ESAB Origo Mig 4001i User manual

Origo™, Aristo®
Instruction manual
0460 740 001 GB 20170604 Valid for: 833-xxx-xxxx, 852-xxx-xxxx
Mig 4001i

TABLE OF CONTENTS
0460 740 001 © ESAB AB 2017
1SAFETY ......................................................................................................... 4
1.1 Meaning of symbols ................................................................................. 4
1.2 Safety precautions ................................................................................... 4
2INTRODUCTION............................................................................................ 7
2.1 Equipment ................................................................................................. 7
2.2 Control panel A24..................................................................................... 7
3TECHNICAL DATA ........................................................................................ 8
4INSTALLATION.............................................................................................. 10
4.1 Lifting instructions ................................................................................... 10
4.2 Location..................................................................................................... 10
4.3 Mains supply............................................................................................. 10
5OPERATION .................................................................................................. 12
5.1 Connections and control devices ........................................................... 12
5.2 Connection of welding and return cable ................................................ 12
5.3 Turning on the power source .................................................................. 12
5.4 Fan control ................................................................................................ 13
5.5 Overheating protection ............................................................................ 13
5.6 MIG/MAG and FCAW-S welding .............................................................. 13
5.7 TIG welding ............................................................................................... 13
5.8 MMA welding............................................................................................. 14
6MAINTENANCE............................................................................................. 15
6.1 Power unit ................................................................................................. 15
6.2 Welding torch............................................................................................ 15
7TROUBLESHOOTING ................................................................................... 16
8ORDERING SPARE PARTS .......................................................................... 17
DIAGRAM ............................................................................................................. 18
ORDERING NUMBERS........................................................................................ 20
SPARE PARTS LIST............................................................................................. 21
ACCESSORIES .................................................................................................... 22
Rights reserved to alter specifications without notice.

1 SAFETY
0460 740 001 -4- © ESAB AB 2017
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
0460 740 001 -5- © ESAB AB 2017
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
0460 740 001 -6- © ESAB AB 2017
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
0460 740 001 -7- © ESAB AB 2017
2 INTRODUCTION
Mig 4001i is a welding power source intended for MIG/MAG welding, as well as for welding
with powder filled cored wire (FCAW-S), TIG welding and for welding with coated electrodes
(MMA).
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
Mig 4001i can be supplied with or without cooling unit. The cooling unit can be retro fitted.
The power source is supplied with:
• 5 m return cable with contact clamp
• 5 m mains cable with 32 Amp connector
• instruction manual for the welding power source
• instruction manual for the control panel (if applicable)
• instruction manual for the cooling unit (if applicable)
Instruction manuals in other languages can be downloaded from the Internet: www.esab.com
2.2 Control panel A24
Welding process parameters are controlled via the control panel. See the separate
instruction manual for a detailed description of the panels.

3 TECHNICAL DATA
0460 740 001 -8- © ESAB AB 2017
3 TECHNICAL DATA
Mig 4001i
Mains voltage 400 V ±10 %, 3 ~ 50/60 Hz
Mains supply Ssc min 2.2 MVA
Primary current
Imax MIG/MAG 26 A
Imax TIG 20 A
Imax MMA 27 A
No-load power demand when in energy-saving
mode 6.5 min. after welding
60 W
Setting range
MIG/MAG 20 A / 15 V - 400 A / 34 V
TIG 4A/10V-400A/26V
MMA 16A/21V-400A/36V
Permissible load at MIG/MAG
30 % duty cycle 400 A / 34 V
60 % duty cycle 320 A / 30 V
100 % duty cycle 250 A / 26.5 V
Permissible load at TIG
30 % duty cycle 400 A / 26 V
60 % duty cycle 320 A / 22.8 V
100 % duty cycle 250 A / 20 V
Permissible load at MMA
30 % duty cycle 400 A / 36 V
60 % duty cycle 320 A / 32.8 V
100 % duty cycle 250 A / 30 V
Power factor at maximum current
MIG/MAG 0.89
TIG 0.91
MMA 0.89
Efficiency at maximum current
MIG/MAG 85 %
TIG 81 %
MMA 85 %
Open-circuit voltage without VRD function 1) 91 V DC
VRD function deactivated 2) 58 V DC
VRD function activated 2) < 35 V
Operating temperature -10 to +40°C
Transportation temperature -20 to +55°C
Constant sound pressure when idling < 70 db (A)

3 TECHNICAL DATA
0460 740 001 -9- © ESAB AB 2017
Mig 4001i
Dimensions l × w × h 652 x 249 x 423 mm
with cooling unit 714 x 249 x 693 mm
Weight 43.5 kg
with cooling unit 63.5 kg
Insulation class H
Enclosure class IP23
Application class
1) Valid for power sources without VRD specification on the rating plate.
2) Valid for power sources with VRD specification on the rating plate. The VRD function is
explained in the instruction manual for the control panel.
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.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION
0460 740 001 - 10 - © ESAB AB 2017
4 INSTALLATION
The installation must be carried out by a professional.
4.1 Lifting instructions
4.2 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
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
0460 740 001 - 11 - © ESAB AB 2017
Make sure that the welding power source is connected to the correct supply voltage and that
it is protected by the correct fuse rating. A protective earth connection must be made in
accordance with regulations.

