ESAB Mig 4004i Pulse Instruction manual

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Aristo®

Mig4004iPulse

380-460 V

Instruction manual

0463 380 331 US 20190429

Valid for: serial no. 528-xxx-xxxx

SAFETY ....................................................................................................... 3

1.1 Meaning of symbols ............................................................................... 3

1.2 California Proposition 65 Warning........................................................ 3

1.3 Safety precautions ................................................................................. 3

1.4 User responsibility ................................................................................. 7

INTRODUCTION.......................................................................................... 10

2.1 Equipment............................................................................................... 10

TECHNICAL DATA ...................................................................................... 11

INSTALLATION............................................................................................ 13

4.1 Location................................................................................................... 13

4.2 Lifting instructions ................................................................................. 13

4.3 Electrical supply ..................................................................................... 13

OPERATION ................................................................................................ 17

5.1 Connections and control devices ......................................................... 18

5.2 Symbols .................................................................................................. 18

5.3 Connection of welding and return cable .............................................. 18

5.4 Turning the power source on/off........................................................... 19

5.5 Fan control .............................................................................................. 19

5.6 Thermal protection ................................................................................. 19

5.7 VRD (Voltage Reducing Device)............................................................ 19

5.8 Remote control unit................................................................................ 19

5.9 Arc voltage feedback ............................................................................. 20

MAINTENANCE........................................................................................... 21

6.1 Inspection and cleaning......................................................................... 21

TROUBLESHOOTING ................................................................................. 22

ORDERING SPARE PARTS........................................................................ 23

DIAGRAM ............................................................................................................ 24

ORDERING NUMBERS ....................................................................................... 25

SPARE PARTS LIST............................................................................................ 26

ACCESSORIES ................................................................................................... 27

Rights reserved to alter specifications without notice.

0463 380 331 © ESAB AB 2019

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 California Proposition 65 Warning

WARNING!

Welding or cutting equipment produces fumes or gases that contain chemicals known in the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

WARNING!

This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm. Wash hands after use.

For more information, go to www.P65Warnings.ca.gov.

1.3 Safety precautions

WARNING!

These Safety Precautions are for your protection. They summarise precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

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1 SAFETY

PROTECT YOURSELF AND OTHERS

Some welding, cutting and gouging processes are noisy and require hearing protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure the skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching.

2. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields and goggles are also required.

3. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to look at the arc and not to expose themselves to the rays of the electric-arc or hot metal.

4. Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants, high-topped shoes, and a welding helmet or cap for protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.

5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned and open pockets eliminated from the front of the clothing.

6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.

7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly for long distances. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS

The heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore:

1. Protect yourself and others from flying sparks and hot metal.

2. Move all combustible materials well away from the work area or cover the materials with a protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.

3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.

4. Do not weld, cut, or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors. Do not perform hot work on closed containers, they may explode.

5. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.

6. Do not use equipment beyond its ratings. For example, an overloaded welding cable can overheat and create a fire hazard.

7. After completing work, inspect the work area to make sure there are no hot sparks or hot metal that could cause a fire later. Use fire watchers when necessary.

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1 SAFETY

ELECTRICAL SHOCK

Contact between live electrical parts and earth can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. Therefore:

1. Be sure the power source frame (chassis) is connected to the earth system of the input power.

2. Connect the workpiece to a good electrical earth.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power source.

6. Make sure that all parts of your body are insulated from both the work piece and from the ground.

7. Do not stand directly on metal or the ground while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power, before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not mistake the work lead for a earth cable.

ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders with pacemakers fitted should consult their doctor before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

a) Route the electrode and work cables together. Secure them with tape when

possible. b) Never coil the torch or work cable around your body. c) Do not place your body between the torch and work cables. Route cables on

the same side of your body. d) Connect the work cable to the workpiece as close as possible to the area being

welded. e) Keep the welding power source and cables as far away from your body as

possible.

