ESAB Mig 4004i Bedienungsanleitung

Instruction manual

0463 279 101 GB 20180831 Valid for: serial no. 806-xxx-xxxx

Mig 4004i, Mig 5004i

TABLE OF CONTENTS

0463 279 101 © ESAB AB 2018

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

1.1 Meaning of symbols ............................................................................... 4

1.2 Safety precautions ................................................................................. 4

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

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

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

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

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

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

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

5OPERATION ................................................................................................ 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

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

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

6.2 Welding torch.......................................................................................... 18

7TROUBLESHOOTING ................................................................................. 19

8ORDERING OF SPARE PARTS .................................................................. 20

DIAGRAM ............................................................................................................ 21

ORDERING NUMBERS....................................................................................... 22

WEAR PARTS...................................................................................................... 23

ACCESSORIES ................................................................................................... 24

Rights reserved to alter specifications without notice.

1 SAFETY

0463 279 101 -4- © ESAB AB 2018

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of

life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and Safety

Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

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

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

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

when it is started up

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

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

0463 279 101 -5- © ESAB AB 2018

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.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY

0463 279 101 -6- © ESAB AB 2018

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only

qualified people remove covers for maintenance and troubleshooting as

necessary. Reinstall panels or covers and close doors when service is

finished and before starting engine.

• Stop engine before installing or connecting unit.

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

FIRE HAZARD

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

materials nearby.

• Do not use on closed containers.

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.

2 INTRODUCTION

0463 279 101 -7- © ESAB AB 2018

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 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

0463 279 101 -8- © ESAB AB 2018

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

Primary current I max

MMA 26 A 36 A

MIG 25 A 35 A

No-load power (idle state) 91 W 91 W

Setting range

MIG/MAG 16 A/14.8 V - 400 A/36.0 V 16 A/14.8 V - 500 A/39.0 V

MMA 16 A/20.8 V - 400 A/34.0 V 16 A/20.8 V - 500 A/40.0 V

Permissible load at MIG/MAG

40% duty cycle - 500 A/39.0 V

60% duty cycle 400 A/34.0 V 420 A/35.0 V

100% duty cycle 350 A/31.5 V 350 A/31.5 V

Permissible load at MMA

40% duty cycle - 500 A/40.0 V

60% duty cycle 400 A/36.0 V 420 A/36.8 V

100% duty cycle 350 A/34.0 V 350 A/34.0 V

Power factor at maximum current 0.93 0.94

Efficiency at maximum current

MMA 90% 90%

MIG 89% 90%

Apparent power at maximum

current

17.2 kVA 23.6 kVA

Active power at maximum

current

16.0 kW 22.2 kW

Ssc min (MVA) 6.1 MVA 8.5 MVA

No-load voltage

VRD function inactivate (U0)1) 55 V 55 V

VRD function active (Ur)1) 25 V 25 V

Working temperature -10 to +40°C -10 to +40°C

Transportation temperature -20 to +55°C -20 to +55°C

Continual sound pressure at

no-load

<70 db (A) <70 db (A)

Dimensions l × w × h 610 × 250 × 445 mm 610 × 250 × 445 mm

Weight (in delivery mode) 46 kg 46 kg

Isolation class transformer H H

Enclosure class IP23 IP23

Application class

3 TECHNICAL DATA

0463 279 101 -9- © ESAB AB 2018

1) The VRD function is explained in chapter "VRD (Voltage Reducing Device)"

Mains supply, Ssc min

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

Mains supply, Zmax

Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP23 is intended for indoor and outdoor use.

Application class

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

electrical hazard.

4 INSTALLATION

0463 279 101 - 10 - © ESAB AB 2018

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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