ESAB | Mig 4004i Pulse WeldCloud™ | Instruction manual | ESAB Mig 4004i Pulse WeldCloud™ User manual

ESAB Mig 4004i Pulse WeldCloud™ User manual
Aristo®
Mig 4004i Pulse,
Mig 4004i Pulse WeldCloud™
380-460 V
Instruction manual
0463 380 131 US 20161014
Valid for: serial no. 419-, 528-, 627-xxx-xxxx
TABLE OF CONTENTS
1
2
SAFETY ...........................................................................................................
3
1.1
Meaning of symbols ......................................................................................
3
1.2
Safety precautions ........................................................................................
3
1.3
User responsibility ........................................................................................
7
INTRODUCTION .............................................................................................. 10
2.1
Equipment ......................................................................................................
10
3
TECHNICAL DATA ......................................................................................... 11
4
INSTALLATION................................................................................................ 13
5
6
4.1
Location..........................................................................................................
13
4.2
Lifting instruction ..........................................................................................
13
4.3
Electrical supply ............................................................................................
13
OPERATION .................................................................................................... 17
5.1
Connections and control devices ................................................................
18
5.2
Symbols .........................................................................................................
19
5.3
Connection of welding and return cable .....................................................
19
5.4
Turning the power source on/off..................................................................
19
5.5
Fan control .....................................................................................................
19
5.6
Thermal protection ........................................................................................
20
5.7
VRD (Voltage Reducing Device)...................................................................
20
5.8
Remote control unit.......................................................................................
20
5.9
Arc voltage feedback ....................................................................................
20
MAINTENANCE ............................................................................................... 21
6.1
7
21
FAULT TRACING............................................................................................. 22
7.1
8
Inspection and cleaning................................................................................
Error codes for Mig 4004i WeldCloud™ ......................................................
23
ORDERING SPARE PARTS ............................................................................ 24
DIAGRAM ............................................................................................................... 25
ORDERING NUMBERS .......................................................................................... 27
SPARE PARTS LIST............................................................................................... 28
ACCESSORIES ...................................................................................................... 29
Rights reserved to alter specifications without notice.
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© ESAB AB 2016
1 SAFETY
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, make sure you read and understand the
instruction manual and follow all labels, employer's safety
practices, and Material Safety Data Sheets (MSDSs).
1.2 Safety precautions
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in the Additional Safety Information section.
Before performing any installation or operating procedures, be sure to read and
follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe the Safety Precautions could
result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require
hearing protection. The arc, like the sun, emits ultraviolet (UV) and
other radiation and can injure the skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes and equipment is
essential to prevent accidents. Therefore:
1.
2.
3.
Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
Always wear safety glasses with side shields in any work area, even if welding helmets,
face shields and goggles are also required.
Use a face shield fitted with the correct filter and cover plates to protect your eyes, face,
neck and ears from sparks and rays of the arc when operating or observing operations.
Warn bystanders not to look at the arc and not to expose themselves to the rays of the
electric-arc or hot metal.
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1 SAFETY
4.
5.
6.
7.
Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
high-topped shoes, and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.
Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of the
clothing.
Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly for long distances. Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS
The heat from flames and arcs can start fires. Hot slag or sparks can
also cause fires and explosions. Therefore:
1.
2.
3.
4.
5.
6.
7.
Protect yourself and others from flying sparks and hot metal.
Move all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.
Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.
Have fire extinguishing equipment handy for instant use, such as a garden hose, water
pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.
Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
After completing work, inspect the work area to make sure there are no hot sparks or
hot metal that could cause a fire later. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact between live electrical parts and earth can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:
1.
2.
3.
4.
5.
6.
7.
8.
Be sure the power source frame (chassis) is connected to the earth system of the input
power.
Connect the workpiece to a good electrical earth.
Connect the work cable to the workpiece. A poor or missing connection can expose you
or others to a fatal shock.
Use well-maintained equipment. Replace worn or damaged cables.
Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
Make sure that all parts of your body are insulated from both the work piece and from
the ground.
Do not stand directly on metal or the ground while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
Put on dry, hole-free gloves before turning on the power.
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1 SAFETY
9.
10.
Turn off the power, before removing your gloves.
Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a earth cable.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor
causes localised Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:
1.
2.
3.
Welders with pacemakers fitted should consult their doctor 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 minimise exposure to EMF:
a)
Route the electrode and work cables together. Secure them with tape when
possible.
b)
Never coil the torch or work cable around your body.
c)
Do not place your body between the torch and work cables. Route cables on the
same side of your body.
d)
Connect the work cable to the workpiece as close as possible to the area being
welded.
e)
Keep the welding power source and cables as far away from your body as
possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therefore:
1.
2.
3.
4.
5.
6.
Keep your head out of the fumes. Do not breathe the fumes and gases.
Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe in the fumes from these materials.
Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other
irritant gases.
If you develop momentary eye, nose or throat irritation while operating, this is an
indication that the ventilation is not adequate. Stop work and take the necessary steps
to improve ventilation in the work area. Do not continue to operate if physical discomfort
persists.
Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
WARNING: This product when used for welding or cutting, produces fumes or gases
that contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:
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1 SAFETY
1.
2.
3.
4.
Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.
Always secure cylinders in an upright position, by chain or strap, to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause
injury. Therefore:
1.
2.
3.
4.
5.
6.
Keep all doors, panels, guards, and covers closed and securely in place.
Stop the engine or drive systems before installing or connecting a unit.
Have only qualified people remove covers for maintenance and troubleshooting as
necessary
To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
Keep hands, hair, loose clothing and tools away from moving parts.
Reinstall panels or covers and close doors when service is finished and before starting
engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
•
•
•
•
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Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or
any other accessories.
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to extend
beyond opposite side of unit.
Keep cables and cords away from moving vehicles when working from an
aerial location.
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1 SAFETY
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1.
2.
3.
4.
5.
6.
Always have qualified personnel perform the installation, troubleshooting
and maintenance work. Do not perform any electrical work unless you are
qualified to perform such work.
Before performing any maintenance work inside a power source,
disconnect the power source from the incoming electrical power.
Maintain cables, earthing wire, connections, power cord and power supply
in safe working order. Do not operate any equipment in faulty condition.
Do not abuse any equipment or accessories. Keep equipment away from
heat sources such as furnaces, wet conditions such as water puddles, oil
or grease, corrosive atmospheres and inclement weather.
Keep all safety devices and cabinet covers in position and in good repair.
Use equipment only for its intended purpose. Do not modify it in any
manner.
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices
for Arc Welding, Cutting and Gouging.” Form 52-529.
The following publications are recommended to you:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding"
AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"
AWS SP - "Safe Practices" - Reprint, Welding Handbook
ANSI/AWS F4.1 - "Recommended Safe Practices for Welding and Cutting
of Containers That Have Held Hazardous Substances"
OSHA 29 CFR 1910 - "Safety and Health Standards"
CSA W117.2 - "Code for Safety in Welding and Cutting"
NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other
Hot Work"
CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases
in Cylinders”
ANSI Z87.1, "Occupational and Educational Personal Eye and Face
Protection Devices"
1.3 User responsibility
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
could result in injury to the operator and damage to the equipment.
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1 SAFETY
1.
2.
3.
4.
5.
Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
The operator must ensure that:
○ no unauthorized person is 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
The workplace must:
○ be suitable for the purpose
○ be free from drafts
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
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 may cause injury 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 - Pose health risks
•
•
•
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Welders with pacemakers fitted should consult their doctor 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 the 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.
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1 SAFETY
FUMES AND GASES - Can be dangerous to your 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 ear defenders or other hearing protection.
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 a fire. Make sure 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!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
This product is solely intended for arc welding.
ESAB can provide you with all necessary welding protection and accessories.
