ESAB AristoMig 4004i Pulse User manual

Aristo®
Instruction manual
0463 431 001 GB 20160218 Valid for: serial no. 551-xxx-xxx
Mig4004iPulse

TABLE OF CONTENTS
0463 431 001 © ESAB AB 2016
1 SAFETY ................................................................................................................ 4
1.1 Meaning of symbols.............................................................................................4
1.2 Safety precautions ...............................................................................................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 ...................................................................................................... 10
5 OPERATION ....................................................................................................... 14
5.1 Connections and control devices.....................................................................14
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.......................................................................................................... 15
5.6 Thermal protection.............................................................................................15
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 TROUBLESHOOTING ........................................................................................ 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
0463 431 001 -4- © ESAB AB 2016
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
Material Safety Data Sheets (MSDSs).
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 431 001 -5- © ESAB AB 2016
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 431 001 -6- © ESAB AB 2016
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 therefore 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 can provide you with all necessary welding protection and accessories.

2 INTRODUCTION
0463 431 001 -7- © ESAB AB 2016
2 INTRODUCTION
The Mig 4004i Pulse combined with U6 or U82offer a complete multi-process package
supporting MMA, TIG, MIG/MAG and pulse MIG.
The power source is intended for use with the wire feed unit Aristo® Feed 3004/4804 or
Aristo® YardFeed 2000 and the cooling unit COOL 1. Aristo® Feed 3004/4804 is available
with two operational solutions, the Aristo® U6 panel and the Aristo® U82pendant. Aristo®
YardFeed 2000 is available with the Aristo® U6 panel.
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The power source is supplied with:
• 5 m return cable with earth clamp
• instruction manual for the welding power source

3 TECHNICAL DATA
0463 431 001 -8- © ESAB AB 2016
3 TECHNICAL DATA
Mig 4004i Pulse
Mains voltage 380-460V, ±10%, 3~ 50/60 Hz
Mains supply Sscmin 5.8 MVA
Primary current Imax 19 A
No-load power 99 W
Setting range (DC)
MIG/MAG 16 A / 14.8 V - 400 A / 34 V
MMA 16 A / 20.6 V - 400 A / 36 V
TIG 4 A / 10.2 V - 400 A / 26 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 0.95
Efficiency at maximum current 89.5 %
Open circuit voltage 55 V
Operating temperature -10 to 40°C (14 to 104°F)
Transport temperature -20 to 55°C (-4 to 131°F)
Constant sound pressure when idling <70 dB (A)
Dimensions l×w×h 445 × 250 × 380 mm (24.0 × 9.8 × 15”)
Weight 45 kg (96 lbs)
Insulation class H
Enclosure class IP 23
Application classification
Mains supply, Ssc 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, 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.

3 TECHNICAL DATA
0463 431 001 -9- © ESAB AB 2016
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION
0463 431 001 - 10 - © ESAB AB 2016
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
4.3 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 Sscmin 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 Sscmin. Refer to the technical data in the
TECHNICAL DATA chapter.

4 INSTALLATION
0463 431 001 - 11 - © ESAB AB 2016
NOTE!
The power source can be powered from a generator. 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 380-460 V, +/- 10%, 3~50/60 Hz
Mains cable area 4C 10Awg (4G4 mm2)
Phase current Ieff Uin 380 V 20 A
Fuse anti-surge 20 A
Fuse CMCB-surge 25 A
Phase current Ieff Uin 400 V 19.2 A
Fuse anti-surge 20 A
Fuse CMCB-surge 25 A
Phase current Ieff Uin 415 V 18 A
Fuse anti-surge 20 A
Fuse CMCB-surge 20 A
Phase current Ieff Uin 440 V 17.6 A
Fuse anti-surge 20 A
Fuse CMCB-surge 20 A
Phase current Ieff Uin 460 V 17 A
Fuse anti-surge 20 A
Fuse CMCB-surge 20 A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. Use the power source in accordance with the relevant
national regulations.

