42
50
60
Hz
750
IPM
19.0
MPM
Feed 4004 HD Wire Feeder
Instruction Manual
Revision: AA Issue Date: November, 2015 Manual No.: 0558012674
Operating Features:
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to
provide you with the best service and reliability in the industry. This product is backed by our extensive
warranty and world-wide service network. To locate your nearest distributor or accredited service provider
see back page.
This manual has been designed to instruct you on the correct use and operation of your ESAB product. Your
satisfaction with this product and its safe operation is our ultimate concern. Therefore, please take the time
to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards
that may exist when working with this product.
We have made every eort to provide you with accurate instructions, drawings, and photographs of the
product(s) while writing this manual. However, errors do occur and we apologize if there are any contained
in this manual.
Due to our constant eort to bring you the best products, we may make an improvement that does not
get reected in the manual. If you are ever in doubt about what you see or read in this manual with the
product you received, then check for a newer version of the manual on our website or contact our customer
support for assistance.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is the Market Leading Brand of Arc Welding Products. We are a mainline supplier to major welding
industry sectors in the Asia Pacic and emerging global markets including; Manufacturing, Construction,
Mining, Automotive, Engineering, Rural and DIY.
We distinguish ourselves from our competition through market-leading, dependable products that have
stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery,
superior customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced products to achieve a safer working
environment for industry operators.
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement, the
Manufacturer assumes no liability for its use.
Operating Manual Number 0558012674 for:
Feed 4004 HD Wire Feeder Part Numbers: 0558102233/0558102234
Published by:
ESAB Welding & Cutting Equipment
P.O. Box 100545
411 South Ebenezer Rd.
Florence, SC 29501-0545
Phone: (843)-669-4411
Fax: (843)-664-4258
www.ESABNA.com
Copyright 2015 by
ESAB Welding & Cutting Equipment
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by
any error or omission in this manual, whether such error results from negligence, accident, or any other cause.
Publication Date: November, 2015
Revision Date:
Record the following information for warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, 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.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION .............................................................. 7
1.01 Arc Welding Hazards ............................................................................7
1.02 Principal Safety Standards......................................................................10
1.03 Symbol Chart ..................................................................................11
SECTION 2: INTRODUCTION...................................................................... 13
2.01 How to Use This Manual........................................................................13
2.02 Equipment Identication.......................................................................13
2.03 Receipt of Equipment ..........................................................................13
2.04 Description ....................................................................................14
2.05 User Responsibility.............................................................................14
2.06 Transportation Methods .......................................................................14
2.07 Packaged Items................................................................................15
2.08 Specications..................................................................................15
2.09 Optional Accessories...........................................................................16
SECTION 3: INSTALLATION, OPERATION and SETUP ............................................... 19
3.01 Environment...................................................................................19
3.02 Location.......................................................................................19
3.03 Ventilation.....................................................................................19
3.04 Mains Supply Voltage Requirements............................................................19
3.05 Electromagnetic Compatibility .................................................................19
3.06 Front Panel Controls, Displays and Features .................................................... 22
3.07 Rear Panel Controls and Features ...............................................................24
3.08 Attaching the Tweco No. 4 MIG Torch.......................................................... 26
3.09 Installing Handle Assembly (Optional) ..........................................................27
3.10 Installing Lifting Eye Kit (Optional)............................................................. 28
3.11 Installing Tweco No. 5 Adaptor (Optional)...................................................... 30
3.12 Installing Wire Spool Cover (optional).......................................................... 39
3.13 Installing Welding Wire Spool ..................................................................42
3.14 Wire Reel Brake ............................................................................... 43
3.15 Inserting Wire into Feed Mechanism ..........................................................44
3.16 Feed Roll Pressure Adjustment ................................................................ 45
3.17 Installing and Changing the Feed Roll / Removing Inlet Guide & Adaptor........................ 45
SECTION 4: SERVICE ............................................................................. 47
4.01 Cleaning The Unit..............................................................................47
4.02 Cleaning The Feed Rolls........................................................................47
4.03 System Maintenance...........................................................................47
4.04 Troubleshooting Guide.........................................................................47
4.05 MIG (GMAW/FCAW) Basic Welding Technique ...................................................47
4.06 MIG (GMAW/FCAW) Welding Troubleshooting ..................................................53
4.07 Troubleshooting .............................................................................. 56
SECTION 5: PARTS LIST .......................................................................... 59
5.01 Equipment Identication.......................................................................59
5.02 How To Use This Parts List ......................................................................59
5.03 Replacement Parts (without wirefeed plate) ................................................... 60
5.04 Replacement Parts- Wirefeed Plate ............................................................ 61
Appendix 1: CONNECTION DIAGRAM ............................................................. 62
This page intentionally blank
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ
OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in Welding and Allied Processes Part 2: Electrical. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE,
AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is
on. The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire,
wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded
equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power
disconnect switch open, or remove line fuses so power
cannot be turned on accidentally.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6. Turn o all equipment when not in use. Disconnect
power to equipment if it will be left unattended or out
of service.