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2 INTRODUCTION
2 INTRODUCTION
The power sources Mig 4004i Pulse combined with U6, U82, or MA25 Pulse and Mig 4004i
Pulse WeldCloud™ combined with U82 offer a complete multi-process package supporting
SMAW (MMA), GTAW (TIG), GMAW (MIG/MAG), and pulse MIG.
The Mig 4004i Pulse WeldCloud™ is provided with a top-mounted control box which
enables wireless monitoring.
The power sources are intended for use with the wire feed unit Feed 3004 or YardFeed 2000
and the cooling unit COOL1. For more information about the feed units and the cooling unit,
refer to the instruction manuals.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The power source is supplied with:
•
•
•
16.4 ft (5 m) return cable with earth clamp
instruction manual for the welding power source
Quick start guide WeldCloud™ (only for Mig 4004i Pulse WeldCloud™)
For Mig 4004i Pulse WeldCloud™, see the separate manual Quick start guide WeldCloud™
for a description on how to install WeldCloud™.
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© ESAB AB 2016
3 TECHNICAL DATA
3 TECHNICAL DATA
Mig 4004i Pulse/Mig 4004i Pulse WeldCloud™
Mains voltage
380-460V, ±10%, 3~ 50/60 Hz
Mains supply Sscmin
2.5 MVA
Primary current Imax
23 A
No-load power
57 W
Setting range (DC)
GMAW (MIG/MAG)
16 A/15 V–400 A/34 V
SMAW (MMA)
16 A/21 V–400 A/36 V
GTAW (TIG)
4 A/10 V–400 A/26 V
Permissible load at GMAW (MIG/MAG)
60 % duty cycle
400 A/34.0 V
100% duty cycle
300 A/29.0 V
Permissible load at SMAW (MMA)
60 % duty cycle
400 A/36.0 V
100% duty cycle
300 A/32.0 V
Permissible load at GTAW (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
55 V
Operating temperature
50 to 104 °F (-10 to 40 °C)
Transportation temperature
-68 to 131°F (-20 to 55°C)
Constant sound pressure when idling
<70 db (A)
Dimensions l×w×h
Mig 4004i Pulse:
24.0 × 10.1 × 17.5 in (613 × 257 × 445 mm)
Mig 4004i Pulse WeldCloud™:
24.0 × 10.1 × 20.3 in (613 × 257 × 517 mm)
Weight
Mig 4004i Pulse: 45 kg (99.2 lb)
Mig 4004i Pulse WeldCloud™: 50 kg (110 lb)
Insulation class
H
Enclosure class
IP23
Application classification
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 104 °F (40 °C).
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3 TECHNICAL DATA
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.
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© ESAB AB 2016
4 INSTALLATION
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 that its cooling air inlets and outlets are not
obstructed.
For Mig 4004i Pulse WeldCloud™, make sure the antenna on the top box is not covered or
blocked.
4.2 Lifting instruction
4.3 Electrical 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.
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4 INSTALLATION
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 power supply voltage, and that it is protected
by the correct fuse size. A protective ground connection must be made, in accordance with
regulations.
A. Rating plate with supply connection data
Recommended fuse sizes and minimum cable areas
Mig 4004i Pulse/Mig 4004i Pulse WeldCloud™
Mains voltage
380–460 V, +/- 10%, 3~50/60 Hz
Electrical cable area
4C 10 AWG (4G4 mm2)
Phase current Ieff Uin 380 V
20 A
Fuse anti-surge
20 A
Fuse MCB-surge type C
25 A
Phase current Ieff Uin 400 V
19.2 A
Fuse anti-surge
20 A
Fuse MCB-surge type C
25 A
Phase current Ieff Uin 440 V
17.6 A
Fuse anti-surge
20 A
Fuse MCB-surge type C
20 A
Phase current Ieff Uin 460 V
17 A
Fuse anti-surge
20 A
Fuse MCB-surge type C
20 A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. Use the power source in accordance with the relevant
national regulations.
