0458 856 087 060523
Valid from program version 1.30
A4
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices
for arc welding equipment, we urge you to read our booklet, “Precations and Safe Practices for Arc, Cutting and Gouging, “Form
52--529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your
supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
CAUTION
Be sure this information reaches the operator .
You can get extra copies through your supplier.
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Instruction manual
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Rights reserved to alter specifications without notice.
1 INTRODUCTION 3...................................................
1.1 The control panel 3..........................................................
1.2 Remote control unit 3........................................................
2 MENUS 4...........................................................
2.1 Main and measurement menus 4..............................................
2.2 Settings menu 4............................................................
3SMAWELDING 4....................................................
3.1 Settings 4..................................................................
3.2 Symbols in the display 5.....................................................
3.3 Settings example 6..........................................................
4 ARC--AIR GOUGING 8................................................
4.1 Settings 8..................................................................
4.2 Symbol in the display 8......................................................
4.3 Settings example 8..........................................................
5 FAULT CODES 9.....................................................
5.1 List of fault codes 9..........................................................
5.2 Fault code descriptions 10.....................................................
6 ORDERING SPARE PARTS 13.........................................
SCHEMATIC DIAGRAM 14................................................
ORDERING NUMBER 15.................................................
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1 INTRODUCTION
This manual describes use of the A4 control panel, which is installed in the Arc 4000i &
Arc 5000i power unit.
For general information on operation, see the power source operating instructions.
1.1 The control panel
1 Display
2 Knob for setting the current.
3 Increase (+) or Decrease (--) selected by the
function pushbuttons. →.
4 First, second and third function pushbuttons
1.2 Remote control unit
Using a remote control unit, the primary parameters of the welding process can be
controlled from a device other than the control panel.
Machines with intergral control panels should have program version 1.21 or higher, in
order for the remote control to function correctly.
Control panel’s behaviour on connection of the remote control unit
S The display freezes in the menu showing when the remote control is connected.
Measurement and setting values are updated, but only shown in those menus in
which the values can be displayed.
S If a fault code symbol is displayed, it cannot be removed until the remote control unit
has been disconnected.
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2 MENUS
The control panel uses several different menus. T hey are the main, m easurement and
settings menus.
2.1 Main and measurement menus
The main menu is always displayed immediately after the
machine is started. The menu shows the values which have
been set. If the main menu is displayed when welding begins, it
switches over automatically to show the m easured values
(measurement menu). The measured values will be displayed
even after welding has been completed.
The settings menu can be accessed without losing the measured values. It is only when
the knob is turned that the setting values are displayed instead of the m easured values.
2.2 Settings menu
Different values can be entered in the settings menu.
To access the settings menu, press , , or
.
When the power source is switched off and restarted, the last values to be set are
recalled.
3SMAWELDING
3.1 Settings
Settings Setting range In steps of: Default value
Process SMA or Arc--air gouging -- SMA
Electrode Rutile, Cellulose, Basic 3 Rutile**
“Hot start”* ON or OFF -- OFF
Hot start time 1--30 1 10
Arc force 0--99 0,5 30**
Current
Arc 4000i
Arc 5000i
16 -- 400 A
16 -- 500 A
1A
1A
164 A
164 A
*) This function cannot be changed while welding is in progress.
**) When selecting electrode type, the start value is always 30 for arc force.
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Hot start
Hot start increases the weld current for an adjustable time at the start of welding, thus
reducing the risk of poor fusion at the beginning of the joint.
Arc force
The arc force is important in determining how the current changes in response to a
change in the arc length. A lower value gives a calmer arc with less spatter.
Current
A higher current produces a wider weld pool, with better penetration into the workpiece.
Irrespective of which menu is displayed, the setting value for the current can b e
changed. T he value is only displayed in the main menu.
3.2 Symbols in the display
Function symbols
SMA welding Arc force
Hot start Rutile electrode
Cellulose electrode Basic electrode
Explanation of symbols
Active symbol (dark background). Active m eans that the function which the
symbol represents can be activated. New values can only be set when the symbol is
active.
Inactive symbol (light background). Inactive means that settings for the
function which the symbol represents cannot be changed. From the settings menu,
pressing an inactive symbol will return the machine to the main menu.
A dot in the upper right--hand corner indicates that “Hot start” is ON.
Value symbols
The value symbols are displayed in the settings menu for each function.
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No arc force High arc force
Short hot start time Long hot start time
3.3 Settings example
Settings Value
Process SMA
Electrode Basic
“Hot start” ON
Hot start time 5
Arc force 50
Current 120 Amp
Process = SMA
S Select the process by pressing the first function pushbutton until is shown in
the display.
Electrode = Basic
S Select the type of electrode by pressing the first function pushbutton until is
shown in the display.
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Hot start time = 5
S Press to turn hot starting ON.
S Press until 5,0 is shown in the display.
Arc force = 50
S Press until is shown in the display.