4 INSTALLATION
0463 431 001 - 12 - © ESAB AB 2016
Installation 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 pictures above how to remove the side panel and
install the mains cable. No other cable must be attached to this connection point.

4 INSTALLATION
0463 431 001 - 13 - © ESAB AB 2016
Connection instruction
The power source is delivered with mains cable and plug connected and approved for 400 V.
If another mains voltage is required, the cable on the printed circuit board has to be moved to
the correct pin (see illustration above), and the mains cable and plug must be changed
according to relevant national regulations. This operation has to be made by persons who
have appropriate electrical knowledge. The power source must be disconnected from mains
while performing this action.

5 OPERATION
0463 431 001 - 14 - © ESAB AB 2016
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.
NOTE!
To achieve the best possible result at Mig short pulsing, the welding and return
cables must not exceed 10 m (33 ft).
5.1 Connections and control devices
1. Mains power supply switch, 0 / 1 5. Positive welding terminal: Welding cable
2. Connection for wire feed unit or remote
control unit
6. Negative welding terminal: Return cable
3. Indicating LED, thermal protection 7. Fuse (10 A) for supply voltage (42 V) for
feeder unit
4. Indicating LED, power supply ON 8. Mains cable

5 OPERATION
0463 431 001 - 15 - © ESAB AB 2016
5.2 Symbols
Remote control unit (2) Overheating (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.
Recommended maximum current values for connection set cables
Imax Cable area Cable length
450 A (60% duty cycle) 70 mm22-35m
(6.6 ft - 114.8 ft)
350 A (100% duty cycle)
550 A (60% duty cycle) 95 mm22-35m
(6.6 ft - 114.8 ft)
430 A (100% duty cycle)
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).
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.
5.5 Fan control
The power source has a time circuit, which keeps the fans running for 6.5 minutes after
welding has stopped, after that 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 150 A, and at
full speed for higher currents.
CAUTION!
The fans may start at any time to protect the power source from overheating.
5.6 Thermal protection
The welding power source has thermal 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 thermal protection resets automatically when the
temperature has fallen within normal operation temperature.

5 OPERATION
0463 431 001 - 16 - © ESAB AB 2016
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. VRD LED is lit when VRD function is activated. The VRD function
must be activated with ESAT by a qualified service technician.
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
• welding torch
• connection cable between power source and wire feed unit
• shielding gas bottle

6 MAINTENANCE
0463 431 001 - 17 - © ESAB AB 2016
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
Only persons with the appropriate electrical knowledge (authorised personnel) may remove
the safety plates to connect or carry out service, maintenance or repair work on the welding
equipment.
For information about the cooling unit see the instruction manual for the cooling unit.
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
air filter should be regularly cleaned. The filter is built of a large and a small mesh. Make sure
that the large mesh is mounted to the upmost part of the power source and the small mesh to
the innermost part of the power source.
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 grill.
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 TROUBLESHOOTING
0463 431 001 - 18 - © ESAB AB 2016
7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorised service
technician.
Type of fault Actions
No arc. • Check that the mains power supply switch
is turned on.
• Check that the mains, welding current
and return cables are correctly
connected.
• Check that the correct current value is
set.
• Check the mains power supply fuses.
Welding current is interrupted during welding • Check whether the thermal protection trip
has operated (indicated by the orange
LED on the front(3))
• Check the main power supply fuses it the
LED indicating power supply(4) is not lit.
• Check that the return cable is correctly
fastened.
The thermal protection trips 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).
• Check that the ambient temperature is not
above the one for the rated duty cycle
40°C/104°F.
Poor welding performance. • Check that the welding current 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 mains power supply fuses.
Nothing happens when the trigger on the
welding torch is pushed.
• Check the fuse on the rear part of the
power source.
• Check if the welding and return cables
are damaged.
• Check that the wire feeder works
correctly. See the wire feeder instruction
manual.

8 ORDERING OF SPARE PARTS
0463 431 001 - 19 - © ESAB AB 2016
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 mentioned standards.
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
0463 431 001 - 20 - © ESAB AB 2016
DIAGRAM