7. Use fully insulated electrode holders. Never dip holder
in water to cool it or lay it down on the ground or the
work surface. Do not touch holders connected to two
welding machines at the same time or touch other
people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth)
ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or replace
damaged parts at once.
13. In conned spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working
above oor level.
15. Keep all panels and covers securely in place.
7
SECTION 1: GENERAL INFORMATION
WARNING
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce
intense heat and strong ultraviolet rays that
can burn eyes and skin. Noise from some
processes can damage hearing.
1. Use a Welding Helmet or Welding Faceshield tted
with a proper shade of lter (see ANSI Z49.1 and AS
1674 listed in Safety Standards) to protect your face
and eyes when welding or watching.
Recommended Protective Filters for Electric Welding
Description of Process
Manual Metal Arc Welding - covered
electrodes (MMAW)
Gas Metal Arc Welding (GMAW) (MIG)
other than Aluminium and Stainless
Steel
Gas Metal Arc Welding (GMAW) (MIG)
Aluminium and Stainless Steel
Gas Tungsten Arc Welding (GTAW) ( TIG)
Flux-cored Arc Welding (FCAW) -with
or without shielding gas.
Air - Arc Gouging Less than or equal to 400 12
Plasma - Arc Cutting
Plasma - Arc Spraying — 15
Plasma - Arc Welding
Submerged - Arc Welding — 2(5)
Resistance Welding — Safety Spectacles or eye shield
Approximate Range of
Welding Current in Amps
Less than or equal to 100 8
Less than or equal to 150 10
Less than or equal to 250 12
Less than or equal to 100 10
Less than or equal to 300 11
Less than or equal to 20 8
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others
from ash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, ame-resistant material (wool and leather) and foot protection.
5. Use approved ear plugs or ear mus if noise level is
high.
6. Never wear contact lenses while welding.
Minimum Shade Number of
Filter(s)
100 to 200 10
200 to 300 11
300 to 400 12
Greater than 400 13
150 to 250 11
250 to 300 12
300 to 400 13
Greater than 400 14
250 to 350 13
100 to 200 11
200 to 250 12
250 to 350 13
Greater than 350 14
300 to 400 12
400 to 500 13
Greater than 500 14
50 to 100 10
100 to 400 12
400 to 800 14
20 to 100 10
100 to 400 12
400 to 800 14
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.
Table 1-1 Protective Filters
8
SECTION 1: GENERAL INFORMATION
WARNING
FUMES AND GASES can be hazardous to
your health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes. Do not breathe the
fumes.
2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
5. Work in a conned space only if it is well ventilated,
or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing injury
or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can
react with vapours to form highly toxic and irritating
gases.
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing
these elements can give o toxic fumes if welded.
WARNING
WELDING can cause re or explosion.
Sparks and spatter y o from the welding arc.
The ying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause res
and burns. Accidental contact of electrode or
welding wire to metal objects can cause sparks,
overheating, or re.
1. Protect yourself and others from ying sparks and hot
metal.
2. Do not weld where ying sparks can strike ammable
material.
3. Remove all ammables within 10M of the welding
arc. If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and openings to adjacent areas.