FUMES AND GASES

Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Shielding gases can cause asphyxiation. Therefore:

1. Keep your head out of the fumes. Do not breathe the fumes and gases.

2. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is provided. Do not breathe in the fumes from these materials.

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1 SAFETY

3. Do not operate near degreasing and spraying operations. The heat or arc can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

4. If you develop momentary eye, nose or throat irritation while operating, this is an indication that the ventilation is not adequate. Stop work and take the necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.

6. WARNING: This product when used for welding or cutting, produces fumes or gases that contain chemicals known to the State of California to cause birth defects and in some cases cancer (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING

Cylinders, if mishandled, can rupture and violently release gas. A sudden rupture of cylinder valve or relief device can injure or kill. Therefore:

1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.

2. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adapters. Maintain hoses and fittings in good condition. Follow the manufacturer's operating instructions for mounting a regulator to a compressed gas cylinder.

3. Always secure cylinders in an upright position, by chain or strap, to suitable hand trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.

4. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks.

MOVING PARTS

Moving parts, such as fans, rotors and belts can cause injury. Therefore:

1. Keep all doors, panels, guards, and covers closed and securely in place.

2. Stop the engine or drive systems before installing or connecting a unit.

3. Have only qualified people remove covers for maintenance and troubleshooting as necessary

4. To prevent accidental starting of equipment during service, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing and tools away from moving parts.

6. Reinstall panels or covers and close doors when service is finished and before starting engine.

WARNING! FALLING EQUIPMENT CAN INJURE

• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any other accessories.

• Use equipment of adequate capacity to lift and support unit.

• If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

• Keep cables and cords away from moving vehicles when working from an aerial location.

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1 SAFETY

WARNING! EQUIPMENT MAINTENANCE

Faulty or improperly maintained equipment can cause injury or death. Therefore:

CAUTION! ADDITIONAL SAFETY INFORMATION

1. Always have qualified personnel perform the installation, troubleshooting and

maintenance work. Do not perform any electrical work unless you are qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect

the power source from the incoming electrical power.

3. Maintain cables, earthing wire, connections, power cord and power supply in

safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from

heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding, Cutting and Gouging.” Form 52-529.

The following publications are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”

2. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”

3. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”

4. AWS SP - “Safe practices” - Reprint, Welding Handbook

5. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of

Containers That Have Held Hazardous Substances”

6. OSHA 29 CFR 1910 - "Safety and health standards"

7. CSA W117.2 - "Code for safety in welding and cutting"

8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other

Hot Work"

9. CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in

Cylinders”

10.ANSI Z87.1, "Occupational and Educational Personal Eye and Face

Protection Devices"

1.4 User responsibility

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed, in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the equipment. Incorrect operation of the equipment may lead to hazardous situations, which could result in injury to the operator and damage to the equipment.

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1 SAFETY

1. Anyone who uses the equipment must be familiar with: ○ its operation ○ the location of emergency stops ○ its function ○ the relevant safety precautions ○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that: ○ no unauthorized person is within the working area of the equipment when it is

started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

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 may cause injury to yourself and others. Take precautions when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves, or wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Pose health risks

• Welders with pacemakers fitted should consult their doctor before welding. EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep the welding power source and cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

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1 SAFETY

FUMES AND GASES - Can be dangerous to your health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use ear defenders or other hearing protection.

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause a fire. Make sure there are no inflammable materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

This product is solely intended for arc welding.

ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information, contact your local ESAB dealer or visit us on our website.

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2 INTRODUCTION

The power source Mig 4004i Pulse combined with U6, U82or MA25 Pulse offers a complete multi-process package supporting SMAW (MMA), GTAW (TIG), GMAW (MIG/MAG) and

pulse MIG.

