ESAB Mig 4004i Pulse Instruction manual

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Aristo®

Mig 4004i Pulse

380-460 V

Instruction manual

0463 431 301 GB 20220103

Valid for: serial no. 551, 704-xxx-xxxx

SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

INTRODUCTION

2.1 Equipment

TECHNICAL DATA

INSTALLATION

4.1 Location

4.2 Lifting instruction

4.3 Mains supply

OPERATION

5.1 Connections and control devices

5.2 Symbols

5.3 Connection of welding and return cable

5.4 Turning the power source on/off

5.5 Fan control

5.6 Thermal protection

5.7 VRD (Voltage Reducing Device)

5.8 Remote control unit

5.9 Arc voltage feedback

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MAINTENANCE

6.1 Inspection and cleaning

TROUBLESHOOTING

ORDERING SPARE PARTS

DIAGRAM

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ORDERING NUMBERS WEAR PARTS

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ACCESSORIES

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Rights reserved to alter specifications without notice.

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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

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

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1 SAFETY

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.

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.

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NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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1 SAFETY

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.

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1 SAFETY

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.

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2 INTRODUCTION

The power source Mig 4004i Pulse combined with U6, U82or MA25 Pulse offer a complete multi-process package supporting MMA, TIG, MIG/MAG and pulse MIG.

The power source are intended for use with the wire feed unit Feed 3004/4804 or YardFeed 2000 and the cooling unit COOL 1. For more information about the feed units and the cooling unit, 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 with:

• 5 m return cable with earth clamp

• instruction manual for the welding power source

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3 TECHNICAL DATA

Mig 4004i Pulse

Mains voltage 380-460V, ±10%, 3~ 50/60 Hz

Mains supply S

Primary current I

scmin

max

5.8 MVA

28 A

No-load power 57 W

Setting range (DC)

MIG/MAG 16 A / 14.8 V - 400 A / 34 V

MMA 16 A / 20.6 V - 400 A / 36 V

TIG 4 A / 10.2 V - 400 A / 26 V

Permissible load at MIG/MAG

60 % duty cycle 400 A / 34.0 V

100% duty cycle 300 A / 29.0 V

Permissible load at MMA

60 % duty cycle 400 A / 36.0 V

100% duty cycle 300 A / 32.0 V

Permissible load at TIG

60 % duty cycle 400 A / 26.0 V

100% duty cycle 300 A / 22.0 V

Power factor at maximum current 0.95

Efficiency at maximum current 89.5 %

Open circuit voltage 55 V

Operating temperature -10 to 40°C (14 to 104°F)

Transport temperature -20 to 55°C (-4 to 131°F)

Constant sound pressure when

<70 dB (A)

idling

Dimensions l×w×h 613 × 257 × 445 mm (24.0 × 10.1 × 17.5 in.)

Weight 48 kg (106 lb)

Insulation class H

Enclosure class IP23

Application classification

Mains supply, S

sc min

Minimum short circuit power on the network in accordance with IEC 61000-3-12.

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 40°C/104°F, 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.

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3 TECHNICAL DATA

Application class

The symbol indicates that the power source is designed for use in areas with increased electrical hazard.

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4 INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user's responsibility to take adequate precautions.

4.1 Location

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

4.2 Lifting instruction

4.3 Mains supply

NOTE! Mains supply requirements

This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater than or equal to S

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 S

NOTE!

The power source can be powered from a generator. For more information, contact authorised ESAB service personnel.

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. Refer to the technical data in the TECHNICAL DATA chapter.

scmin

at the interface point between the user's supply and

scmin

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4 INSTALLATION

Check that the unit is connected to the correct mains power supply voltage, and that it is protected by the correct fuse size. A protective earth connection must be made, in accordance with regulations.