5. Watch for re, and keep a re extinguisher nearby.
6. Be aware that welding on a ceiling, oor, bulkhead, or
partition can cause re on the hidden side.
7. Do not weld on closed containers such as tanks or
drums.
8. Connect work cable to the work as close to the welding area as practical to prevent welding current from
travelling long, possibly unknown paths and causing
electric shock and re hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut o welding
wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause ying metal. As
welds cool, they can throw o slag.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and ttings designed for the specic
application; maintain them and associated parts in
good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA publication
P-1 listed in Safety Standards.
9
SECTION 1: GENERAL INFORMATION
!
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
ngers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualied people remove guards or covers
for maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from
moving parts.
6. Reinstall panels or guards and close doors when servicing is nished and before starting engine.
WARNING
This product, when used for welding or cutting,
produces fumes or gases which contain chemicals know to the State of California to cause birth
defects and, in some cases, cancer. (California
Health & Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The
Eects of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Con-
clusions Section of the U.S. Congress, Oce of Technology
Assessment, Biological Eects of Power
Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing
Oce, May 1989): “...there is now a very large volume of
scientic ndings based on experiments at the cellular
level and from studies with animals and people which
clearly establish that low frequency magnetic elds and
interact with, and produce changes in, biological systems.
While most of this work is of very high quality, the results
are complex. Current scientic understanding does not
yet allow us to interpret the evidence in a single coherent
framework. Even more frustrating, it does not yet allow us
to draw denite conclusions about questions of possible
risk or to oer clear science-based advice on strategies to
minimize or avoid potential risks.”
To reduce magnetic elds in the workplace, use the
following procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away
from body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910,
from Superintendent of Documents, U.S. Government
Printing Oce, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation
for Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders,
CGA Pamphlet P-1, from Compressed Gas Association,
1235 Jeerson Davis Highway, Suite 501, Arlington, VA
22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye
and Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.
Cutting and Welding Processes, NFPA Standard 51B,
from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Safety in Welding and Allied Processes Part 1: Fire
Precautions, AS 1674.1-1997 from SAI Global Limited,
www.saiglobal.com.
Safety in Welding and Allied Processes Part 2:
Electrical, AS 1674.2-2007 from SAI Global Limited, www.
saiglobal.com.
Filters for Eye Protectors - Filters for protection
against radiation generated in welding and allied operations AS/NZS 1338.1:1992 from SAI Global Limited, www.
saiglobal.com. 1
10
SECTION 1: GENERAL INFORMATION
1.03 Symbol Chart
Note that only some of these symbols will appear on your model.
On
O
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
X
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectier
Remote
Duty Cycle
Slow Run-In
Panel/Local
Manual Metal
Arc Welding (MMAW)
Gas Metal Arc
Welding (GMAW)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage O.
Welding Torch
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
t2
Preow Time
Postow Time
t1
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preow, release
to start arc. Press to stop arc, and
hold for preow.
Burnback Time
t
Gas Inlet
IPM
MPM
Inches Per Minute
Metres Per Minute
Solid Wire
115V 15A
Receptacle RatingAuxiliary Power
Voltage Input
V
Figure 1-1 Symbol Chart
Cored Wire
11
SECTION 1: GENERAL INFORMATION
This page intentionally blank
12
SECTION 2: INTRODUCTION
!
2.01 How to Use This Manual
To ensure safe operation, read the entire manual, including the chapter on safety instructions
and warnings. Throughout this manual, the
word WARNING, CAUTION and NOTE may appear. Pay particular attention to the information
provided under these headings. These special
annotations are easily recognized as follows:
WARNING
Gives information regarding possible personal injury. Warnings will be enclosed in a box such as this.
CAUTION
Refers to possible equipment
damage. Cautions will be shown in
bold type.
NOTE
Oers helpful information concerning
certain operating procedures. Notes
will be shown in italics.
Additional copies of this manual may
be purchased by contacting ESAB
at the address and phone number
for your location listed in the inside
back cover of this manual. Include the
Owner’s Manual number and equip-
ment identication numbers.
