ESAB Retrofit Aristo Mig 4004i WeldCloud User manual

Aristo®
Instruction manual
0463 331 001 GB 20150108 Valid for: 240-xxx-xxxx
Mig 4004i Pulse

TABLE OF CONTENTS
0463 331 001 © ESAB AB 2015
1 SAFETY ................................................................................................................ 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 ...................................................................................................... 11
5 OPERATION ....................................................................................................... 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 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 FAULT TRACING................................................................................................ 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 331 001 -4- © ESAB AB 2015
1 SAFETY
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
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 extinquishing equipment must be clearly marked and close at hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Do not use the power source for thawing frozen pipes.

1 SAFETY
0463 331 001 -5- © ESAB AB 2015
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the unit in accordance with applicable standards
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from earth and the workpiece
• Ensure your working stance is safe
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
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Read and understand the instruction manual before
installing or operating.
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.

1 SAFETY
0463 331 001 -6- © ESAB AB 2015
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 331 001 -7- © ESAB AB 2015
2 INTRODUCTION
The Mig 4004i Pulse is a welding power source intended for MIG/MAG welding with pulsed
current.
The power source is intended for use with the wire feed unit Feed 3004/4804 with the control
panel U6.
ESAB's 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 331 001 -8- © ESAB AB 2015
3 TECHNICAL DATA
Mig 4004i Pulse
Mains voltage 380-440 V, +/- 10%, 3~ 50/60 Hz
Mains supply Sscmin 1.8 MVA
Primary current Imax 28 A
No-load power 40 W
Setting range (DC)
MIG/MAG 16 A / 15 V - 400 A / 34 V
MMA 16A/21V-400A/36V
TIG 4A/10V-400A/34V
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 0,94
Efficiency at maximum current 88 %
Open circuit voltage
VRD function inactive1) 55V
VRD function active1) <35V
Operating temperature -10 to +40° C
Transportation temperature -20 to +55° C
Constant sound pressure when idling <70 db (A)
Dimensions l×w×h 610 × 250 × 445 mm
Weight 44.5 kg
Insulation class H
Enclosure class IP 23
Application classification
1) 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.

3 TECHNICAL DATA
0463 331 001 -9- © ESAB AB 2015
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 331 001 - 10 - © ESAB AB 2015
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