A. Rating plate with supply connection

data

Recommended fuse sizes and minimum cable areas

Mig 4004i Pulse

Mains voltage 380-460 V, +/- 10%, 3~50/60 Hz

Mains cable area

Phase current I

effUin

4G4 mm

380 V 20 A

Fuse anti-surge 20 A

Fuse MCB-surge type C 25 A

Phase current I

effUin

400 V 19.2 A

Fuse anti-surge 20 A

Fuse MCB-surge type C 25 A

Phase current I

effUin

415 V 18 A

Fuse anti-surge 20 A

Fuse MCB-surge type C 20 A

Phase current I

effUin

440 V 17.6 A

Fuse anti-surge 20 A

Fuse MCB-surge type C 20 A

Phase current I

effUin

460 V 17 A

Fuse anti-surge 20 A

Fuse MCB-surge type C 20 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.

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4 INSTALLATION

Installation of mains cable

If the mains cable needs to be changed, the earth connection to the bottom plate must be made in a correct way. See from the pictures above how to remove the side panel and install the mains cable. No other cable must be attached to this connection point.

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4 INSTALLATION

Connection instruction 0465 152 883

Connection instruction 0465 152 884

Power source ordering no. Default input voltage setting

0465 152 883 400 V Delivered with mains cable and plug

connected.

0465 152 884 415 V Delivered with mains cable.

If another mains voltage is required, the cable on the printed circuit board has to be moved to the correct pin (see illustration above), and the mains cable and plug must be changed according to relevant national regulations. This operation has to be made by persons who have appropriate electrical knowledge. The power source must be disconnected from mains while performing this action.

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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!

WARNING!

Secure the equipment - particularly if the ground is uneven or sloping.

NOTE!

To achieve the best possible result at Mig short pulsing, the welding and return cables must not exceed 10 m (33 ft).

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5 OPERATION

5.1 Connections and control devices

1. Negative welding terminal: Return

cable

2. Mains power supply switch, 0 / 1 6. Positive welding terminal: Welding cable

3. Connection for wire feed unit or remote

control unit

4. Indicating LED, power supply ON 8. Mains cable

5. Indicating LED, thermal protection

7. Fuse (10 A) for supply voltage (42 V) for

feeder unit

5.2 Symbols

Remote control unit (2) Overheating (3)

Power supply ON (4)

5.3 Connection of welding and return cable

The power source has two outputs, a positive terminal (+) and a negative terminal (-), for connecting welding and return cables.

Connect the return cable to the negative terminal on the power source. Secure the return cable's contact clamp to the work piece and ensure that there is good contact between the work piece and the output for the return cable on the power source.

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5 OPERATION

Recommended maximum current values for connection set cables

max

450 A (60% duty cycle)

350 A (100% duty cycle)

550 A (60% duty cycle)

430 A (100% duty cycle)

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 40°C (104°F).

Cable area Cable length

70 mm

95 mm

2 - 35 m

(6.6 ft - 114.8 ft)

2 - 35 m

(6.6 ft - 114.8 ft)

5.4 Turning the power source on/off

Turn the power source on by turning switch (2) to the ”1” position. Turn the power source off by turning the switch (2) to the ”0” position. Regardless the mains supply is interrupted abnormally or the power source is switched off in the normal manner, the welding data will be stored, so it will be available next time the unit is turned on.

5.5 Fan control

The power source has a time circuit, which keeps the fans running for 6.5 minutes after welding has stopped, after that the unit switches to energy-saving mode. The fans start again when welding begins. The fans run at reduced speed for welding currents up to 150 A, and at full speed for higher currents.

CAUTION!

The fans may start at any time to protect the power source from overheating.

5.6 Thermal protection

The welding power source has thermal protection circuit that operates if the internal temperature becomes too high. When this occurs the welding current is blocked and a fault code is displayed on the control panel. The thermal protection resets automatically when the temperature has fallen within normal operation temperature.

5.7 VRD (Voltage Reducing Device)

The VRD function ensures that the open-circuit voltage does not exceed 35V when welding is not being carried out. VRDLED is lit when the VRD function is activated. The VRD function must be activated by a qualified service technician, by means of ESAT (ESAB Software Administration Tool, a kit for technical service including a software to manage settings, update of software etc.).

The VRD function is blocked when the system senses that welding has started.

