ESAB Mig 4004i Pulse Instruction manual

Aristo®

Mig 4004i Pulse

Instruction manual

0463 331 001 GB 20150108 Valid for: 240-xxx-xxxx

TABLE OF CONTENTS

1 SAFETY ................................................................................................................ 4

2 INTRODUCTION...................................................................................................7

2.1 Equipment............................................................................................................. 7

3 TECHNICAL DATA ............................................................................................... 8

4 INSTALLATION................................................................................................... 10

4.1 Location .............................................................................................................. 10

4.2 Lifting instruction...............................................................................................10

4.3 Mains supply ...................................................................................................... 11

5 OPERATION ....................................................................................................... 14

5.1 Connections and control devices..................................................................... 15

5.2 Symbols .............................................................................................................. 15

5.3 Connection of welding and return cable.......................................................... 15

5.4 Turning the power source on/off ...................................................................... 15

5.5 Fan control.......................................................................................................... 16

5.6 Overheating protection......................................................................................16

5.7 VRD (Voltage Reducing Device) ....................................................................... 16

5.8 Remote control unit ...........................................................................................16

5.9 MIG/MAG and self shielded cored wire welding .............................................16

6 MAINTENANCE.................................................................................................. 17

6.1 Inspection and cleaning ....................................................................................17

6.2 Welding torch .....................................................................................................17

7 FAULT TRACING................................................................................................ 18

8 ORDERING OF SPARE PARTS ......................................................................... 19

DIAGRAM ..................................................................................................................20

ORDERING NUMBERS .............................................................................................21

SPARE PARTS LIST.................................................................................................. 22

ACCESSORIES .........................................................................................................23

Rights reserved to alter specifications without notice.

0463 331 001 © ESAB AB 2015

1 SAFETY

1 SAFETY

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

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

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment when it

is started up

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

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could

become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinquishing equipment must be clearly marked and close at hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Do not use the power source for thawing frozen pipes.

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© ESAB AB 2015

1 SAFETY

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.

ELECTRIC SHOCK - Can kill

• Install and earth the unit in accordance with applicable standards

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

• Insulate yourself from earth and the workpiece

• Ensure your working stance is safe

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

FIRE HAZARD

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

NOISE - Excessive noise can damage hearing

• Protect your ears. Use earmuffs or other hearing protection.

• Warn bystanders of the risk

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

Read and understand the instruction manual before installing or operating.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

CAUTION!

Read and understand the instruction manual before
installing or operating.

0463 331 001

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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© ESAB AB 2015

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 can provide you with all necessary welding protection and accessories.

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© ESAB AB 2015

2 INTRODUCTION

2 INTRODUCTION

The Mig 4004i Pulse is a welding power source intended for MIG/MAG welding with pulsed
current.

The power source is intended for use with the wire feed unit Feed 3004/4804 with the control
panel U6.

ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.

2.1 Equipment

The power sources are supplied with:

• 5 m return cable with earth clamp

• 5 m mains cable with 32 Amp connector

• instruction manual for the welding power source

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© ESAB AB 2015

3 TECHNICAL DATA

3 TECHNICAL DATA

Mig 4004i Pulse

Mains voltage 380-440 V, +/- 10%, 3~ 50/60 Hz

Mains supply S

Primary current I

scmin

max

1.8 MVA

28 A

No-load power 40 W

Setting range (DC)

MIG/MAG 16 A / 15 V - 400 A / 34 V

MMA 16 A / 21 V - 400 A / 36 V

TIG 4 A / 10 V - 400 A / 34 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 0,94

Efficiency at maximum current 88 %

Open circuit voltage

VRD function inactive

VRD function active

1)

1)

55V

<35V

Operating temperature -10 to +40° C

Transportation temperature -20 to +55° C

Constant sound pressure when idling <70 db (A)

Dimensions l×w×h 610 × 250 × 445 mm

Weight 44.5 kg

Insulation class H

Enclosure class IP 23

Application classification

1)

The VRD function is explained in the instruction manual for the control panel.

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.

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© ESAB AB 2015

3 TECHNICAL DATA

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.

Application class

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

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© ESAB AB 2015

4 INSTALLATION

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

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© ESAB AB 2015

4 INSTALLATION

4.3 Mains supply

NOTE!
Mains supply requirements

High power equipment may, due to the primary current drawn from the mains
supply, influence the power quality of the grid. Therefore connection restrictions
or requirements regarding the maximum permissible mains impedance or the
required minimum supply capacity at the interface point to the public grid may
apply for some types of equipment (see technical data). In this case 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 may be
connected.

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© ESAB AB 2015

4 INSTALLATION

NOTE!

The power source can be connected for generator power. For more information,
contact authorised ESAB service personnel.

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 380-440V, +/- 10%, 3~50/60 Hz

Mains cable area

Phase current I

4G4 mm

Uin 380V 22 A

eff

2

Fuse anti-surge 25 A

Fuse CMCB-surge 32 A

Phase current I

Uin 400V 19 A

eff

Fuse anti-surge 20 A

Fuse CMCB-surge 32 A

Phase current I

Uin 440V 18 A

eff

Fuse anti-surge 20 A

Fuse CMCB-surge 32 A

NOTE!

The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. They may not be applicable in other countries: make sure
that the cable area and fuse sizes comply with the relevant national regulations.

