ESAB U5000i Aristo MIG 5000i U5000i TIG Stick Welder Instruction Manual

Aristo®
Mig U5000i
400 V
Instruction manual
0459 291 701 20220103
Valid for: serial no. 950-xxx-xxxx

EU DECLARATION OF CONFORMITY

According to:
The Low Voltage Directive 2014/35/EU; The EMC Directive 2014/30/EU;
The RoHS Directive 2011/65/EU; The Ecodesign Directive 2009/125/EC
Type of equipment
Arc welding power source
Type designation
Mig 50001/ 5000iw with serial number from 950 xxx xxxx (2009 w50)
Mig U5000i / U5000iw  with serial number from 950 xxx xxxx (2009 w50)
Brand name or trademark
ESAB
Manufacturer or his authorised representative established within the EEA
ESAB AB
Undholmsallen 9, Box 8004, SE-402 77 Gtiteborg, Sweden Phone: +46 31 50 90 00, www.esab.com
The following EN standards and regulations in force within the EEA has been used in the design: EN IEC 60974-1:2018/A1:2019 Arc welding equipment – Part 1: Welding power sources EN IEC 60974-2: 2019 Arc welding equipment – Part 2: Liquid cooling systems EN IEC 60974-3:2019 Arc welding equipment – Part 3: Arc striking and stabilizing devices EN 60974-10:2014/A1:2015, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) EU no. 2019/1784 Ecodesign requirements for welding equipment pursuant to Directive 2009/125/EC
Additional Information:
Restrictive use, Class A equipment, intended for use in locations other than residential. IEC EN draft standard 26/708/CDV have been used to establish EU no. 2019/1784 data. Mig 5000i(w) and U5000i(w) are part of the ESAB Aristo product family.
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised representative established within the EEA, that the equipment in question complies with the safety and environmental requirements stated above.

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
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

WARNING!
Arc welding and cutting can be injurious 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 – Can be dangerous to health

•  Welders having pacemakers should consult their physician 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 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.

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.

RC 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 earmuffs 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 fire. Make sure that there are no inflammable materials nearby.
•  Do not use on closed containers.

HOT SURFACE – Parts can burn

• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to prevent burns.

MALFUNCTION – Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!

CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
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.

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.

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.

INTRODUCTION

The Mig U5000i is a MIG/MAG and TIG welding power source, which can also be used for MMA welding.
The manual is valid for:

• Mig U5000iw with 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.
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, 5m return cable and instruction manual.

TECHNICAL DATA

| Mig U5000i
---|---
Mains voltage| 400 V ±10%, 3~ 50/60 Hz
Mains supply| Sscmin 8.7 MVA

Zmax 0.018 Ω

Primary current
Imax MIG/MAG (GMAW)| 33 A
Imax MMA (SMAW)| 34 A
Imax TIG (GTAW)| 26 A
No-load power demand when in energy-saving mode, 6.5 min. after welding
TIG/MIG (GTAW/GMAW)| 45 W
MMA (SMAW)| 55 W
Voltage/current range
MIG/MAG (GMAW)| 8 – 60 V / 16 – 500 A
MMA (SMAW)| 16 – 500 A
TIG (GTAW)| 4 – 500 A
Permissible load at MIG/MAG (GMAW)
60 % duty cycle| 500 A / 39 V
100 % duty cycle| 400 A / 34 V
Permissible load at MMA (SMAW)
60 % duty cycle| 500 A / 40 V
100 % duty cycle| 400 A / 36 V
Permissible load at TIG (GTAW)
60 % duty cycle| 500 A / 30 V
100 % duty cycle| 400 A / 26 V
Power factor at maximum current (I2)
MMA| 0.91
TIG| 0.90
MIG| 0.90
Efficiency at maximum current (I2)
MMA| 87 %
TIG| 82 %
MIG| 83 %
Open-circuit voltage U 0 max
MIG/MAG (GMAW), TIG (GTAW) without VRD function 1)| ** 72 – 88 V
MMA (SMAW) without VRD function 1)| 68 – 80 V
U0L “Live TIG (GTAW)”, VRD function deactivated 2)| 79 V
| Mig U5000i**
---|---
MIG/MAG (GMAW), MMA (SMAW), VRD

function deactivated 2)

| 59 V
VRD function activated 2)| < 35 V
Operating temperature| -10 to +40 °C
(14 to 104 °F)
Transportation temperature| -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 × 19.5 in.)
625 × 394 × 776 mm
(24.6 × 15.5 × 30.6 in.)
Continual sound pressure at no-load| <70 db (A)
Weight

without cooling unit
with cooling unit

| 71 kg (159 lb)
91 kg (200 lb)
Insulation class transformer| H
Enclosure class| IP23
Application class| S

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.