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4 INSTALLATION
Installation of electrical cable
If the electrical cable needs to be changed, the ground connection to the bottom plate must
be made correctly. See from the illustrations above how to remove the side panel and install
the mains cable. No other cable must be attached to this connection point.
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4 INSTALLATION
Connection instruction
The power source is connected to 460 V 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
illustration above), and the mains cable and plug must be changed according to relevant
national regulations. This operation must be performed by someone who has the appropriate
knowledge of electrical systems. The power source must be disconnected from mains while
performing this action.
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5 OPERATION
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!
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.
NOTE!
To achieve the best possible result at Mig short pulsing, the welding and return
cables must not exceed 33 ft (10 m).
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5 OPERATION
5.1 Connections and control devices
1. Negative welding terminal: Return cable
2. Electrical power supply switch, 0 / 1
3. Connection for wire feed unit or remote
control unit
4. Indicating LED, power supply ON
5. Indicating LED, thermal protection
6. Positive welding terminal: Welding cable
7. Fuse (10 A) for supply voltage (42 V) for
feeder unit
8. Mains cable
9. USB memory connection
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10. Antenna
11. Indicating LED, white, power supply ON
(WeldCloud™)
12. Indicating LED, red, connection status (lit
LED = connection error)
13. CAN connection
14. Arc voltage monitoring (+), red banana
socket
15. Arc voltage monitoring (-), black banana
socket
16. Ethernet connection
17. Robot interface
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5 OPERATION
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.
Connect the return cable to the negative terminal 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.
Recommended maximum current values for connection set cables
Imax
450 A (60% duty cycle)
350 A (100% duty cycle)
550 A (60% duty cycle)
430 A (100% duty cycle)
450 A (60% duty cycle)
350 A (100% duty cycle)
550 A (60% duty cycle)
430 A (100% duty cycle)
Cable area
Cable length
Note
70 mm2
6.6 ft–114.8 ft
(2–35 m)
19 pole
95 mm2
6.6 ft–114.8 ft
(2–35 m)
19 pole
70 mm2
6.6 ft–114.8 ft
(2–35 m)
19 pole, water
95 mm2
6.6 ft–114.8 ft
(2–35 m)
19 pole, water
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 104°F (40°C).
5.4 Turning the power source on/off
Turn the power source on by turning switch (2) to the ”1” position. Turn the power source off
by turning the switch (2) to the ”0” position. Welding data will be stored regardless of whether
the electrical supply is interrupted abnormally or the power source is switched off in the
normal manner, which allows it to be available the 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 150 A, and at
full speed for higher currents.
CAUTION!
The fans may start at any time to protect the power source from overheating.
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5 OPERATION
5.6 Thermal protection
The welding power source has thermal 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 thermal protection resets automatically when the
temperature has fallen within normal operation temperature.
5.7 VRD (Voltage Reducing Device)
The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding
is not being carried out. VRD LED is lit when the VRD function is activated. The VRD
function must be activated by a qualified service technician, by means of ESAT (ESAB
Software Administration Tool, a kit for technical service including software to manage
settings, update of software, etc.).
The VRD function is blocked when the system senses that welding has started.
5.8 Remote control unit
For more information about the operation of the remote control unit, see the instruction
manual for the control panel.
5.9 Arc voltage feedback
To achieve a good welding result, the arc voltage feedback is a crucial factor. In GMAW
(MIG/MAG) welding, the power source is prepared to sense the arc voltage in the wire
feeder. Prerequisite for this functionality is that an ESAB wire feeder and an ESAB
interconnection cable is used! This method of measuring the arc voltage compensates for the
voltage drop in the welding cable to the wire feeder. With an ESAB torch supporting
"TrueArcVoltage," the voltage drop all the way to the contact tip is compensated.
WARNING!
The external arc voltage inputs (the red and black banana sockets) at the back
end of the WeldCloud™ top box should not be used, unless the equipment has
been configured for this setup by authorized ESAB service personnel.
