ESAB Mig 4004i, Mig 5004i User manual

Category
Welding System
Type
User manual

This manual is also suitable for

ESAB Mig 4004i, Mig 5004i are versatile welding power sources suitable for MIG/MAG, FCAW-S, and MMA welding. They offer precise welding control with adjustable voltage and wire feed speed, enabling you to tackle various welding projects. These machines prioritize safety with features like VRD (Voltage Reducing Device) to minimize the risk of electric shock. Their compact design and portability make them ideal for workshops and construction sites. Additionally, they come equipped with a 5-meter return cable and a mains cable for easy setup.

ESAB Mig 4004i, Mig 5004i are versatile welding power sources suitable for MIG/MAG, FCAW-S, and MMA welding. They offer precise welding control with adjustable voltage and wire feed speed, enabling you to tackle various welding projects. These machines prioritize safety with features like VRD (Voltage Reducing Device) to minimize the risk of electric shock. Their compact design and portability make them ideal for workshops and construction sites. Additionally, they come equipped with a 5-meter return cable and a mains cable for easy setup.

Instruction manual
0463 279 001 GB 20151211 Valid for: 145-xxx-xxxx, 211-xxx-xxxx
Mig 4004i, Mig 5004i
TABLE OF CONTENTS
0463 279 001 © ESAB AB 2015
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 Remote control unit ........................................................................................... 16
5.8 VRD (Voltage Reducing Device) .......................................................................16
5.9 MIG/MAG and FCAW-S welding ........................................................................16
5.10 MMA 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.
1 SAFETY
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© ESAB AB 2015
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 extinguishing 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.
1 SAFETY
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© ESAB AB 2015
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.
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.
1 SAFETY
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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.
2 INTRODUCTION
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© ESAB AB 2015
2 INTRODUCTION
The Mig 4004i and Mig 5004i are welding power sources intended for MIG/MAG welding, as
well as for welding with powder filled cored wire (FCAW-S) and for welding with coated
electrodes (MMA).
The power sources are intended for use with the wire feed unit Feed 3004/4804.
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
3 TECHNICAL DATA
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© ESAB AB 2015
3 TECHNICAL DATA
Mig 4004i Mig 5004i
Mains voltage 380-440 V, +/- 10%,
3~ 50/60 Hz
380-440 V, +/- 10%,
3~ 50/60 Hz
Mains supply S
scmin
1.8 MVA 2.2 MVA
Mains supply Z
max
- 0.22
Primary current I
max
26 A 36 A
No-load power in energy-saving
mode 6.5 min. after welding 40 W 40 W
Setting range
MIG/MAG 16 A/15 V - 400 A/34 V 16 A/15 V - 500 A/39 V
MMA 16 A/20 V - 400 A/36 V 16 A/21 V - 500 A/40 V
Permissible load at MIG/MAG
60 % duty cycle 400 A/34 V 500 A/40 V
80 % duty cycle - 400 A/34 V
100% duty cycle 350 A/31.5 V 350 A/31.5 V
Permissible load at MMA
60 % duty cycle 400 A/36 V 500 A/40 V
80 % duty cycle - 400 A/36 V
100% duty cycle 350 A/34 V 350 A/34 V
Power factor at maximum current 0.93 0.95
Efficiency at maximum current 89 % 89 %
Open-circuit voltage
VRD function inactivate
1)
55 V 55 V
VRD function active
1)
<35 V <35 V
Operating temperature -10 to +40°C -10 to +40°C
Transportation temperature -20 to +55°C -20 to +55°C
Constant sound pressure when
idling
<70 db (A) <70 db (A)
Dimensions l × w × h 610 × 250 × 445 mm 610 × 250 × 445 mm
Weight 46 kg 46 kg
Insulation class H H
Enclosure class IP 23 IP 23
Application class
1)
The VRD function is explained in chapter "VRD (Voltage Reducing Device)"
Mains supply, S
sc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
Mains supply, Z
max
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
3 TECHNICAL DATA
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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.
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.
4 INSTALLATION
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© ESAB AB 2015
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 INSTALLATION
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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
scmin
at the interface point between the user'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
. Refer to the technical data in the
TECHNICAL DATA chapter.
4 INSTALLATION