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© ESAB AB 2015

4 INSTALLATION

Connection instruction

The power source is connected to 400V 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 picture
above. This operation has to be made by persons who have appropriate electrical
knowledge.

Change 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 picture above in which order the washers, nuts and
screws are placed.

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© ESAB AB 2015

5 OPERATION

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.

0463 331 001

NOTE!

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

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© ESAB AB 2015

5 OPERATION

5.1 Connections and control devices

1. Mains power supply switch, 0 / 1 5. Connection (+): Welding cable

2. Connection for wire feed unit or remote

control unit

3. Indicating lamp, orange, overheating 7. Fuse for supply voltage for feeder unit 42V,

4. Indicating lamp, white, power supply ON 8. Mains cable

6. Connection (-): Return cable

10A

5.2 Symbols

Remote control unit (2) Over heating (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

5.4 Turning the power source on/off

Turn the power source on by turning switch (1) to the ”1” position. Turn the power source off
by turning the switch (1) 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.

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© ESAB AB 2015

5 OPERATION

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 200 A, and at
full speed for higher currents.

5.6 Overheating protection

The welding power source has overheating 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 overheating protection resets automatically when
the temperature has fallen.

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. This is indicated by a lit VRD led on the control panel of the wire feed
unit.

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.

5.9 MIG/MAG and self shielded cored wire welding

An arc melts a continuously supplied wire. The weld pool is protected by shielding gas. For
MIG/MAG and self shielded cored wire welding, the power source is supplemented with:

• wire feed unit

• wire feed unit

• connection cable between power source and wire feed unit

• shielding gas cylinder

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© ESAB AB 2015

6 MAINTENANCE

6 MAINTENANCE

NOTE!

Regular maintenance is important for safe, reliable operation.

Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.

6.1 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
airfilter should be regularly cleaned.

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 grille.

4. Reinstall the filter.

6.2 Welding torch

Wear parts should be cleaned and replaced at regular intervals in order to achieve
trouble-free welding.

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© ESAB AB 2015

7 FAULT TRACING

7 FAULT TRACING

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

Type of fault Actions

No arc. • Check that the mains power supply

switch is turned on.

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

• Check that the correct current value is
set.

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

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

• Check the main power supply fuses.

The thermal overload trips operate frequently • Check to see whether the air filters are

clogged.

• Make sure that you are not exceeding the
rated data for the power source (i.e. that
the unit is not being overloaded).

Poor welding performance. • Check that the welding current supply

and return cables are correctly
connected.

• Check that the correct current value is
set.

• Check that the correct welding wires are
being used.

• Check the main power supply fuses.

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© ESAB AB 2015

8 ORDERING OF SPARE PARTS

8 ORDERING OF 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 said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the back cover of this
document. 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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© ESAB AB 2015

DIAGRAM

DIAGRAM

0463 331 001

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© ESAB AB 2015

ORDERING NUMBERS

ORDERING NUMBERS

Ordering number Denomination Type Note

0465 152 881 Welding power source Aristo® Mig 4004i Pulse

0459 839 071 Spare parts list

Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

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© ESAB AB 2015

SPARE PARTS LIST

SPARE PARTS LIST

Item Ordering no. Denomination

1 0462 197 001 Dust filter

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© ESAB AB 2015

ACCESSORIES

ACCESSORIES

0462 151 880

0459 839 039

Trolley

Spare parts list for trolley

0460 946 880 Stabilizer kit for counter balance (1)

0463 125 880 Trolley bracket

option when no cooling unit is assembled




0458 705 880

0458 705 882

0460 526 886

0460 526 887

0460 526 896

0460 526 897

0460 526 889

0460 526 899

0460 526 987

0460 526 996

0460 526 997

0460 526 989

Counter balance device
(includes mast and counter balance)

for 300 mm bobbin

for 440 mm bobbin

Feed 3004 U6

Feed 3004 MA23

Feed 3004 U6, with water

Feed 3004 MA23, with water

Feed 3004 MA24

Feed 3004 MA24

Feed 4804 MA23

Feed 4804 U6, with water

Feed 4804 MA23, with water

Feed 4804 MA24

0460 526 999

0463 331 001

Feed 4804 MA24, with water

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© ESAB AB 2015

ACCESSORIES

0462 300 880 Cooling unit COOL 1

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 m

10 m

15 m

25 m

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

1.7 m

5 m

10 m

15 m

25 m

35 m

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

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© ESAB AB 2015

ACCESSORIES

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

5 m

10 m

25 m

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

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

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© ESAB AB 2015

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna-Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Heist-op-den-Berg
Tel: [phone]
Fax: [phone]

BULGARIA

ESAB Kft Representative Office
Sofia
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Herlev
Tel: [phone]
Fax: [phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]

ITALY

ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: [phone]
Fax: [phone]

THE NETHERLANDS

ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel: [phone]
Fax: [phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Romania Trading SRL
Bucharest
Tel: [phone]
Fax: [phone]

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel: [phone]
Fax: [phone]

ESAB International AB
Gothenburg
Tel: [phone]
Fax: [phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

UKRAINE

ESAB Ukraine LLC
Kiev
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem-MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting
Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

AUSTRALIA

ESAB South Pacific
Archerfield BC QLD 4108
Tel: [phone]
Fax: [phone]

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
USJ
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Africa

EGYPT

ESAB Egypt
Dokki-Cairo
Tel: [phone]
Fax: [phone]

SOUTH AFRICA

ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

www.esab.com