NOTE!
To compensate for the voltage drop in the return cable, the power source can be
configured (by authorized ESAB service personnel) to use an external arc voltage
sense wire from the workpiece.
0463 380 131
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© ESAB AB 2016
6 MAINTENANCE
6 MAINTENANCE
CAUTION!
Only persons with the appropriate electrical knowledge (authorized personnel)
may remove the cover of the product or carry out service, maintenance, or repair
work on the welding equipment.
CAUTION!
The product is covered by manufacturer's warranty. Any attempt to carry out
repair work by non-authorized service centers will invalidate the warranty.
NOTE!
Regular maintenance is important for safe and reliable operation.
For information about the cooling unit see the instruction manual for the cooling unit.
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
air filter should be regularly cleaned. The filter is built of a large and a small mesh. Make sure
the large mesh is mounted to the upmost part of the power source and the small mesh to the
innermost part of the power source.
Replacing and cleaning the dust filter:
1.
2.
3.
4.
Release the dust filter according to the figure.
Blow the filter clean with compressed air (reduced pressure).
Ensure the filter with the finest mesh is placed toward the grill.
Reinstall the filter.
0463 380 131
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© ESAB AB 2016
7 FAULT TRACING
7 FAULT TRACING
Try these recommended checks and inspections before requesting a visit from an authorized
service technician.
Type of fault
No arc.
Actions
•
•
•
•
Welding current is interrupted during welding •
•
•
The thermal overload trips frequently
•
•
Poor welding performance.
•
•
•
•
Nothing happens when the trigger on the
welding torch is pushed.
•
•
•
0463 380 131
- 22 -
Check that the electrical power supply
switch is turned on.
Check that the electrical, welding current,
and return cables are connected correctly.
Check that the correct current value is set.
Check the electrical power supply fuses.
Check whether the thermal overload trip
has operated (indicated by the orange
lamp on the front)
Check the main power supply fuses.
Check that the return cable is correctly
fastened.
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).
Check that the welding current and return
cables are connected correctly.
Check that the correct current value is set.
Check that the correct welding wires are
being used.
Check the electrical power supply fuses.
Check the fuse on the rear part of the
power source.
Check if the welding and return cables are
damaged.
Check that the wire feeder works correctly.
See the wire feeder instruction manual.
© ESAB AB 2016
7 FAULT TRACING
7.1 Error codes for Mig 4004i WeldCloud™
The following two status LEDs are located on
the front of the Mig 4004i WeldCloud™:
1.
2.
White LED to indicate power supply ON
Red LED to indicate errors
Errors are indicated by the red LED, using Morse code. Present error codes are listed below.
Error code
Morse code 1) Meaning
•——
W
••
I
LED is steady ON.
1)•
Description
There is no wire connection between the W82 weld data unit
(24AP1) and the Quark 2188/2189 board (25AP1).
The Quark 2188/2189 board (25AP1) has no network
connectivity.
Configuration file error (i.e., the configuration file is corrupted)
symbolizes a short LED signal and — symbolizes a long LED signal.
For further information about WeldCloud™, see the WeldCloud™ instruction manual
(0463 450).
0463 380 131
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© ESAB AB 2016
8 ORDERING SPARE PARTS
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 4004i Pulse and Mig 4004i Pulse WeldCloud™ are designed and tested in accordance
with the international standard IEC 60974-1 and US standards ANSI/IEC 60974-1:2008. It is
the obligation of the service unit which has carried out the service or repair work to make
sure the product still conforms to the mentioned standards.
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.
