welding power source
Mig U5000i
WeldCloud™
With WeldCloud™ unit
0445 400 886
Welding power source
Mig U5000iw
WeldCloud™
With cooling unit and
WeldCloud™ unit
0459 839 020
Spare parts list
Mig 5000i, Mig
U5000i, Mig
5000i
WeldCloud™,
Mig U5000i
WeldCloud™
Technical documentation is available on the Internet at: www.esab.com
0459 087 687
- 27 -
© ESAB AB 2017
SPARE PARTS LIST
SPARE PARTS LIST
Item
Ordering no.
1
0458 398 001 Filter
2
0458 383 991 Front grill
0459 087 687
Denomination
- 28 -
© ESAB AB 2017
ACCESSORIES
ACCESSORIES
0458 530 880
Trolley
0458 603 880
Trolley 2 (for feeder with counterbalance
device and/or 2 gas bottles)
0458 731 880
0278 300 401
Guide pin
(B) Insulating bushing, included in guide pin
0459 145 880
Autotransformer TUA2
0459 087 687
- 29 -
© ESAB AB 2017
ACCESSORIES
0459 307 881
Handle (1 piece) with mounting screws
0459 491 910
Remote control adapter RA12 12 pole
For analogue remote controls to CAN based
equipment.
0459 491 880
Remote control unit MTA1 CAN
MIG/MAG: wire feed speed and voltage
MMA: current and arc force
TIG: current, pulse and background current
0459 491 882
Remote control unit M1 10Prog CAN
Choice of on of 10 programs
MIG/MAG: voltage deviation
TIG and MMA: current deviation
0459 491 883
Remote control unit AT1 CAN
MMA and TIG: current
0459 491 884
Remote control unit AT1 CF CAN
MMA and TIG: rough and fine setting of
current.
Remote control cable 12 pole - 4 pole
0459 554 880
5m
0459 554 881
10 m
0459 554 882
15 m
0459 554 883
25 m
0459 554 884
0.25 m
0459 087 687
- 30 -
© ESAB AB 2017
ACCESSORIES
Connection set 12 pole - 12 pole
0456 528 880
1.7 m
0456 528 890
5m
0456 528 881
10 m
0456 528 882
15 m
0456 528 883
25 m
0456 528 884
35 m
Connection set water 12 pole - 12 pole
0456 528 885
1.7 m
0456 528 895
5m
0456 528 886
10 m
0456 528 887
15 m
0456 528 888
25 m
0456 528 889
35 m
Connection set water
12 pole cable plug - 10 pole cable socket
0459 528 970
1.7 m
0459 528 971
5m
0459 528 972
10 m
0459 528 973
15 m
0459 528 974
25 m
0459 528 975
35 m
0700 006 897
Return cable 5 m 95 mm2
0456 855 880
Water flow guard 0.7 l/min
0461 203 880
Water return flow guard Mech 7 m
0459 087 687
- 31 -
© ESAB AB 2017
ACCESSORIES
0459 579 880
MMC kit for power source Mig
0459 546 880
Connection set for connection of two wire
feed units
0414 191 881
Cooling unit OCE2H
0465 720 002
ESAB ready mixed coolant (10 l / 2.64 gal)
Use of any other cooling liquid than the
prescribed one might damage the equipment.
In case of such damage, all warranty
undertakings from ESAB cease to apply.
0459 087 687
- 32 -
© ESAB AB 2017
ACCESSORIES
0459 087 687
- 33 -
© ESAB AB 2017
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.
Heist-op-den-Berg
Tel: +32 15 25 79 30
Fax: +32 15 25 79 44
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: +359 2 974 42 88
Fax: +359 2 974 42 88
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
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
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
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting
Products
Florence, SC
Tel: +1 843 669 4411
Fax: +1 843 664 5748
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
GERMANY
ESAB Welding & Cutting GmbH
Langenfeld
Tel: +49 2173 3945-0
Fax: +49 2173 3945-218
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
SWITZERLAND
ESAB Europe GmbH
Baar
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
www.esab.com
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 0220
Fax: +1 905 670 4879
SPAIN
ESAB Ibérica S.A.
San Fernando de Henares
(MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising