Mig 4004i Mig 5004i - · PDF fileThe Mig 4004i and Mig 5004i are welding power sources intended for MIG/MAG welding, as well as for welding with powder filled cored wire ... Mig 4004i,

GB

Valid for serial no. 145-xxx-xxxx, 211-xxx-xxxx0463 279 001 GB 20121105

Mig 4004iMig 5004i

Instruction manual

- 2 -

- 3 -TOCe

Rights reserved to alter specifications without notice.

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

2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Lifting instruction 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Mains supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Connections and control devices 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Symbols 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Connection of welding and return cable 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Turning the power source on/off 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Fan control 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Overheating protection 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Remote control unit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 VRD (Voltage Reducing Device) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 MIG/MAG and FCAW-S welding 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 MMA welding 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Inspection and cleaning 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Welding gun 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 FAULT TRACING 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING OF SPARE PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDER NUMBER 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS LIST 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on ornear the equipment observes all the relevant safety precautions. Safety precautions must meet therequirements that apply to this type of equipment. The following recommendations should beobserved 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 theequipment. Incorrect operation of the equipment may lead to hazardous situations which can resultin 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

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

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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WARNING

Read and understand the instruction manual before installing or operating.

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

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 zoneand 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.

PROTECT YOURSELF AND OTHERS!

CAUTION

This product is solely intended for arc welding.

CAUTION

Read and understand the instruction manual beforeinstalling or operating.

CAUTION

Class A equipment is not intended for use in residential locations wherethe electrical power is provided by the public low-voltage supply system.There may be potential difficulties in ensuring electromagneticcompatibility of class A equipment in those locations, due to conductedas well as radiated disturbances.

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Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and ElectronicEquipment and its implementation in accordance with national law, electrical and/orelectronic equipment that has reached the end of its life must be disposed of at arecycling facility.

As the person responsible for the equipment, it is your responsibility to obtaininformation 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

The Mig 4004i and Mig 5004i are welding power sources intended for MIG/MAGwelding, as well as for welding with powder filled cored wire (FCAW-S) and forwelding 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 on page 20.

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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3 TECHNICAL DATA

Mig 4004i Mig 5004i

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

Mains supply Sscmin

Mains supply Zmax

1.8 MVA

-

2.2 MVA

0.22 Ω

Primary current Imax 26 A 36 A

No-load power 100 W

Setting range (DC)MIG/MAGMMA

16 A/15 V - 400 A/34 V16 A/21 V - 400 A/36 V

16 A/15 V - 500 A/39 V16 A/21 V - 500 A/40 V

Permissible load at MIG/MAG60 % duty cycle 80 % duty cycle 100% duty cycle

400 A/34 V-350 A/31.5 V

500 A/40 V400 A/34 V350 A/31.5 V

Permissible load at MMA60 % duty cycle 80 % duty cycle 100% duty cycle

400 A/36 V-350 A/34 V

500 A/40 V400 A/36 V350 A/34 V

Power factor at maximum current 0,93 0,95

Efficiency at maximum current 89 % 89 %

Open circuit voltageVRD function inactive1)

VRD function active1)55 V

<35 V

Operating temperature -10 to +40°C

Transportation temperature -20 to +55°C

Constant sound pressure whenidling

<70 db (A)

Dimensions lxwxh 610 x 250 x 445 mm

Weight 46 kg

Insulation class H

Enclosure class IP 23

Application classification

1) The VRD function is explained in chapter 5.8.

Mains supply, Ssc minMinimum 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 ata certain load without overloading. The duty cycle is valid for 40°C.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solidobjects or water. Equipment marked IP23 is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increasedelectrical 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 maycause 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 arenot obstructed.

4.2 Lifting instruction

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4.3 Mains supply

Note

Mains supply requirements

High power equipment may, due to the primary current drawn from the mains supply, influence thepower quality of the grid. Therefore connection restrictions or requirements regarding themaximum permissible mains impedance or the required minimum supply capacity at the interfacepoint to the public grid may apply for some types of equipment (see technical data). In this case itis the responsibility of the installer or user of the equipment to ensure, by consultation with thedistribution network operator if necessary, that the equipment may be connected.

Note

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

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Check that the unit is connected to the correct mains power supply voltage, and thatit is protected by the correct fuse size. 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 4004i Mig 5004i

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

Mains cable area 4G4 mm2 4G6 mm2

Phase current IeffUin 380V 21 A 27 A

Fuse anti-surgeFuse CMCB-surge

25 A32 A

35 A32 A

Phase current IeffUin 400V 19 A 26 A


20 A32 A

35 A32 A

Phase current IeffUin 440V 18.5 A 24 A


20 A32 A

25 A32 A

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

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Connection instruction

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The power source is connected to 400V from factory. If another mains voltage isrequired, the cable on the printed circuit board has to be moved and placed on thecorrect pin. See picture above. This operation has to be made by persons who haveappropriate electrical knowledge.

Change of mains cable

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If the mains cable needs to be changed, the earth connection to the bottom platemust be made in a correct way. See from the picture above in which order thewashers, nuts and screws are placed.

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5 OPERATION

General safety regulations for handling the equipment can be found onpage 4. Read through before you start using the equipment!

WARNING

Secure the equipment - particularly if theground is uneven or sloping.

