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GB
Mig 4004i
Mig 5004i
Instruction manual
0463 279 001 GB 20121105 Valid for serial no. 145-xxx-xxxx, 211-xxx-xxxx
- 2 -
Turning the power source on/off
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
TOCe
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GB
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:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding and cutting
2.
The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is started up.
S no-one is unprotected when the arc is struck
3.
The workplace must:
S be suitable for the purpose
S be free from drafts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof clothing, safety gloves.
S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns.
5.
General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
WARNING
Do not use the power source for thawing frozen pipes.
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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.
S
S
S
ELECTRIC SHOCK - Can kill
S
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
S
Keep your head out of the fumes.
S
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.
S
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
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.
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Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/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
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's accessories for the product can be found on page
2.1
Equipment
The power sources are supplied with:
S
5 m return cable with earth clamp
S
5 m mains cable with 32 Amp connector
S instruction manual for the welding power source ba53de
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© ESAB AB 2011
GB
3 TECHNICAL DATA
Mains voltage
Mains supply S scmin
Mains supply Z max
Primary current I max
No-load power
Setting range (DC)
MIG/MAG
MMA
Permissible load at MIG/MAG
60 % duty cycle
80 % duty cycle
100% duty cycle
Permissible load at MMA
60 % duty cycle
80 % duty cycle
100% duty cycle
Power factor at maximum current
Efficiency at maximum current
Open circuit voltage
VRD function inactive
1)
VRD function active
1)
Operating temperature
Transportation temperature
Constant sound pressure when idling
Dimensions lxwxh
Weight
Insulation class
Enclosure class
Application classification
-
-
-
Mig 4004i
1.8 MVA
26 A
Mig 5004i
380-440 V, +/- 10%, 3
50/60 Hz
2.2 MVA
0.22
Ω
36 A
100 W
16 A/15 V - 400 A/34 V
16 A/21 V - 400 A/36 V
400 A/34 V
350 A/31.5 V
400 A/36 V
350 A/34 V
0,93
89 %
16 A/15 V - 500 A/39 V
16 A/21 V - 500 A/40 V
500 A/40 V
400 A/34 V
350 A/31.5 V
500 A/40 V
400 A/36 V
350 A/34 V
0,95
89 %
55 V
<35 V
-10 to +40
° C
-20 to +55
° C
<70 db (A)
610 x 250 x 445 mm
46 kg
H
IP 23
1)
The VRD function is explained in chapter 5.8
.
Mains supply, S sc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12
Mains supply, Z max
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.
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 designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased electrical hazard.
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GB
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
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© ESAB AB 2011
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4.3
Mains supply
Note
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the power quality of the grid. Therefore connection restrictions or requirements regarding the maximum permissible mains impedance or the required minimum supply capacity at the interface point to the public grid may apply for some types of equipment (see technical data). In this case 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 may be connected.
Note
The power source can be connected for generator power. For more information, contact authorised ESAB service personnel.
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GB
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.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable areas
Mains voltage
Mains cable area
Phase current I eff
Uin 380V
Fuse anti-surge
Fuse CMCB-surge
Phase current I eff
Uin 400V
Fuse anti-surge
Fuse CMCB-surge
Phase current I eff
Uin 440V
Fuse anti-surge
Fuse CMCB-surge
Mig 4004i
380-440V, +/- 10%, 3
4G4 mm
2
21 A
25 A
32 A
19 A
20 A
32 A
18.5 A
20 A
32 A
Mig 5004i
50/60 Hz
4G6 mm
27 A
35 A
32 A
26 A
35 A
32 A
24 A
25 A
32 A
2
NB: 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.
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Connection instruction ins-06
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 ins-07
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.
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GB
5 OPERATION
General safety regulations for handling the equipment can be found on page
4 . Read through before you start using the equipment!
WARNING
Secure the equipment - particularly if the ground is uneven or sloping.
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© ESAB AB 2011
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5.1
Connections and control devices
1 Mains power supply switch, 0 / 1
2 Connection for wire feed unit or remote control unit
3 Indicating lamp, overheating
4 Indicating lamp, power supply ON
5 Connection (+):
MIG/MAG: Welding cable
MMA: Welding cable or return cable
6 Connection (-):
MIG/MAG: Return cable
MMA: Return cable or welding cable
7 Fuse for supply voltage for feeder unit
8 Mains cable
5.2
Symbols
Remote control unit (2)
Power supply ON (4)
Over heating (3)
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.