0463 380 131
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© ESAB AB 2016
DIAGRAM
DIAGRAM
Mig 4004i Pulse and Mig 4004i Pulse WeldCloud™
0463 380 131
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© ESAB AB 2016
DIAGRAM
Additional diagram for Mig 4004i Pulse WeldCloud™
0463 380 131
- 26 -
© ESAB AB 2016
ORDERING NUMBERS
ORDERING NUMBERS
Ordering
number
Denomination
Type
Note
0465 152 882 Welding power source Aristo® Mig 4004i Pulse
380-460 V version
0445 301 881 Welding power source Aristo® Mig 4004i Pulse
WeldCloud™
380–460 V version
0463 396 001 Spare parts list
Mig 4004i Pulse, Mig 4004i
Pulse WeldCloud™
Technical documentation is available on the Internet at: www.esab.com
0463 380 131
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© ESAB AB 2016
SPARE PARTS LIST
SPARE PARTS LIST
0463 380 131
Item
Ordering no.
Denomination
1
0462 197 001
Dust filter
2
0463 396 001
Warning label
- 28 -
© ESAB AB 2016
ACCESSORIES
ACCESSORIES
Trolleys
0462 151 880
Trolley 11, 4-wheel
Not to use with Aristo® Mig 4004i Pulse
WeldCloud™.
0463 125 880
Trolley bracket for Trolley 11
Use together with trolley 0462 151 880.
Not for use with Aristo® Mig 4004i Pulse
WeldCloud™.
Option when no cooling unit is assembled.
0460 564 880
Trolley 8, 2-wheel
0460 815 880
Shelf for YardFeed and MobileFeed.
0460 565 880
Trolley 9, 4-wheel
For use together with counter balance device.
Not for use with Aristo® Mig 4004i Pulse
WeldCloud™.
0461 310 880
Trolley adapter kit
For fitting of power source Mig 4004i Pulse to
trolley 0460 565 880.
0460 946 880
Stabilizer kit for counter-balance (1)
Use together with trolley 0460 565 880.
0463 380 131
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© ESAB AB 2016
ACCESSORIES
0458 705 880
Counterbalance device
Includes mast and counterbalance.
For 11 in. (300 mm) bobbin.
Wire feeders
0460 526 680
Feed 3004 MA25 Pulse Al
0460 526 681
Feed 3004w MA25 Pulse Al
0460 526 682
Feed 3004 MA25 Steel
0460 526 683
Feed 3004w MA25 Steel
0460 526 486
Feed 3004 U6
0460 526 896
Feed 3004 U6, water-cooled
0460 526 481
Feed 3004 for U82
0460 526 891
Feed 3004 for U82, water-cooled
0459 906 896
YardFeed 2000 U6, water-cooled
Feeder accessories
0458 674 880
1 Bobbin cover, plastic
0459 431 880
1 Bobbin cover, metal
0455 410 001
1 Adapter for 11 lb (5 kg) bobbin
0463 380 131
- 30 -
© ESAB AB 2016
ACCESSORIES
0459 233 880
1 Adapter for 17 in. (440 mm) bobbin
0458 706 880
1 Lifting eye
F102 440 880
2 Quick connector Marathon Pac™
899F50
2 Quick connector Marathon Pac™ NA
0558 002 354
Connector Adapter Marathon Pac™ NA
0458 707 880
1 Wheel kit for feeder, front wheels
turnable
0463 380 131
- 31 -
© ESAB AB 2016
ACCESSORIES
0457 341 881
1 Strain relief for welding torch
0459 234 880
Strain relief for interconnection cables
Cooler
0462 300 880
Water cooling unit, COOL1
0456 855 881
Flow guard, COOL1
Control panels
0460 820 880
0463 380 131
Aristo®U82, complete including holder
- 32 -
© ESAB AB 2016
ACCESSORIES
0460 820 881
Aristo®U82, plus complete including
holder
0460 877 891
Control cable extension U82, 24.6 ft (7.5 m)
Connection set, 70 mm2 10 pole cable plug - 10 pole cable socket
0349 312 450
5.6 ft (1.7 m)
0349 312 451
