ESAB 350mpi POWER SOURCE

F15-481-K
November, 2008
ESAB 350mpi
POWER SOURCE
P/N 36975 - 208-230/460 Vac 3-phase, 230 Vac 1-phase, 60 Hz
P/N 36977 - 400/440 Vac 3-phase 50/60 Hz
P/N 36976 - 575 Vac 3-phase, 60 Hz
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe
practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting,
and Gouging", Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt
to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand
these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or
operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels
and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts
that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or
replacement become necessary, the manufacturer recommends that a telephone or written request for service advice
be made to the Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user
of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty
maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
PREFACE
The purpose of this manual is to provide the operator with information required to install and operate the
power source. Some technical reference material is also provided to assist in basic troubleshooting the
power source. If it is determined that the power supply is not operating properly, the operator should
contact ESAB at (843) 664-4416 for assistance.
The following is a list of terms/acronyms used throughout this manual.
CC
Constant Current
CV
Constant Voltage
GMAW
Gas Metal Arc Welding, CV mode (same as MIG)
GMAW-P
Gas Metal Arc Welding - Pulsed, CV mode (same as pulsed MIG)
GTAW
Gas Tungsten Arc Welding, CC mode (same as TIG)
MIG
Metal Inert Gas, CV mode (same as GMAW)
SMAW
Shielded Metal Arc Welding, CC mode (same as Stick)
Stick
Stick Welding, CC mode (same as SMAW)
TIG
Tungsten Inert Gas, CC mode (same as GTAW)
2
TABLE OF CONTENTS
SECTION
PARAGRAPH
TITLE
PAGE
USER RESPONSIBILITY ...............................................................................................................
2
SAFETY
................................................................................................................
5
SECTION 1
1.1
1.2
1.3
DESCRIPTION .......................................................................................
General ....................................................................................................
Duty Cycle ..............................................................................................
Volt-Ampere Curves ................................................................................
11
11
11
11
SECTION 2
2.1
2.2
2.3
2.4
2.5
INSTALLATION ......................................................................................
General ....................................................................................................
Required Tools ........................................................................................
Unpacking and Placement ......................................................................
Input Connections ...................................................................................
Output Connections ................................................................................
13
13
13
13
14
15
SECTION 3
3.1
3.2
3.3
3.4
3.5
3.6
OPERATION ..........................................................................................
General ....................................................................................................
Welding Controls / Indicators ..................................................................
MIG / GMAW (CV) Operation .................................................................
TIG / GTAW (CC) Operation ...................................................................
Stick / SMAW (CC) Operation ................................................................
Overview of Error Codes and Programs Updates ..................................
19
19
19
21
21
22
23
SECTION 4
4.1
4.2
MAINTENANCE...................................................................................... 25
General .................................................................................................... 25
Inspection and Cleaning .......................................................................... 25
SECTION 5
5.1
5.2
TROUBLESHOOTING .......................................................................... 27
General .................................................................................................... 27
Functionality Check (Table 5-1) .............................................................. 27
SECTION 6
REPLACEMENT PARTS ....................................................................... 33
3
TABLE OF CONTENTS
4
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in
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 Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure 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. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. 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 watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair 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.
4. 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 clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground 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.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and
welding machines. Therefore:
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. 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.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. 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.
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
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 welding power source and cables as far away
from your body as possible.
5
10/98
SAFETY PRECAUTIONS
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. 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.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. 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.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
1. 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 fumes
from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
5. WARNING: This product, when used for welding or
cutting, produces fumes or gases which
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.)
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, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, valve, or relief device can injure or
kill. Therefore:
1. 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 adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. 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. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert!
Your safety is involved.
Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could
result in personal injury or loss of life.
Means hazards which could result in
minor personal injury.
6
SP98-10
PRÉCAUTIONS
AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.
c. Les étincelles ou les projections de métal incandescent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent
ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:
DE
SÉCURITÉ
a. Éloigner suffisamment tous les matériaux combustibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.
b. Les étincelles ou les projections de métal incandescent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur
de façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer
ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous tension venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assurer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.
c. Mettez toujours à la terre le poste de soudage/coupage
en le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en
effet provoquer une surchauffe de l’équipement et un
danger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce en
un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de
passage d’un courant de sortie par des chaînes de
7
9/97
levage, des câbles de grue ou divers chemins
électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.
