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.