5.8 Remote control unit

For more information about the operation of the remote control unit, see the instruction manual for the control panel.

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5 OPERATION

5.9 Arc voltage feedback

To achieve a good welding result, the arc voltage feedback is a crucial factor. In MIG/MAG welding, the power source is prepared to sense the arc voltage in the wire feeder. Prerequisite for this functionality is that an ESAB wire feeder and an ESAB interconnection cable is used! This method of measuring the arc voltage, compensates for the voltage drop in the welding cable to the wire feeder. With an ESAB torch supporting "TrueArcVoltage", the voltage drop all the way to the contact tip is compensated.

WARNING!

The external arc voltage inputs (the red and black banana sockets) at the back end of the WeldCloud™ top box should not be used, unless the equipment has been configured for this setup by authorised ESAB service personnel.

NOTE!

To compensate the voltage drop in the return cable, the power source can be configured (by authorised ESAB service personnel) to use an external arc voltage sense wire from the workpiece.

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6 MAINTENANCE

CAUTION!

Only persons with the appropriate electrical knowledge (authorised personnel) may remove the cover of the product or carry out service, maintenance or repair work on the welding equipment.

CAUTION!

The product is covered by manufacturer's warranty. Any attempt to carry out repair work by non-authorized service centers will invalidate the warranty.

NOTE!

Regular maintenance is important for safe and reliable operation.

For information about the cooling unit see the instruction manual for the cooling unit.

6.1 Inspection and cleaning

Check regularly that the power source is free from dirt.

The power source should be regularly blown clean using dry compressed air at reduced pressure. More frequently in dirty environments.

Otherwise the air inlet/outlet may become blocked and cause overheating. To avoid this, the air filter should be regularly cleaned. The filter is built of a large and a small mesh. Make sure that the large mesh is mounted to the upmost part of the power source and the small mesh to the innermost part of the power source.

Replacing and cleaning the dust filter:

1. Release the dust filter according to the figure.

2. Blow the filter clean with compressed air (reduced pressure).

3. Ensure that the filter with the finest mesh is placed towards the grill.

4. Reinstall the filter.

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7 TROUBLESHOOTING

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

Type of fault Actions

No arc. • Check that the mains power supply

switch is turned on.

• Check that the mains, welding current and return cables are correctly connected.

• Check that the correct current value is set.

• Check the mains power supply fuses.

Welding current is interrupted during welding • Check whether the thermal protection

trip has operated (indicated by the orange LED on the front(5))

• Check the main power supply fuses if the LED indicating power supply(4) is not lit.

• Check that the return cable is correctly fastened.

The thermal protection trips 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).

• Check that the ambient temperature is not above the one for the rated duty cycle 40°C/104°F.

Poor welding performance. • Check that the welding current and

return cables are correctly connected.

• Check that the correct current value is set.

• Check that the correct welding wires are being used.

• Check the mains power supply fuses.

Nothing happens when the trigger on the welding torch is pushed.

• Check the fuse on the rear part of the power source.

• Check if the welding and return cables are damaged.

• Check that the wire feeder works correctly. See the wire feeder instruction manual.

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8 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.

Mig 4004i Pulse is designed and tested in accordance with the international and European standards IEC-/EN 60974-1 and IEC-/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.

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.

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DIAGRAM

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ORDERING NUMBERS

Ordering

Denomination Type Note

number

0465 152 883 Welding power source Aristo® Mig 4004i Pulse 380-460V. CE

0465 152 884 Welding power source Aristo® Mig 4004i Pulse 380-460V. CE, AU

0463 396 001 Spare parts list Mig 4004i Pulse, Mig 4004i

Pulse WeldCloud™

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

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WEAR PARTS

Item Ordering no. Denomination

1 0462 197 001 Dust filter

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ACCESSORIES

Trolleys

0462 151 880 Trolley 11, 4-wheel

0463 125 880 Trolley bracket for Trolley 11

Use together with trolley 0462 151 880.

Option when no cooling unit is assembled.

0460 565 880 Trolley

For use together with counter balance device.