2.02 Equipment Identication
The unit’s identication number (specication or
part number), model, and serial number usually
appear on a nameplate attached to the machine. Equipment which does not have a nameplate attached to the machine is identied only
by the specication or part number printed on
the shipping container. Record these numbers
for future reference.
2.03 Receipt of Equipment
When you receive the equipment, check it
against the invoice to make sure it is complete
and inspect the equipment for possible damage due to shipping. If there is any damage,
notify the carrier immediately to le a claim.
Furnish complete information concerning damage claims or shipping errors to the location in
your area listed in the inside back cover of this
manual.
Include all equipment identication numbers as
described above along with a full description of
the parts in error.
Move the equipment to the installation site
before un-crating the unit. Use care to avoid
damaging the equipment when using bars,
hammers, etc., to un-crate the unit.
SECTION 2: INTRODUCTION
!
2.04 Description
The Feed 4004 HD Wire Feeder oers both
load and line voltage compensation helping to
maintain a constant wire feed speed, even with
changes in the input voltage and/or load.
The Feed 4004 HD Wire Feeder’s sheet metal box
totally encloses the solid state control circuitry.
A hinged, latched feedhead cover allows quick
and easy access to the feedhead featuring
quick change feed rolls, and tool-less knobs and
clamps for changeover of guides and guns.
The Feed 4004 HD Wire Feeder comes with an
abundance of standard features including:
• ControlPaneloptionsforU6orU82
• anon/orockerswitch
• awirefeedspeedcontrol
• apowersourcevoltagecontrol
• twoquickchange,gear-drivenfeedrolls
• agasvalvesolenoid
• anisolatedguntriggerforoperatorsafety
• avarietyofadd-onoptionstocongurethe
unit for any wire-welding situation.
2.05 User Responsibility
This equipment will perform as per the information contained herein when installed, operated,
maintained and repaired in accordance with the
instructions provided. This equipment must be
checked periodically. Defective equipment (including welding leads) should not be used. Parts
that are broken, missing, plainly worn, distorted
or contaminated, should be replaced immediately. Should such repairs or replacements become
necessary, it is recommended that such repairs
be carried out by appropriately qualied persons
approved by ESAB. Advice in this regard can
be obtained by contacting an Accredited ESAB
Distributor.
This equipment or any of its parts should not
be altered from standard specication without
prior written approval of ESAB. The user of this
equipment shall have the sole responsibility for
any malfunction which results from improper
use or unauthorized modication from standard
specication, faulty maintenance, damage or
improper repair by anyone other than appropriately qualied persons approved by ESAB.
The Feed 4004 HD Wire Feeder has been
designed to comply with CSA NRTL/C, NEMA
EW 3, IEC 60974-1, IEC 60974-5 and IEC 6097410 standards.
The instructions in the next section detail how to
correctly and safely set up the machine and give
guidelines on gaining the best eciency and
quality from the Power Source. Please read these
instructions thoroughly before using the unit.
2.06 Transportation Methods
!
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts.
Disconnect wire feeder from Power Source before moving
the wire feeder.
WARNING
FALLING EQUIPMENT can cause serious personal injury and
equipment damage.
Lift unit with optional handle at the top of the
unit. Use handcart or similar device of adequate
capacity. If using a fork lift vehicle, place and
secure unit on a proper skid before transporting.
14
SECTION 2: INTRODUCTION
2.07 Packaged Items
Feed 4004 HD Wire Feeder (Part No.: 0558102233/0558102234)
•Feed4004HDWireFeeder
•OperatingManual
•DriveRoll0.9-1.2mm,V-groovetted
2.08 Specications
Description Feed 4004 HD Wire Feeder
Wire feeder Part Number 0558102233/0558102234
Wire feeder Dimensions H 255mm x W 460mm x D 755mm
Wire feeder Mass 21.5kg
Input Voltage 42VAC, 350VA
Input Voltage Tolerance ±15%
Input Frequency 50/60 Hz
Gas Solenoid Voltage 42 vdc
Maximum Gas Pressure 0.7 Mpa (7 bar)
MIG Welding Output, 40°C, 10 min
Minimum Wire Feed Speed 1.5 MPM (60 IPM)
Maximum Wire Feed Speed 19 MPM (750 IPM)
Operating Temperature Range 0°C - 40°C
Interconnection Plug 19 pin
Solid
Wire Sizes
Flux Cored 1.0mm (0.035”) to 1.6mm (1/16”)
Aluminium
550A at 60%
450A at 100%
0.9mm (0.035”) to 1.6mm (1/16”)
1.2mm (0.045”) to 3.2mm (1/8”)
Maximum Wire Spool Weight 60 lb./ 27kg
Table 2-1 Feed 4004 HD Wire Feeder Specication
NOTE
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.
