Applicable Systems
ESAB Welding Equipment
Symptoms
The ESAB welder displays error ES004, indicating undervoltage protection has been triggered. The input supply voltage has dropped below the minimum rated voltage, causing unstable welding output.
Possible Causes
- Supply voltage sag from an overloaded circuit or an undersized extension cable
- One input phase is lost due to a blown fuse or a tripped circuit breaker
- Welder input connection is loose or corroded, causing voltage drop under load
Troubleshooting Steps
- Step 1: Measure the input voltage at the welder terminals under load during welding
Voltage remains above the minimum rated voltage during full-load welding current - Step 2: Check all three input phases for continuity and verify all fuses and breakers are intact
All three phases are present and all fuses and breakers are closed with no open circuits - Step 3: Inspect the input cable and connector for loose terminals or corrosion
All terminals are tight and clean with no corrosion, and the cable is the correct gauge for the welder rating
How to Reset
To reset: 1) Restore the supply voltage or replace blown fuses. 2) Tighten and clean input connections. 3) Use the correct cable size. 4. Power cycle and press RESET. 5. Verify stable voltage during welding.
Source: ESAB Welding Equipment Manual, ESAB Corporation
Category: Welding