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ESAB Mig 4004i - User Manual

ESAB Mig 4004i
28 pages
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Instruction manual
0463 279 101 GB 20180831
Valid for: serial no. 806-xxx-xxxx
Mig 4004i, Mig 5004i

Questions and Answers

  • F
    fwalkerJul 28, 2025
    Why is the ESAB Mig 4004i having poor welding performance?
    • K
      Kara DavisJul 28, 2025
      If you're experiencing poor welding performance with your ESAB Welding System, start by verifying that the welding current supply and return cables are properly connected. Also, ensure that you have set the correct current value and are using the appropriate welding wires. Finally, check the main power supply fuses.
  • R
    Robert PriceAug 5, 2025
    What to do if welding current is interrupted during welding with ESAB Mig 4004i?
    • M
      Morgan FrenchAug 5, 2025
      If the welding current is interrupted during welding with your ESAB Welding System, examine whether the thermal overload trip has activated, which is indicated by the orange lamp on the front. Also, inspect the main power supply fuses.
  • M
    Michael RussellAug 12, 2025
    Why do thermal overload trips operate frequently on my ESAB Mig 4004i?
    • S
      sheltontammyAug 13, 2025
      If you find that the thermal overload trips operate frequently on your ESAB Welding System, first, inspect the air filters to see if they are clogged. Secondly, verify that you are not exceeding the rated data for the power source, ensuring the unit is not being overloaded.
  • M
    Marilyn PhillipsAug 20, 2025
    How to fix no arc on ESAB Welding System?
    • B
      Brandon HuntAug 20, 2025
      If there is no arc in your ESAB Welding System, ensure that the mains power supply switch is turned on. Also, check that the welding current supply and return cables are correctly connected, and verify that the correct current value is set.

Summary

EU DECLARATION OF CONFORMITY

Equipment Type and Designation

Details the type and designation of the welding power source.

Manufacturer and Standards Compliance

Lists manufacturer details and harmonized standards used in the product's design.

Declaration of Conformity Statement

Declares the equipment's compliance with stated safety requirements.

SAFETY

Understanding Safety Symbols

Explains the meaning of danger, warning, and caution symbols for safe operation.

General Workplace and User Safety

Outlines essential safety precautions for users and the work environment.

Personal Protective Equipment

Details recommended personal safety equipment for welding operations.

Operational Safety Precautions

Lists general precautions for safe operation and maintenance.

Specific Hazard Warnings

Covers electric shock, EMF, fumes, arc rays, and noise hazards.

Equipment Misuse and Disposal Guidance

Warns against misuse, clarifies intended use, and guides on electronic waste disposal.

INTRODUCTION

Product Overview and Supplied Equipment

Introduces the welding power sources and lists included accessories.

TECHNICAL DATA

Electrical and Performance Specifications

Details mains voltage, current, power, and efficiency specifications.

Operational Limits and Environmental Data

Covers temperature ranges, sound pressure, dimensions, and weight.

Technical Terminology Explanations

Clarifies terms like Ssc min, Zmax, duty cycle, enclosure, and application class.

INSTALLATION

Location and Lifting Procedures

Guides on selecting the location and safe lifting of the unit.

Mains Supply Requirements

Details the necessary mains supply specifications and compliance.

Fuse and Cable Recommendations

Provides recommended fuse sizes and minimum cable areas for installation.

Voltage Connection and Cable Management

Explains voltage connection adjustments and mains cable replacement.

OPERATION

Safe Handling and Equipment Securing

Emphasizes safe handling practices and securing the equipment.

Unit Controls and Connections Overview

Identifies and explains the function of controls, indicators, and connection terminals.

Welding and Return Cable Connection

Details the correct procedure for connecting welding and return cables.

Power Source On;Off Procedure

Explains how to turn the power source on and off.

Key Operational Features

Covers fan control, overheating protection, remote controls, and VRD function.

Welding Modes Explained

Describes MIG/MAG, FCAW-S, and MMA welding processes.

MAINTENANCE

Safety Precautions for Maintenance

Outlines critical safety warnings and cautions before performing maintenance.

Inspection and Cleaning Procedures

Details regular inspection and cleaning of the unit, including the dust filter.

Welding Torch Wear Parts

Discusses the importance of cleaning and replacing welding torch wear parts.

TROUBLESHOOTING

Common Faults and Corrective Actions

Provides guidance on diagnosing and resolving common operational faults.

ORDERING OF SPARE PARTS

Spare Parts and Service Information

Guides users on how to order spare parts and emphasizes using authorized technicians.

DIAGRAM

Electrical Schematic Diagram

Presents the electrical schematic diagram of the welding power source for reference.

ORDERING NUMBERS

Product and Accessory Ordering Codes

Lists ordering numbers for the welding power source, manuals, and related accessories.

WEAR PARTS

Dust Filter Wear Part

Identifies the dust filter as a wear part and provides its ordering number.

ACCESSORIES

Trolleys and Handling Accessories

Lists trolleys, adapter kits, and stabilizers for moving and supporting the equipment.

Wire Feed Units and Cooling Systems

Details various wire feed units and cooling units available as accessories.

Connection Sets and Remote Controls

Lists connection sets of various lengths and types of remote controls.

Specialized Remote Controls and Cables

Describes specific remote control units and cables for advanced operations.

ESAB Mig 4004i Specifications

General IconGeneral
Rated Input Current22 A
Output Current Range30-400 A
Duty Cycle60% at 400 A
Wire Diameter Range0.8-1.6 mm
Cooling MethodForced Air
Protection ClassIP23
Power Factor0.93
Input Voltage400 V
Efficiency85%

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