In the interest of continuous improvement, ESAB reserves the right to change the specications or
design of any of its products without prior notice.
15
SECTION 2: INTRODUCTION
2.09 Optional Accessories
Feed Rolls & Guides
Warrior Feed 404HD Feed Rolls (as delivered -*) Guides (as delivered -*)
Wire Diameter: in.
(mm)
.035 (0.9)-.045 (1.2) V-Solid 0558102372* set
.035 (0.9)-.035 (0.9) V-Solid 0558102374 set
.045 (1.2)-.045 (1.2) V-Solid 0558102375 set
.045 (1.2)/.052 (1.4)-
.062 (1.6)
.030 (0.8)/.035 (0.9)-
.045 (1.2)
.045 (1.2)-.045 (1.2) K-Cored 0558102384 set
.045 (1.2) /.052 (1.4
)- 1/16 (1.6)
.052 (1.4)-.052 (1.4) K-Cored 0558102385 set
1/16 (1.6)-1/16 (1.6) K-Cored 0558102386 set
5/64-3/32" K-Cored 0558102381 set
7/64" K-Cored 0558102382 set
1/8" K-Cored 0558102383 set
3/64 - 1/16" U-Soft 0558102377 set
5/64” - 3/32” U-Soft 0558102378 set
Type Part Number Qty Guide Tube Qty Center
Guide
0558102387* 1 0558102389* 1 0558102390* 1
of 2
0558102387 1 0558102389 1 0558102390 1
of 2
0558102387 1 0558102389 1 0558102390 1
of 2
V-Solid 0558102373 set
K-Cored 0558102379 set
K-Cored 0558102380 set
0558102387 1 0558102389 1 0558102390 1
of 2
0558102387 1 0558102389 1 0558102390 1
of 2
0558102387 1 0558102389 1 0558102390 1
of 2
0558102387 1 0558102389 1 0558102390 1
of 2
0558102387 1 0558102389 1 0558102390 1
of 2
0558102387 1 0558102389 1 0558102390 1
of 2
N/A 1 0558102389 1 0558102390 1
of 2
N/A 1 0558102389 1 0558102390 1
of 2
N/A 1 0558102389 1 0558102390 1
of 2
N/A 1 0558102389 1 0558102390 1
of 2
N/A 1 0558102389 1 0558102390 1
of 2
Qty Inlet Guide Qty
16
Table 2-2 Feed Rolls
note :
Two feed rolls are required for each wire size.
note :
* indicates tted as standard.
Other Accessories
OKC50 Connectors female cable connector, 1/0-4/0 cable (50 mm²) 13735631 (0160361881)
OKC50 Connectors male cable connector, 1/0-4/0 cable (50 mm²) 13792513 (0160360881)
V350A Spray Master 15ft. Air-cooled MIG Gun (SVM315-116) 1036-1756
V450A Spray Master 15ft. Air-cooled MIG Gun (SVM415-116) 1040-1833
SECTION 2: INTRODUCTION
Ordering Information – Accessories
Description Part Number
Marathon Pac Conduit QC Adaptor Kit 899F50
Lifting Eye Kit W4016701
Heavy Duty 4 Wheel Trolley W4000002
CONN SET 5.6FT 10/10P 500A 0459528780
CONN SET 16.4FT 10/10P 500A 0459528781
CONN SET 32.8FT 10/10P 500A 0459528782
CONN SET 49.2FT 10/10P 500A 0459528783
CONN SET 82FT 10/10P 500A 0459528784
CONNECT SET 500A 10/10P 35M 0459528785
Table 2-3 Options and Accessories
17
Other Accessories
SECTION 2: INTRODUCTION
18
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SECTION 3: INSTALLATION, OPERATION and SETUP
3.01 Environment
These units are designed for use in environments with increased hazard of electric shock as
outlined in IEC 60974.5.