The power source is intended for use with the wire feed unit Feed 3004 or YardFeed 2000 and the cooling unit COOL1. 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:

• 16.4 ft (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 380-460V, ±10%, 3~ 50/60 Hz

Mains supply S

Primary current I

scmin

max

2.5 MVA

23 A

No-load power 57 W

Setting range (DC)

GMAW (MIG/MAG) 16 A/15 V–400 A/34 V

SMAW (MMA) 16 A/21 V–400 A/36 V

GTAW (TIG) 4 A/10 V – 400 A/26 V

Permissible load at GMAW (MIG/MAG)

60 % duty cycle 400 A/34.0 V

100% duty cycle 300 A/29.0 V

Permissible load at SMAW (MMA)

60 % duty cycle 400 A/36.0 V

100% duty cycle 300 A/32.0 V

Permissible load at GTAW (TIG)

60 % duty cycle 400 A/26.0 V

100% duty cycle 300 A/22.0 V

Power factor at maximum current 58.3/0.94

Efficiency at maximum current 88 %

Open circuit voltage 55 V

Operating temperature 50 to 104°F (-10to40°C)

Transportation temperature -68 to 131°F (-20 to 55°C)

Constant sound pressure when idling <70 db (A)

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

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 104°F (40°C).

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 that its cooling air inlets and outlets are not obstructed.

4.2 Lifting instructions

4.3 Electrical 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

0463 380 331

. 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

NOTE!

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

Check that the unit is connected to the correct power supply voltage, and that it is protected by the correct fuse size. A protective ground 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

Electrical cable area

Phase current I

effUin

380 V 20 A

4C 10 AWG (4G4 mm2)

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

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 electrical cable

If the electrical cable needs to be changed, the ground connection to the bottom plate must be made correctly. See from the illustrations 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

The power source is connected to 460 V from factory. If another mains voltage is required, the cable on the printed circuit board has to be moved and placed on the correct pin (see illustration above), and the mains cable and plug must be changed according to relevant national regulations. This operation must be performed by someone who has the appropriate knowledge of electrical systems. 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 33 ft (10 m).

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5 OPERATION

5.1 Connections and control devices

1. Negative welding terminal: Return cable 5. Indicating LED, thermal protection

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

3. Connection for wire feed unit or remote

control unit

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

feeder unit

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

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.

Recommended maximum current values for connection set cables

max

450 A (60% duty cycle)

350 A (100% duty cycle)

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Cable area Cable length Note

0.5ft (70 mm)

6.6 ft–114.8 ft (2–35 m)

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19 pole

5 OPERATION

max

550 A (60% duty cycle)

430 A (100% duty cycle)

450 A (60% duty cycle)

350 A (100% duty cycle)

550 A (60% duty cycle)

430 A (100% duty cycle)

Cable area Cable length Note

0.5ft (95 mm)

0.5ft (70 mm)

0.5ft (95 mm)

6.6 ft–114.8 ft (2–35 m)

19 pole

19 pole, water

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading. The duty cycle is valid for 104°F (40°C).

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. Welding data will be stored regardless of whether the electrical supply is interrupted abnormally or the power source is switched off in the normal manner, which allows it to be available the 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, then 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 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 GMAW (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 authorized ESAB service personnel.

NOTE!

To compensate for the voltage drop in the return cable, the power source can be configured (by authorized 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 (authorized 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 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 the filter with the finest mesh is placed toward the grill.

4. Reinstall the filter.

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7 TROUBLESHOOTING

Try these recommended checks and inspections before requesting a visit from an authorized service technician.

Type of fault Actions

No arc. • Check that the main power supply

switch is turned on.

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

• Check that the correct current value is set.

• Check the electrical power supply fuses.

Welding current is interrupted during welding • Check whether the thermal overload trip

has operated (indicated by the orange lamp on the front)

• Check the main power supply fuses.

• Check that the return cable is correctly fastened.

The thermal overload 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).

Poor welding performance. • Check that the welding current and

return cables are connected correctly.

• Check that the correct current value is set.

• Check that the correct welding wires are being used.

• Check the electrical 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 standard IEC 60974-1 and US standard ANSI/IEC 60974-1:2008. It is the obligation of the service unit which carried out the service or repair work to make sure that the product still conforms to these standards.