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© ESAB AB 2015
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 Mig 5004i
Mains voltage 380-440V, +/- 10%, 3~50/60 Hz
Mains cable area
4G4 mm
2
4G6 mm
2
Phase current I
eff
Uin 380 V 21 A 27 A
Fuse anti-surge 25 A 35 A
Fuse TypeCMCB-surge 32 A 32 A
Phase current I
eff
Uin 400 V 19 A 26 A
Fuse anti-surge 20 A 35 A
Fuse TypeCMCB-surge 32 A 32 A
Phase current I
eff
Uin 440 V 18.5 A 24 A
Fuse anti-surge 20 A 25 A
Fuse TypeCMCB-surge 32 A 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.
4 INSTALLATION
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© ESAB AB 2015
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.
5 OPERATION
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© ESAB AB 2015
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.
5 OPERATION
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5.1 Connections and control devices
1. Mains power supply switch, 0 / 1 5. Connection (+): MIG/MAG: Welding cable
MMA: Welding cable or return cable
2. Connection for wire feed unit or remote
control unit
6. Connection (-): MIG/MAG: Return cable
MMA: Return cable or welding cable
3. Indicating lamp, overheating 7. Fuse for supply voltage for feeder unit
4. Indicating lamp, power supply ON 8. Mains cable
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. The output to which the welding cable is connected
depends on the welding method or type of electrode used.
Connect the return cable to the other output on the power source. Secure the return cable's
contact clamp to the work piece and ensure that there is good contact be tween the work
piece and the output for the return cable on the power source.
For MMA welding, the welding cable can be connected to the positive terminal (+) or
negative terminal (-) depending on the type of electrode used. The connecting polar ity is
stated on the electrode packaging.
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
5 OPERATION
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© ESAB AB 2015
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, 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 Remote control unit
The remote control unit must be connected to the remote control unit socket on the power
source before activation. When the remote control unit is activated, the panel on the wire
feed unit is inactive.
5.8 VRD (Voltage Reducing Device)
The VRD function ensures that the open-circuit voltage does not exceed 35V when welding
is not being carried out. This is indicated by a lit VRD LED on the panel.
The VRD function is blocked when the system senses that welding has started.
If the VRD function is activated and the open-circuit voltage exceeds the 35V limit, this is
indicated by an error message (16) appearing in the display and welding cannot be started
whilst the error message is displayed.
5.9 MIG/MAG and FCAW-S welding
An arc melts a continuously supplied wire. The weld pool is protected by shielding gas. For
MIG/MAG and FCAW-S welding, the power source is supplemented with:
wire feed unit
welding torch
connection cable between power source and wire feed unit
shielding gas bottle
5.10 MMA welding
MMA welding may also be referred to as welding with coated electrodes. Striking the arc
melts the electrode and its coating forms protective slag.
For welding with coated electrodes, the power source is supplemented with:
welding cable with electrode clamp.
6 MAINTENANCE
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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.
7 FAULT TRACING
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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.
8 ORDERING OF SPARE PARTS
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© ESAB AB 2015
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, Mig 5004i 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.
DIAGRAM
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DIAGRAM
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  • Page 24 24
  • Page 25 25
  • Page 26 26

ESAB Mig 4004i, Mig 5004i User manual

Category
Welding System
Type
User manual
This manual is also suitable for

ESAB Mig 4004i, Mig 5004i are versatile welding power sources suitable for MIG/MAG, FCAW-S, and MMA welding. They offer precise welding control with adjustable voltage and wire feed speed, enabling you to tackle various welding projects. These machines prioritize safety with features like VRD (Voltage Reducing Device) to minimize the risk of electric shock. Their compact design and portability make them ideal for workshops and construction sites. Additionally, they come equipped with a 5-meter return cable and a mains cable for easy setup.

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