S Press until 5,0 is shown in the display.
Current = 120 Ampere
S Turn the knob for setting the current until the display shows 120 Amp.
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4 ARC--AIR GOUGING
Arc--air gouging involves the use of a special electrode consisting of a carbon bar with a
copper case. An arc is formed between the carbon bar and the workpiece, air is
supplied to blow away the melted material, and a seam is formed.
4.1 Settings
Settings Setting range In steps of Default setting
Process SMA or Arc--air gouging -- SMA
Voltage 8--60 V 0.25 V (displayed with
one decimal.)
37.0 V
Voltage
Higher voltage produces wider and deeper penetration into the workpiece.
4.2 Symbol in the display
Function symbol
Arc--air gouging
4.3 Settings example
Setting Value
Process Arc--air gouging
Voltage 45 V
Process = Arc--air gouging
S Select the process by pressing the first function pushbutton until is shown in
the display.
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Voltage = 45 V
S Turn the knob for setting the voltage until the display shows 45 V.
5 FAULT CODES
Fault codes are used to indicate that a fault has occurred in the equipment. They are
shown in the display in the form of a symbol as follows:
Fault codes are updated every three seconds. The upper numeral in the
symbol is the number of the particular fault code: see Item NO TAG. T he
lower figure indicates where the fault is:
0 = the control panel
2 = the power unit
4 = the remote control
The above symbol shows that the control panel (0) has lost contact with the power unit.
If sever a l faults have been detected, only the code for the last fault to occur will be
displayed.
Press any of the function keys in order to clear the symbol from the display.
Symbols may be steady or flashing, depending on the type of fault.
Flashing symbols are highlighted with “ o” in the list of fault codes.
5.1 List of fault codes
Fault
code
Description Control
panel
Power unit Remote
control
1 EPROM x x x
2 RAM x x
3 External Read/Write RAM x
4 5V power supply x
5 High intermediate voltage power supply x
6 High temperature x
8 Power supply 1* x x x
9 Power supply 2* x x
10 Power supply 3* x
12 Communication error (warning) x x x
14 Communication error (bus off) x
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Fault
code
Remote
control
Power unitControl
panel
Description
15 Messages lost x x x
16 High open--circuit voltage x
18 Lost contact with the power unit x
19 Incorrect settings values in external RAM x
20 Memory allocation error x
22 Transmitter buffer overflow x
23 Receiver buffer overflow x
26 Watchdog x
28 St ack overflow x x
29 No cooling water flow x
31 No reply from the display unit x
32 No gas flow x
Unit Power supply 1* Power supply 2* Power supply 3*
Control panel +3V
Power unit +15V --15V +24V
Remote control +13V +10V
5.2 Fault code descriptions
Fault
code1
Description
1 Program memory error (EPROM)
The program memory has “lost” a value, i.e. the value in some particular memory location dif-
fers from the original value.
This fault does not disable any functions.
Action: Restart the machine. If the fault persists, send for a service technician.
2 Microprocessor RAM error
The microprocessor is unable to read/write from/to a certain memory position in its internal
memory.
This fault does not disable any functions.
Action: Restart the machine. If the fault persists, send for a service technician.
3 External RAM error
The microprocessor is unable to read/write from/to a certain memory position in its external
memory.
This fault does not disable any functions.
Action: Restart the machine. If the fault persists, send for a service technician.
4 5 V power supply low
The power supply voltage is too low.
The microprocessor stops all normal activities while waiting to be turned off.
Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a ser-
vice technician.
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Fault
code1
Description
5 Intermediate DC voltage outside limits
The voltage is too low or too high. Too high a voltage can be due to severe transients on the
mains power supply or to a weak power supply (high inductance of the supply).
The power unit turns off automatically.
Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a ser-
vice technician.
6 High temperature
The thermal overload cutout has operated.
The power unit turns off automatically, and cannot be restarted until the cutout has reset.
Action: Check that the cooling air inlets or outlets are not blocked or clogged with dirt. Check
the duty cycle being used, to make sure that the equipment is not being overloaded.
8 Low battery voltage +3V, (control panel)
The voltage of the memory retention battery in the control panel is too low .
This fault does not disable any functions.
Action: Send for a service technician.
8 +15V power supply, (wire feed unit and power unit)
The voltage is too high or too low.
Action: Send for a service technician.
9 --15V power supply, (power unit)
The voltage is too high or too low.
Action: Send for a service technician.
10 +24V power supply, (power unit)
The voltage is too high or too low.
Action: Send for a service technician.
12 Communication error (warning)
The CAN circuit’s error counter has too high a value, and contact with the control panel may
be lost. This can occur if the load is temporarily too high.
Action: Check the equipment to ensure that only one remote control unit with an adapter is
connected. If the fault persists, send for a service technician.
14 Communication error
The CAN circuit’s error counter has too high a value, and welding is stopped.
This can occur if the load is temporarily too high.