Rating plate with supply connection data
NOTE!
The welding power source is designed for connection to a
400 volt system with four conductors.
If the power source is to be used in countries with a
higher or lower supply voltage, the power source must be
connected via a safety transformer.
Recommended fuse sizes and minimum cable area
Mig 4001i
Mains voltage 400 V 3 ~ 50 Hz
Mains cable area mm24G4mm2
Phase current Ieff 16 A
Fuse
anti-surge
type C MCB

20 A
20 A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. For other regions, supply cables must be suitable for the
application and meet local and national regulations.

5 OPERATION
0460 740 001 - 12 - © ESAB AB 2017
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!
5.1 Connections and control devices
1Connection for wire feed unit or remote
control unit
4Mains power supply switch, 0 / 1 /
START
2Connection (-) MIG/MAG: Return cable
TIG: Welding torch
MMA: Return cable or welding cable
5Fuse for operating voltage, 42 V
3Connection (+) MIG/MAG: Welding
cable
TIG: Return cable
MMA: Welding cable or return cable
5.2 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 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 (+) or
negative terminal (-) depending on the type of electrode used. The connecting polarity is
stated on the electrode packaging.
5.3 Turning on the power source
Turn on the mains power by turning switch (4) to the ”START” position. Release the switch,
and it will return to the ”1” position.

5 OPERATION
0460 740 001 - 13 - © ESAB AB 2017
If the mains power supply should be interrupted while welding is in progress, and then be
restored, the power unit will remain de-energised until the switch is again turned manually to
the ”START” position.
Turn the unit off by turning the switch to the ”0” position.
Whether the mains power supply is interrupted or the power unit is switched off in the normal
manner, welding data will be stored so that it is available next time the unit is started.
5.4 Fan control
The power source has a time control that means that the fans continue to run for 6.5 minutes
after welding has stopped, and the unit switches to energy-saving mode. The fans start again
when welding restarts.
The fans run at reduced speed for welding currents up to 144 A, and at full speed for higher
currents.
5.5 Overheating protection
The welding power source has overheating protection that operates if the temperature
becomes too high. When this occurs the welding current is interrupted and a fault code is
displayed on the control panel.
The overheating protection resets automatically when the temperature has fallen.
5.6 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
• gas bottle
To ensure problem-free operation, the installation height from the cooling unit to the welding
torch must be max. 7 m. Heights in excess of this can cause problems, such as long starting
times, air bubbles, vacuums, etc.
If an installation height in excess of 7 m is required, we recommend an installation kit
comprising a non-return valve and a solenoid valve, refer to chapter "ACCESSORIES". Once
these valves have been installed, the hose package must be horizontal during the initial
startup so that everything fills with water. Then raise the wire feed unit and hose package to
the high height. Continued safe operation at installation heights of up to 12 m can now
commence.
5.7 TIG welding
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten electrode,
which does not itself melt. The weld pool and the electrode are protected by shielding gas.
For TIG welding, the welding power source is supplemented with:
• a TIG torch with gas valve
• an argon gas tube
• an argon gas regulator
• tungsten electrode

5 OPERATION
0460 740 001 - 14 - © ESAB AB 2017
”Live TIG-start”
At a ”Live TIG-start” the tungsten electrode is placed against the workpiece. When the
electrode is then lifted away from workpiece, the arc is struck at a limited current level (12 -
15 A)
5.8 MMA welding
For welding with coated electrodes, the power source is supplemented with:
• welding cable with electrode clamp

6 MAINTENANCE
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6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
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 Power unit
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on: the welding process, arc times,
placement, and the surrounding environment. It is normally sufficient to blow down the power
source with dry compressed air (reduced pressure) once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.
Replacing and cleaning the dust filter
• Release the dust filter according to the figure.
• Blow the filter clean with compressed air (reduced pressure).
• Ensure that the filter with the finest mesh is placed towards the grille.
• 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
0460 740 001 - 16 - © ESAB AB 2017
7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault Action
No arc. • Check that the mains power supply
switch is turned on.
• Check that the welding and return cables
are correctly connected.
• Check that the correct current value is
set.
• Check the mains power supply fuses.
The welding current is interrupted during
welding.
• Check whether the overloading protection
has deployed (indicated in the control
panel).
• Check the mains power supply fuses.
The overheating protection trips frequently. • Check to see whether the dust filter is
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 and return cables
are correctly connected.
• Check that the correct current value is
set.
• Check that the correct wire or electrode is
used.
• Check the mains power supply fuses.

8 ORDERING SPARE PARTS
0460 740 001 - 17 - © ESAB AB 2017
8 ORDERING 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 4001i is designed and tested in accordance with the international and European
standards EN 60974-1/-2 and 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 said standard.
Spare parts and wear parts can 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
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DIAGRAM

DIAGRAM
0460 740 001 - 19 - © ESAB AB 2017

ORDERING NUMBERS
0460 740 001 - 20 - © ESAB AB 2017
ORDERING NUMBERS
Ordering no. Denomination Type Notes
0460 455 882 Welding power source Origo™ Mig 4001i
0460 455 883 Welding power source Origo™ Mig 4001iw with cooling unit
0460 455 884 Welding power source Origo™ Mig 4001i A24 with control panel A24
0459 839 032 Spare parts list Origo™ Mig 4001i
0460 737 0 Instruction manual Control panel A22, A24
Technical documentation is available on the Internet at: www.esab.com