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 152 882 Welding power source Aristo® Mig 4004i Pulse 380-460V version

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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SPARE PARTS LIST

Item Ordering no. Denomination

1 0462 197 001 Dust filter

2 0463 396 001 Warning label

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ACCESSORIES

Trolleys

0462 151 880 Trolley 11, 4-wheel

0558 102 236 HD Trolley 2-Cyl

0558 102 311 Kit Bracket 4004i for HD Trolley

0463 125 880 Trolley bracket for Trolley 11

Use together with trolley 0462 151 880.

Option when no cooling unit is assembled.

0460 564 880

0460 815 880

Trolley 8, 2-wheel

Shelf for YardFeed and MobileFeed.

0460 565 880 Trolley 9, 4-wheel

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.

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ACCESSORIES

0458 705 880 Counterbalance device

Includes mast and counterbalance.

For 11 in. (300 mm) bobbin.

Wire feeders

0460 526 680

0460 526 681

0460 526 682

0460 526 683

0460 526 486

0460 526 896

0460 526 481

0460 526 891

0459 906 896

0558102480

Feed 3004 MA25 Pulse Al

Feed 3004w MA25 Pulse Al

Feed 3004 MA25 Steel

Feed 3004w MA25 Steel

Feed 3004 U6

Feed 3004 U6, water-cooled

Feed 3004 for U8



Feed 3004 for U82, water-cooled



YardFeed 2000 U6, water-cooled

4004HD with U8

Feederaccessories

0458 674 880 1 Bobbin cover, plastic

0459 431 880 1 Bobbin cover, metal

0455 410 001 1 Adapter for 11 lb (5 kg) bobbin

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ACCESSORIES

0459 233 880 1 Adapter for 17 in. (440 mm) bobbin

0458 706 880 1 Lifting eye

F102 440 880

899F50

2 Quick connector Marathon Pac™

2 Quick connector Marathon Pac™ NA

0558 002 354 Connector Adapter Marathon Pac™ NA

0458 707 880 1 Wheel kit for feeder, front wheels

turnable

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ACCESSORIES

0457 341 881 1 Strain relief for welding torch

0459 234 880 Strain relief for interconnection cables

0349 312 450 4004D feeder interconnection cable

Cooler

0462 300 880 Water cooling unit, COOL1

0456 855 881 Flow guard, COOL1

Control panels

0460 820 880 Aristo®U82, complete including holder

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ACCESSORIES

0460 820 881 Aristo®U82, plus complete including

holder

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

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

5.6 ft (1.7 m)

16.0 ft (5 m)

32.8 ft (10 m)

49.2 ft (15 m)

82.0 ft (25 m)

114.8 ft (35 m)

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

5.6 ft (1.7 m)

16.0 ft (5 m)

32.8 ft (10 m)

49.2 ft (15 m)

82.0 ft (25 m)

114.8 ft (35 m)

Remote controls

0459 491 880 Remote control unit MTA1 CAN

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GMAW (MIG/MAG): wire feed speed and voltage

SMAW (MMA): current and arc force

GTAW (TIG): current, pulse and background current

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ACCESSORIES

0459 491 882 Remote control M1 10 Prog. CAN

Remote control cable 10 pole - 4 pole

0459 960 880

0459 960 881

0459 960 882

0459 960 883

16 ft (5m)

32.8 ft (10 m)

82.0 ft (25 m)

10 in. (0.25 m)

Remote adapter kit

0459 681 880

0459 681 881

For Miggy-/Railtrac

For MXH PP and PSF RS3

Connection kit

0459 020 883 For MXH™ 300/400w PP connection kit

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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ACCESSORIES

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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 California Proposition 65 Warning

1.3 Safety precautions

1.4 User responsibility

2 INTRODUCTION

2.1 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 Location

4.2 Lifting instructions

4.3 Electrical 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

SPARE PARTS LIST

ACCESSORIES