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