AH

0935

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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 cableis 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 returncable'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.

For MMA welding, the welding cable can be connected to the positive terminal (+) ornegative terminal (-) depending on the type of electrode used. The connecting polarity is stated on the electrode packaging.

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5.4 Turning the power source on/off

Turn the machine on by turning switch (1) to the ”1” position. Turn the machine off byturning the switch (1) to the ”0” position. Regardless the mains supply is interruptedabnormally or the machine is switched off in the normal manner, the welding data willbe 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 minutesafter welding has stopped, then the unit switches to energy-saving mode. The fansstart again when welding begins. The fans run at reduced speed for welding currentsup 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 theinternal temperature becomes too high. When this occurs the welding current isblocked and a fault code is displayed on the control panel. The overheatingprotection 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 thepower source before activation. When the remote control unit is activated, the panelon 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 whenwelding 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 weldingcannot 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 shieldinggas. 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

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5.10 MMA welding

MMA welding may also be referred to as welding with coated electrodes. Striking thearc 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

Regular maintenance is important for safe, reliable operation.

Only those persons who have appropriate electrical knowledge (authorizedpersonnel) may remove the safety plates.

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts anywork to rectify any faults in the product during the guarantee 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 atreduced pressure. More frequently in dirty environments.

Otherwise the air inlet/outlet may become blocked and cause overheating. To avoidthis, 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.

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6.2 Welding gun

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

7 FAULT TRACING

Try these recommended checks and inspections before sending for an authorisedservice 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 arecorrectly connected.

� Check that the correct current value is set.

Welding current is interruptedduring 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 thepower source (i.e. that the unit is not being overloaded).

Poor welding performance. � Check that the welding current supply and return cables arecorrectly 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

Repair and electrical work should be performed by an authorised ESAB servicetechnician. Use only ESAB original spare and wear parts.

Mig 4004i, Mig 5004i is designed and tested in accordance with the international andEuropean standards IEC/EN 60974-1 and IEC/EN 60974-10. It is the obligation of theservice 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 last page ofthis publication.

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© ESAB AB 2011

Diagram

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Mig 4004i, Mig 5004i

© ESAB AB 2011

Order number

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Ordering no. Denomination Type Notes

0465 154 880 Welding power source Mig 4004i

0465 155 880 Welding power source Mig 5004i

0459 839 071 Spare parts list Mig 4004i, Mig 5004i

0740 800 217 Service manual Mig 4004i, Mig 5004i

0462 305 001 Instruction manual Cooling unit COOL 1

0444 408 101 Instruction manual Feed unit Feed 3004/4804

Technical documentation is available on the Internet at www.esab.com


© ESAB AB 2011

Spare parts list

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Item Ordering no. Denomination

1 0462 197 001 Dust filter

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© ESAB AB 2011

Accessories

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Trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare parts list for trolley . . . . . . . . . . . . . . . . . . .

0462 151 880

0459 839 039

Trolley bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .

option when no cooling unit is assembled

0463 125 880

Feed 3004 MA23 . . . . . . . . . . . . . . . . . . . . . . . . .

Feed 3004 MA23, with water . . . . . . . . . . . . . .

Feed 3004 MA24 . . . . . . . . . . . . . . . . . . . . . . . . .


Feed 4804 MA23 . . . . . . . . . . . . . . . . . . . . . . . . .


Feed 4804 MA24 . . . . . . . . . . . . . . . . . . . . . . . . .


0460 526 887

0460 526 897

0460 526 889

0460 526 899

0460 526 987

0460 526 997

0460 526 989

0460 526 999

Cooling unit COOL 1 . . . . . . . . . . . . . . . . . . . . . 0462 300 880


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Connection set, 70 mm2

10 pole cable plug - 10 pole cable socket

1.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection set water, 70 mm2

10 pole cable plug - 10 pole cable socket

1.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0459 528 780

0459 528 781

0459 528 782

0459 528 783

0459 528 784

0459 528 785

0459 528 790

0459 528 791

0459 528 792

0459 528 793

0459 528 794

0459 528 795

Remote control unit MTA1 CAN . . . . . . . . . . .

MIG/MAG: wire feed speed and voltage

MMA: current and arc force

TIG: current, pulse and background current

0459 491 880

Remote control unit AT1 CAN . . . . . . . . . . . .

MMA and TIG: current

0459 491 883

Remote control unit AT1 CF CAN . . . . . . . . .

MMA and TIG: rough and fine setting of current

0459 491 884


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Remote control cable 10 pole - 4 pole

5m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0459 960 880

0459 960 881

0459 960 882

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

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www.esab.com

110915© ESAB AB

ESAB subsidiaries and representative offices

Europe

AUSTRIAESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUMS.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28

BULGARIAESAB Kft Representative OfficeSofiaTel/Fax: +359 2 974 42 88

THE CZECH REPUBLICESAB VAMBERK s.r.o. VamberkTel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARKAktieselskabet ESAB HerlevTel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLANDESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCEESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANYESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

GREAT BRITAINESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03

ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74

HUNGARYESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALYESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01

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Documents

Mig 4004i Mig 5004i - · PDF fileThe Mig 4004i and Mig 5004i are welding power sources intended for MIG/MAG welding, as well as for welding with powder filled cored wire ... Mig 4004i,