0461 310 880 Trolley adapter kit

For fitting of power source Mig4004i Pulse to trolley 0460565880.

0460 946 880 Stabilizer kit for counter balance (1)

Use together with trolley 0460 565 880

 

0458 705 880

Counter balance device

(includes mast and counter balance)

for 300 mm (11 in.) bobbin

0458 705 882

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for 440 mm (17 in.) bobbin

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ACCESSORIES

0463 125 880 Trolley bracket

Use together with trolley 0462 151 880.

Option when no cooling unit is assembled

Wire feeders

0460 526 670

0460 526 671

0460 526 672

0460 526 673

0460 526 881

0460 526 886

0460 526 891

0460 526 896

0460 526 991

0460 526 996

0459 906 896

0445 800 886

0445 800 887

Feed 3004 MA25 Pulse Al

Feed 3004w MA25 Pulse Al

Feed 3004 MA25 Pulse Steel

Feed 3004w MA25 Pulse Steel

Feed 3004 U8



Feed 3004 U6

Feed 3004 U82, water-cooled



Feed 3004 U6, water-cooled

Feed 4804 U82, water-cooled



Feed 4804 U6, water-cooled

Yardfeed 2000, water-cooled

Aristo® Robust Feed U0

Aristo® Robust Feed U6

Wire feeder accessories

Accessories for wire feeders can be found in the wire feeder instruction manual.

Cooler

0462 300 880 Water cooling unit, COOL1

0456 855 881 Flow guard, COOL1

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ACCESSORIES

Connection set, 70 mm210 pole cable plug - 10 pole cable socket

0459 528 780

0459 528 781

0459 528 782

0459 528 783

0459 528 784

0459 528 785

1.7 m (5.6 ft)

5 m (16.0 ft)

10 m (32.8 ft)

15 m (49.2 ft)

25 m (82.0 ft)

35 m (114.8 ft)

Control panels

0460 820 880 Aristo®U82, complete including holder

0460 820 881 Aristo®U82, plus complete including

holder

0460 877 891 Control cable extension U82, 7.5 m (24.6 ft)

Connection set, 70 mm210 pole cable plug - 10 pole cable socket

0349 312 450

0349 312 451

0349 312 452

0349 312 453

0349 312 454

0349 312 455

1.7 m (5.6 ft)

5 m (16.0 ft)

10 m (32.8 ft)

15 m (49.2 ft)

25 m (82.0 ft)

35 m (114.8 ft)

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ACCESSORIES

Connection set water, 70 mm210 pole cable plug - 10 pole cable socket

0459 528 790

0459 528 791

0459 528 792

0459 528 793

0459 528 794

0459 528 795

1.7 m (5.6 ft)

5 m (16.0 ft)

10 m (32.8 ft)

15 m (49.2 ft)

25 m (82.0 ft)

35 m (114.8 ft)

Remote controls

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 491 883 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 10 pole - 4 pole

0459 960 880

0459 960 881

0459 960 882

0459 960 883

5 m (16.0 ft)

10 m (32.8 ft)

25 m (82.0 ft)

0.25 m (114.8 ft)

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ACCESSORIES

For Mig 4004i Pulse:

0445 302 881 Retrofit Mig 4004i WeldCloud™

Information on PSF welding torches can be found in separate brochures.

For more information about the accessories contact the nearest ESAB agency.

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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

http://manuals.esab.com

For contact information visit esab.com

ESAB Mig 4004i Pulse Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 Location

4.2 Lifting instruction

4.3 Mains supply

5 OPERATION

5.1 Connections and control devices

5.2 Symbols

5.3 Connection of welding and return cable

5.4 Turning the power source on/off

5.5 Fan control

5.6 Thermal protection

5.7 VRD (Voltage Reducing Device)

5.8 Remote control unit

5.9 Arc voltage feedback

6 MAINTENANCE

6.1 Inspection and cleaning

7 TROUBLESHOOTING

8 ORDERING SPARE PARTS

DIAGRAM

ORDERING NUMBERS

WEAR PARTS

ACCESSORIES