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

4.2 Placing
Position the welding power source such that its cooling air inlets and outlets are not obstructed.
4.3 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.

Recommended fuse sizes and minimum cable areas

Fuse
Anti-surge| 25 A
Type C MCB| 32 A

NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations. For other regions, supply cables must be suitable for the application and meet local and national regulations.
4.4 Terminating resistor
In order to avoid communication interference, the ends of the CAN bus must be fitted with 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 be fitted with the 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 it is possible to manage up to 4 wire feed units from one power source.
It is possible to choose between the following connections:

• 1 TIG torch and 1 MIG gun (Universal power source required)
• 2 MIG/MAG guns
• 1 TIG torch and 3 MIG guns (Universal power source required)
•  4 MIG guns

When welding with water-cooled MIG gund on all wire feed units, it is recommended to connect a separate cooling unit for the 2 extra guns.
We recommend connecting the guns in parallel.
Two wire feed units
A connection kit is required when connecting two wire feed units, see chapter “ACCESSORIES”.

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 chapter “ACCESSORIES”.

A. Water connection
B. Welding current connection
C. Control box connection

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!

5.1 Connections and control devices

1. Connection for cooling water from the TIG torch – RED
2. Connection with ELP* for cooling water to the TIG torch – BLUE
3.  Cooling water filler
4.  Connection for welding current cable (+) at MMA welding or for return cable at TIG welding
5.  Connection for the remote control
6.  Connection for return cable (-) or for welding current cable at TIG welding
7.  Connection for start signal from the torch
8. Connection for gas to the TIG torch
9. Mains power supply switch, 0 / 1 /START
10. White indicating lamp – Power supply ON
11.  Orange indicating lamp – Overheating
12. Connection for control cable to the wire feed unit or to the terminating resistor
13. Connection for gas hose
14. Connection for welding current to the wire feed unit
15.  Connection for cooling water to the wire feed unit – BLUE
16.  Connection for cooling water from the wire feed unit – RED
17. Fuse for supply voltage for feeder unit, 42 V

• ELP = ESAB Logic Pump, see section “Cooling unit” in this chapter.
  5.2 Turning on the power source
  Turn on the mains power by turning switch (7) 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.
  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 restarts.
  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 chapter “ACCESSORIES”. 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 commence.
  Water connection (TIG welding)
  The cooling unit is equipped with a detection system ELP (ESAB Logic Pump) 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 TIG torch.
  If a water-cooled TIG 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.
  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.

MAINTENANCE

NOTE!
Regular maintenance is important for safe and reliable operation.
Only those persons who have 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).
• Replace the filter with the finer mesh on the side against the grille (2) (out from the power source).
• Replace the fan grille with the dust filter.

• Top up with coolant ESAB’s ready mixed coolant is recommended for use. See chapter “ACCESSORIES”.
• 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.

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.

FAULT TRACING

Try these recommended checks and inspections before sending for an authorised service technician.

• 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.| • 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.

ORDERING SPARE PARTS

Mig U5000iw is 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 has carried out the service or repair work to make sure that the product still conforms to the mentioned 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 esab.com. 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.

DIAGRAM

Cooling unit

ORDERING NUMBERS

Technical documentation is available on the Internet at: www.esab.com

SPARE PARTS LIST

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 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
0459 554 881
0459 554 882
0459 554 883
0459 554 884| 5 m
10 m
15 m
25 m
0.25 m|

| Connection set 12 pole – 12 pole|
---|---|---
0456 528 880
0456 528 890
0456 528 881
0456 528 882
0456 528 883
0456 528 884| 1.7 m 5 m 10 m 15 m 25 m 35 m|

| Connection set water 12 pole – 12 pole
0456 528 885
0456 528 895
0456 528 886
0456 528 887
0456 528 888
0456 528 889| 1.7 m 5 m 10 m 15 m 25 m 35 m
| Connection set water 12 pole cable plug – 10 pole cable socket|
0459 528 970
0459 528 971
0459 528 972
0459 528 973
0459 528 974
0459 528 975| 1.7 m
5 m
10 m
15 m
25 m
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 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.|

A WORLD OF PRODUCTS AND SOLUTIONS.

For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

http://manuals.esab.com

Documents / Resources

| ESAB U5000i Aristo MIG 5000i U5000i TIG Stick Welder [pdf] Instruction Manual
U5000i Aristo MIG 5000i U5000i TIG Stick Welder, U5000i, Aristo MIG 5000i U5000i TIG Stick Welder, 5000i U5000i TIG Stick Welder, U5000i TIG Stick Welder, TIG Stick Welder, Stick Welder
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References

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