Action: Review the handling of welding settings data during welding. Turn off the mains
power supply to reset the unit. If the fault persists, send for a service technician.
15 Messages lost
A message has overwritten another message. This error can be caused by frequent pushing
of the panel pushbuttons while welding is in progress.
The welding process stops.
Action: Review the handling of welding programs during welding. Turn off the mains power
supply to reset the unit. If the fault persists, send for a service technician.
16 High open --circuit voltage
The open--circuit voltage has been too high.
Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a ser-
vice technician.
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Fault
code1
Description
18 Lost contact
The control panel has lost contact with the power unit.
The current activity stops.
Action: Check the cables. If the fault persists, send for a service technician.
19 Incorrect settings values in external RAM
This fault will be detected if the information in the battery--backed memory has become corrup-
ted.
Action: The fault will correct itself, but the data stored in the current memory position will be
lost.
20 Memory allocation error
The microprocessor is unable to reserve sufficient memory space.
This fault will generate fault code 26.
Action: Send for a service technician.
22 Transmitter buffer overflow
The transmitter buffer has become overfilled.
The current activity stops.
Action: Review the handling of welding programs during welding.
23 Receiver buffer overflow
CAN messages are being received at a higher rate than the welding data board can handle.
The current activity stops.
Action: Review the handling of welding programs during welding.
26 Watchdog
Something has prevented the processor from performing its normal duties.
This fault does not disable any functions.
Action: Review the handling of welding programs during welding.
28 Stack overflow
The internal memory has become overfilled.
This fault can be caused by abnormal processor loading.
Action: Review the handling of settings data during welding.
29 No cooling water flow
The flow monitor switch has operated.
The current activity stops.
Action: Check the cooling water circuit and the pump.
31 No reply from the display unit
The microprocessor is not receiving replies from the display board.
Action: Send for a service technician.
32 No gas flow
Gasflowislessthan6l/min.
Action: Check the gas valve, hoses and connectors.
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6 ORDERING SPARE PARTS
Note!
Supplier warranty is void if customer attempts any work on product during the warranty
period.
When ordering replacement parts, order by part number and part name, as illustrated
on the figure. Always provide the series or serial number on the unit on which the parts
will b e used. The serial number is stamped on the rating plate.
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Schematic diagram
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A4
Edition 060523
Ordering number
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Ordering no. Denomination
0458 535 888 Aristot A4
0458 856 170 Instruction manual SE
0458 856171 Instruction manual DK
0458 856 172 Instruction manual NO
0458 856173 Instruction manual FI
0458 856 174 Instruction manual GB
0458 856 175 Instruction manual DE
0458 856 176 Instruction manual FR
0458 856 177 Instruction manual NL
0458 856 178 Instruction manual ES
0458 856 179 Instruction manual IT
0458 856 180 Instruction manual PT
0458 856 181 Instruction manual GR
0458 856 182 Instruction manual PL
0458 856 183 Instruction manual HU
0458 856 184 Instruction manual CZ
0458 856 127 Instruction manual RU, GB
0458 856 187 Aristot A4, US
0458 856 990 Spare parts list
The instruction manuals and the spare parts list are available on the Internet at www.esab.com
Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page where you can
both search for and download instructions and spare parts lists.
ESAB Welding & Cutting Products, Florence, SC We lding Equipment
COMMUNICATION GUIDE -- CUSTOMER SERVICES
A CUSTOMER SERVICE QUESTIONS:
Telephone: (800) 362--7080 / Fax: (800) 634-- 7548 Hours: 8.00 AM to 7:00 P M EST
Order E ntry P roduct Availability Pricing Order Information Returns
B ENGINEERING SERVICE:
Telephone: (834) 664--4416 / Fax: (800) 446-- 5693 Hours: 7.30 AM to 5:00 P M EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C TECHNICAL SERVICE:
Telephone: (800) ESAB-- 123 / Fax: (843) 664--4452 Hours: 8.00 AM to 5:00 P M EST
Part Numbers Technical Applications Specifications Equipment Recommendations
D LITERATURE REQUESTS:
Telephone: (843) 664--5562 / Fax: (843) 664-- 5548 Hours: 7.30 AM to 4:00 P M EST
E W ELDING EQUIPMENT REPAIRS:
Telephone: (843) 664--4487 / Fax: (843) 664-- 5557 Hours: 7.30 AM to 3:30 P M EST
Repair Estim ates Repair Status
F WELDING EQUIPMENT TRAINING:
Telephone: (843) 664--4428 / Fax: (843) 679-- 5864 Hours: 7.30 AM to 4:00 P M EST
Training S chool Information and Registrations
G WELDING PROCESS ASSISTANCE:
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H TECHNICAL ASST. CONSUMABLES:
Telephone: (800) 933--7070 Hours: 7.30 AM to 5:00 P M EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB--123
Fax: (843) 664--4452
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers:
Comprehensive Product Information
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PO BOX 100545, Florence SC 29501--0545
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