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5.4
Turning the power source on/off
Turn the machine on by turning switch (1) to the ”1” position. Turn the machine off by turning the switch (1) to the ”0” position. Regardless the mains supply is interrupted abnormally or the machine 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:
S wire feed unit
S welding torch
S connection cable between power source and wire feed unit
S shielding gas bottle
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GB
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:
S welding cable with electrode clamp.
6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized personnel) may remove the safety plates.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the guarantee period.
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.
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© ESAB AB 2011
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6.2
Welding gun
Wear parts should be cleaned and replaced at regular intervals in order to achieve trouble-free welding.
7 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised service technican.
No arc.
Type of fault
Welding current is interrupted during welding
The thermal overload trips operate frequently
Poor welding performance.
Actions
S Check that the mains power supply switch is turned on.
S Check that the welding current supply and return cables are correctly connected.
S Check that the correct current value is set.
S Check whether the thermal overload trip has operated
(indicated by the orange lamp on the front)
S Check the main power supply fuses.
S Check to see whether the air filters are clogged.
S Make sure that you are not exceeding the rated data for the power source (i.e. that the unit is not being overloaded).
S Check that the welding current supply and return cables are correctly connected.
S Check that the correct current value is set.
S Check that the correct welding wires are being used.
S Check the main power supply fuses.
8 ORDERING OF SPARE PARTS
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. It is the obligation of the service unit which has carried out the service or repair work to make sure that the pro duct still conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication.
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© ESAB AB 2011
Diagram ba53e
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© ESAB AB 2011
Mig 4004i, Mig 5004i
Order number
Ordering no.
Denomination
0465 154 880 Welding power source
0465 155 880 Welding power source
0459 839 071 Spare parts list
0740 800 217 Service manual
0462 305 001 Instruction manual
0444 408 101 Instruction manual
Mig 4004i
Mig 5004i
Type
Mig 4004i, Mig 5004i
Mig 4004i, Mig 5004i
Cooling unit COOL 1
Feed unit Feed 3004/4804
Technical documentation is available on the Internet at www.esab.com
Notes ba53o
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© ESAB AB 2011
Mig 4004i, Mig 5004i
Spare parts list
Item Ordering no.
1
Denomination
0462 197 001 Dust filter ins-05 ba53s
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© ESAB AB 2011
Mig 4004i, Mig 5004i
Accessories
Trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare parts list for trolley . . . . . . . . . . . . . . . . . . .
0462 151 880
0459 839 039
Trolley bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .
option when no cooling unit is assembled
0463 125 880
Feed 3004 MA23 . . . . . . . . . . . . . . . . . . . . . . . . .
Feed 3004 MA23, with water . . . . . . . . . . . . . .
Feed 3004 MA24 . . . . . . . . . . . . . . . . . . . . . . . . .
Feed 3004 MA24, with water . . . . . . . . . . . . . .
Feed 4804 MA23 . . . . . . . . . . . . . . . . . . . . . . . . .
Feed 4804 MA23, with water . . . . . . . . . . . . . .
Feed 4804 MA24 . . . . . . . . . . . . . . . . . . . . . . . . .
Feed 4804 MA24, with water . . . . . . . . . . . . . .
0460 526 887
0460 526 897
0460 526 889
0460 526 899
0460 526 987
0460 526 997
0460 526 989
0460 526 999
Cooling unit COOL 1 . . . . . . . . . . . . . . . . . . . . . 0462 300 880 ba53a
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© ESAB AB 2011
Mig 4004i, Mig 5004i
Connection set, 70 mm
2
10 pole cable plug - 10 pole cable socket
1.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 m . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection set water, 70 mm
2
10 pole cable plug - 10 pole cable socket
1.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote control unit MTA1 CAN . . . . . . . . . . .
MIG/MAG: wire feed speed and voltage
MMA: current and arc force
TIG: current, pulse and background current
0459 528 780
0459 528 781
0459 528 782
0459 528 783
0459 528 784
0459 528 785
0459 528 790
0459 528 791
0459 528 792
0459 528 793
0459 528 794
0459 528 795
0459 491 880
Remote control unit AT1 CAN . . . . . . . . . . . .
MMA and TIG: current
0459 491 883
Remote control unit AT1 CF CAN . . . . . . . . .
MMA and TIG: rough and fine setting of current
0459 491 884 ba53a
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© ESAB AB 2011
Mig 4004i, Mig 5004i
Remote control cable 10 pole - 4 pole
5m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0459 960 880
0459 960 881
0459 960 882
For more information of the accessories contact the nearest ESAB agency.
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© ESAB AB 2011
NOTES
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- 23 notes
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone numbers to our distributors in other countries, please visit our home page www.esab.com
www.esab.com
© ESAB AB 110915
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