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).
1.2Safety 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
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.
0459 419 401
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
•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.
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.
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.
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.
Application class
The symbolindicates that the power source is designed for use in areas with increased
electrical hazard.
Mains supply, S
sc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
1) Valid for power sources without VRD specification on the rating plate.
2) Valid for power sources with VRD specification on the rating plate. The VRD function is
explained in the instruction manuals for the control panel, if the panel has that function.
Cooling unit
Cooling power50 Hz – 1.65 kW at 25 °C (77 °F) ambient
temperature and flow 1.0l/min (0.26 gal/min)
60 Hz – 1.55 kW at 25 °C (77 °F) ambient
temperature and flow 1.0l/min (0.26 gal/min)
The installation must be carried out by a professional.
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
supply and 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
scmin
TECHNICAL DATA chapter.
4.1Lifting instructions
Power sourceTrolley and power sourceTrolley2 and power source
at the interface point between the user's
scmin
. Refer to the technical data in the
4.2Placing
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
Check that the unit is connected to the correct mains power supply
voltage, and that it is protected by the correct fuse sizes. A protective
earth connection must be made, in accordance with regulations.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable areas
Mig U4000i/4000iw400 V 3~ 50 Hz
Mains voltage400 V
Mains cable area, mm
2
4G4
Phase current, I
1eff
16 A
Fuse
Anti-surge20 A
Type C MCB20 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.
4.4Terminating resistor
In order to avoid communication interference, the ends of the
CAN bus must be fitted with terminating resistors.
One end of the CAN bus is at the control panel, which has an
integral terminating resistor. The other end at the power
source must be fitted with the terminating resistor, as shown
on the right.
4.5Connection of multiple wire feed units
With control unit and wire feed units without control panel it is possible to manage up to 4
wire feed units from one power source.
It is possible to choose between the following connections:
General safety regulations for handling the equipment can be found in chapter
"SAFETY". Read through before you start using the equipment!
5.1Connections and control devices
1Connection for cooling water from the
TIG torch - RED
2Connection with ELP* for cooling water
to the TIG torch - BLUE
3Cooling water filler12 Connection for control cable to the wire
4Connection for welding current cable (+)
at MMA welding or for return cable at
TIG welding
5Connection for the remote control14 Connection for welding current to the
6Connection for return cable (-) or for
welding current cable at TIG welding
7Connection for start signal from the torch 16 Connection for cooling water from the
8Connection for gas to the TIG torch17 Fuse for supply voltage for feeder unit,
9Mains power supply switch, 0 / 1 /
START
* ELP = ESAB Logic Pump, see section 5.5
10 White indicating lamp - Power supply ON
11 Orange indicating lamp - Overheating
feed unit or to the terminating resistor
13 Connection for gas hose
wire feed unit
15 Connection for cooling water to the wire
feed unit - BLUE
wire feed unit - RED
42 V
5.2Turning on the power source
Turn on the mains power by turning switch (7) to the ”START” position. Release the switch,
and it will return to the ”1” position.
If the mains power supply should be interrupted while welding is in progress, and then be
restored, the power source will remain de-energised until the switch is again turned manually
to the ”START” position.
Turn the unit off by turning the switch to the ”0” position.
Whether in the event of a loss of power supply or of turning the power source off in the
normal manner, welding data will be stored so that it is available next time the unit is started.
5.3Fan control
The power source fans continue to run for 6,5 minutes after welding has stopped, and the
unit switches to energy-saving mode. They start again when welding restarts.
The fans run at reduced speed for welding currents up to 144 A, and at full speed for higher
currents.
5.4Overheating protection
The power source has two thermal overload trips which operate if the internal temperature
becomes too high, interrupting the welding current and lighting the orange indicating lamp on
the front of the unit. They reset automatically when the temperature has fallen.
5.5Cooling unit
To ensure problem-free operation, the installation height from the cooling unit to the welding
torch must be max. 7 m. Heights in excess of this can cause problems, such as long starting
times, air bubbles, vacuums, etc.
If an installation height in excess of 7 m is required, we recommend an installation kit
comprising a non-return valve and a solenoid valve, refer to accessories in chapter
"ACCESSORIES". Once these valves have been installed, the hose package must be
horizontal during the initial startup so that everything fills with water. Then raise the wire feed
unit and hose package to the high height. Continued safe operation at installation heights of
up to 12 m can now commence.
Water connection (TIG welding)
The cooling unit is equipped with a detection system ELP (ESAB Logic Pump) which checks
that the water hoses are connected.
The power source On/Off switch must be in the “0” position (Off) when connecting a
water-cooled TIG torch.
If a water-cooled TIG torch is connected, the water pump starts automatically when the main
On/Off switch is turned to ”START” and/or when welding starts. After welding, the pump
continues to run for 6,5 minutes, and then switches to the energy-saving mode.
Function when welding
To start welding, the welder presses the welding torch trigger switch. The power source turns
on and starts the wire feed and the cooling water pump.
To stop welding, the welder releases the welding torch trigger switch. Welding ceases, but
the cooling water pump continues to run for 6,5 minutes, after which the unit switches to
energy-saving mode.
Water flow guard (optional)
The water flow guard interrupts the welding current in the event of loss of coolant, and
displays an error message on the control panel. The water flow guard is an accessory.
5.6Remote control unit
When the remote control unit is connected, the power source and wire feed unit are in
remote control mode; the buttons and knobs are blocked. The functions can only be adjusted
via the remote unit.
If the remote control unit is not to be used, the remote control unit must be disconnected from
the power source / wire feed unit, as otherwise it will remain in remote control mode.
Regular maintenance is important for safe, reliable operation.
Only personnel with the appropriate electrical skills (authorised electricians) may remove
safety plates.
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.
6.1Daily
Carry out the following maintenance every day.
•Check that all cables and connections are fault free. Tighten if necessary and replace
any defective parts.
•Check the water level and water flow, top up with coolant if necessary.
6.2If necessary
•Regularly check that the power source is not clogged with dirt.
Clogged or blocked air inlets and outlets result in overheating.
•Clean the dust filter.
• Remove the fan grille with the dust filter (1).
• Swing out the grille (2).
• Release the dust filter (3).
• Blow the filter clean with compressed air
(reduced pressure).
• Replace the filter with the finer mesh on the
side against the grille (2) (out from the
power source).
• Replace the fan grille with the dust filter.
• Top up with coolant
ESAB's ready mixed coolant is recommended for use. See
accessories in chapter "ACCESSORIES".
• Top up with coolant until it covers half the inlet pipe.
CAUTION!
The coolant must be handled as chemical waste.
6.3Every year
Carry out the following maintenance at least once a year.
•Clean off any dirt and dust. Blow the power source clean with dry compressed air
(reduced pressure).
•Change the coolant and clean the hoses and water reservoir with clean water.
•Check seals, cables and connections. Tighten if necessary and replace any defective
parts.
Mig U4000i/4000iw are designed and tested in accordance with the international and
European standards IEC-/EN 60974-1, /-2, /-3 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.
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Spare parts and wear parts can 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.
Use of any other cooling liquid than the
prescribed one might damage the equipment.
In case of such damage, all warranty
undertakings from ESAB cease to apply.