16.0 ft (5 m)
0349 312 452
32.8 ft (10 m)
0349 312 453
49.2 ft (15 m)
0349 312 454
82.0 ft (25 m)
0349 312 455
114.8 ft (35 m)
Connection set water, 70 mm2 10 pole cable plug - 10 pole cable socket
0459 528 790
5.6 ft (1.7 m)
0459 528 791
16.0 ft (5 m)
0459 528 792
32.8 ft (10 m)
0459 528 793
49.2 ft (15 m)
0459 528 794
82.0 ft (25 m)
0459 528 795
114.8 ft (35 m)
Remote controls
0459 491 880
Remote control unit MTA1 CAN
GMAW (MIG/MAG): wire feed speed and
voltage
SMAW (MMA): current and arc force
GTAW (TIG): current, pulse and background
current
0463 380 131
- 33 -
© ESAB AB 2016
ACCESSORIES
0459 491 882
Remote control M1 10 Prog. CAN
Remote control cable 10 pole - 4 pole
0459 960 880
16 ft (5m)
0459 960 881
32.8 ft (10 m)
0459 960 882
82.0 ft (25 m)
0459 960 883
10 in. (0.25 m)
Remote adapter kit
0459 681 880
For Miggy-/Railtrac
0459 681 881
For MXH PP and PSF RS3
Connection kit
0459 020 883
For MXH™ 300/400w PP connection kit
For Mig 4004i Pulse WeldCloud™:
0445 499 880
0463 380 131
Trolley, 4-wheel
For use with Aristo® Mig 4004i Pulse
WeldCloud™.
- 34 -
© ESAB AB 2016
ACCESSORIES
0445 499 881
Trolley, 4-wheel
For use with Aristo® Mig 4004i Pulse
WeldCloud™ with Cool1.
0462 062 001
USB memory 2 Gb
0445 501 880
Robot Interface Kit DeviceNet WeldCloud™
0445 501 881
Robot Interface Kit Profibus WeldCloud™
0445 501 882
Robot Interface Kit CANopen WeldCloud™
0445 501 883
Robot Interface Kit EtherNet IP WeldCloud™
For Mig 4004i Pulse:
0445 302 881
Retrofit Mig 4004i WeldCloud™
Information on PSF welding torches can be found in separate brochures.
For more information about the accessories contact the nearest ESAB agency.
0463 380 131
- 35 -
© ESAB AB 2016
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A
B
C
D
E
F
G
H
CUSTOMER SERVICE QUESTIONS:
Telephone: (800) 372-2123, (800) 426-1888
Fax: (800) 634-7548, (800) 535-0557
Order Entry
Product Availability
Pricing
Hours: 8.00 AM to 7:00 PM EST
Order Information
ENGINEERING SERVICE:
Telephone: (834) 664-4416
Fax: (800) 446-5693
Warranty Returns
Authorized Repair Stations
Returns
Hours: 7.30 AM to 5:00 PM EST
Welding Equipment Troubleshooting
TECHNICAL SERVICE:
Telephone: (800) 372-2123, (800) 426-1888
Fax: (800) 664-4452, (800) 221-4401
Part Numbers
Technical Applications
Specifications
Hours: 8.00 AM to 5:00 PM EST
Equipment Recommendations
LITERATURE REQUESTS:
Telephone: (843) 664-5562
Fax: (843) 664-5548
Hours: 7.30 AM to 4:00 PM EST
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487
Fax: (843) 664-5557
Repair Estimates
Repair Status
Hours: 7.30 AM to 3:30 PM EST
WELDING EQUIPMENT TRAINING:
Telephone: (940) 381-1203
Fax:
Training School Information and Registrations
Hours: 7.30 AM to 4:00 PM EST
WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123
Fax:
Hours: 7.30 AM to 4:00 PM EST
TECHNICAL ASST. CONSUMABLES:
Telephone: (800) 933-7070
Fax:
Hours: 7.30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4452
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers:
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
ESAB Welding & Cutting Products
PO BOX 100545, Florence SC 29501-0545
© ESAB AB 2016
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