ESAB Mig 4004i User manual

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

4 INSTALLATION
0463 279 101 - 11 - © ESAB AB 2018
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 279 101 - 12 - © ESAB AB 2018
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 Mig 5004i
Mains voltage 380–440 V, ±10%, 3~50/60 Hz
Mains cable area 4G4 mm24G6 mm2
Primary current Imax Uin 380 V 27 A 35 A
Phase current I1eff Uin 380 V 21 A 21 A
Fuse anti-surge 25 A 25 A
Fuse TypeCMCB-surge 25 A 25 A
Primary current Imax Uin 400 V 26 A 34 A
Phase current I1eff Uin 400 V 20 A 21 A
Fuse anti-surge 20 A 25 A
Fuse TypeCMCB-surge 20 A 25 A
Primary current Imax Uin 440 V 24 A 32 A
Phase current I1eff Uin 440 V 19 A 20 A
Fuse anti-surge 20 A 20 A
Fuse TypeCMCB-surge 20 A 25 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
0463 279 101 - 13 - © ESAB AB 2018
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
0463 279 101 - 14 - © ESAB AB 2018
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!
NOTE!
When moving the equipment use intended handle. Never pull the cables.
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.

5 OPERATION
0463 279 101 - 15 - © ESAB AB 2018
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) 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. 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
0463 279 101 - 16 - © ESAB AB 2018
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
0463 279 101 - 17 - © ESAB AB 2018
6 MAINTENANCE
WARNING!
Disconnect power before performing maintenance.
CAUTION!
Only persons with the appropriate electrical knowledge (authorised personnel)
may remove safety plates.
CAUTION!
The product is covered by manufacturer's warranty. Any attempt to carry out
repair work by non-authorised service centers will invalidate the warranty.
NOTE!
Regular maintenance is important for safe and reliable operation.
NOTE!
Perform maintenance more often during severe dusty conditions.
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 MAINTENANCE
0463 279 101 - 18 - © ESAB AB 2018
6.2 Welding torch
Wear parts should be cleaned and replaced at regular intervals in order to achieve
trouble-free welding.

7 TROUBLESHOOTING
0463 279 101 - 19 - © ESAB AB 2018
7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorised service
technican.
Type of fault Corrective action
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
0463 279 101 - 20 - © ESAB AB 2018
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 Class A. 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 and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. 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.