A. Examples of environments with increased hazard of electric shock are:
1. In locations in which freedom of movement
is restricted, so that the operator is forced to
perform the work in a cramped (kneeling,
sitting or lying) position with physical contact
with conductive parts.
2. In locations which are fully or partially limited
by conductive elements, and in which there
is a high risk of unavoidable or accidental
contact by the operator.
3. In wet or damp hot locations where humidity
or perspiration considerably reduces the skin
resistance of the human body and the insulation properties of accessories.
F. The enclosure design of this Wire Feeder
meets the requirements of IP23S as outlined
in AS 60529. This provides adequate protection against solid objects (greater than
12mm), and from water falling as spray at
an angle up to 60o from vertical. Under no
circumstances should the unit be operated
or connected in a micro environment that
will exceed the stated conditions. For further
information please refer to AS 60529.
G. Precautions must be taken against the Wire
Feeder toppling over. The Wire Feeder must
be located on a suitable horizontal surface in
the upright position when in use.
3.03 Ventilation
WARNING
B. Environments with increased hazard of
electric shock do not include places where electrically conductive parts in the near vicinity of
the operator, which can cause increased hazard,
have been insulated.
3.02 Location
Be sure to locate the Wire feeder according
to the following guidelines:
A. In areas, free from moisture and dust.
B. Ambient temperature between 0° C to 40° C.
C. In areas, free from oil, steam and corrosive
gases.
D. In areas, not subjected to abnormal vibration
or shock.
E. In areas, not exposed to direct sunlight or
rain.
Since the inhalation of welding fumes can be harmful,
ensure that the welding area is eectively ventilated.
3.04 Mains Supply Voltage Requirements
CAUTION
This Wire feeder cannot be connected directly to the mains supply.
It must be connected to a suitable
Wire feeder control socket on a power
source.
3.05 Electromagnetic Compatibility
WARNING
Extra precautions for Electromagnetic Compatibility may
be required when this Welding Power Source is used in a
domestic situation.
SECTION 3: installation, Operation and Setup
A. Installation and Use - Users Responsibility
The user is responsible for installing and
using the welding equipment according to the
manufacturer’s instructions. If electromagnetic
disturbances are detected then it shall be the
responsibility of the user of the welding equipment to resolve the situation with the technical
assistance of the manufacturer. In some cases
this remedial action may be as simple as earthgrounding the welding circuit, see NOTE below.
In other cases it could involve constructing an
electromagnetic screen enclosing the Welding Power Source and the work, complete with
associated input lters. In all cases, electromagnetic disturbances shall be reduced to the point
where they are no longer troublesome.
NOTE
The welding circuit may or may
not be earthed for safety reasons.
Changing the earth-grounding ar-
rangements should only be authorised
by a person who is competent to as-
sess whether the changes will increase
the risk of injury, e.g. by allowing paral-
lel welding current return paths which
may damage the grounding circuits
of other equipment. Further guidance
is given in IEC 60974-13 Arc Welding
Equipment - Installation and use (un-
der preparation).
B. Assessment of Area
Before installing welding equipment, the
user shall make an assessment of potential electromagnetic problems in the surrounding area.
The following shall be taken into account.
1. Other supply cables, control cables, signal-
ling and telephone cables; above, below and
adjacent to the welding equipment.
2. Radio and television transmitters and receiv-
ers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of
industrial equipment.
5. The health of people around, e.g. the use of
pace-makers and hearing aids.
6. Equipment used for calibration and measure-
ment.
7. The time of day that welding or other activi-
ties are to be carried out.
8. The immunity of other equipment in the
environment: the user shall ensure that other
equipment being used in the environment
is compatible: this may require additional
protection measures.
The size of the surrounding area to be
considered will depend on the structure of the
building and other activities that are taking
place. The surrounding area may extend beyond
the boundaries of the premises.
20
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