4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la formation de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’éliminer du voisinage de l’opérateur tout dégagement de
fumée visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des
dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qualifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et
des équipements accessoires. Gardez-les à l’écart
des sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corrosives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tous
les panneaux de l’armoire de commande en veillant à
les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément à
son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ-Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cutting” AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Welding” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
9/97
8
PRECAUCION DE SEGURIDAD
ADVERTENCIA: Estas Precauciones de Seguridad
son para su protección. Ellas hacen resumen de
información proveniente de las referencias listadas
en la sección "Información Adicional Sobre La Seguridad". Antes de
hacer cualquier instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas a continuación
así como también todo manual, hoja de datos de seguridad del
material, calcomanias, etc. El no observar las Precauciones de
Seguridad puede resultar en daño a la persona o muerte .
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco, como
el sol , emite rayos ultravioleta (UV) y
otras radiaciones que pueden dañar la piel y los ojos.
El metal caliente causa quemaduras. EL entrenamiento
en el uso propio de los equipos y sus procesos es
esencial para prevenir accidentes. Por lo tanto:
5. No use el equipo fuera de su rango de operación. Por ejemplo, el
calor causado por cable sobrecarga en los cables de soldar
pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área
de trabajo para cerciorarse de que las chispas o metal caliente
ocasionen un fuego más tarde. Tenga personal asignado para
vigilar si es necesario.
7. Para información adicional , haga referencia a la publicación
NFPA Standard 51B, "Fire Prevention in Use of Cutting and
Welding Processes", disponible a través de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto con
las partes eléctricas energizadas y tierra
puede causar daño severo o muerte. NO
use soldadura de corriente alterna (AC)
en áreas húmedas, de movimiento
confinado en lugares estrechos o si hay
posibilidad de caer al suelo.
1. Asegúrese de que el chasis de la fuente de poder
1. Utilice gafas de seguridad con protección a los lados siempre
2.
3.
4.
5.
6.
que esté en el área de trabajo, aún cuando esté usando careta
de soldar, protector para su cara u otro tipo de protección.
Use una careta que tenga el filtro correcto y lente para proteger
sus ojos, cara, cuello, y oídos de las chispas y rayos del arco
cuando se esté operando y observando las operaciones. Alerte
a todas las personas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
Use guantes de cuero a prueba de fuego, camisa pesada de
mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y
careta de soldar con capucha para el pelo, para proteger el
cuerpo de los rayos y chispas calientes provenientes del metal
fundido. En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las chispas.
Chispas y partículas de metal caliente puede alojarse en las
mangas enrolladas de la camisa , el ruedo del pantalón o los
bolsillos. Mangas y cuellos deberán mantenerse abotonados,
bolsillos al frente de la camisa deberán ser cerrados o eliminados.
Proteja a otras personas de los rayos del arco y chispas calientes
con una cortina adecuada no-flamable como división.
Use careta protectora además de sus gafas de seguridad
cuando esté removiendo escoria o puliendo. La escoria puede
estar caliente y desprenderse con velocidad. Personas cercanas
deberán usar gafas de seguridad y careta protectora.
2.
3.
4.
5.
6.
7.
8.
9.
10.
CAMPOS ELECTRICOS Y MAGNETICOS
- Son peligrosos. La corriente eléctrica
fluye através de cualquier conductor
causando a nivel local Campos Eléctricos
y Magnéticos (EMF). Las corrientes en el
área de corte y soldadura, crean EMF
alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área de trabajo o
cubra los materiales con una cobija a prueba de fuego. Materiales
combustibles incluyen madera, ropa, líquidos y gases flamables,
solventes, pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en las grietas
y agujeros de pisos y paredes causando fuegos escondidos en
otros niveles o espacios. Asegúrese de que toda grieta y agujero
esté cubierto para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado hasta
que la pieza de trabajo esté totalmente limpia y libre de
substancias que puedan producir gases inflamables o vapores
tóxicos. No trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso
instantáneo, como por ejemplo una manguera con agua, cubeta
con agua, cubeta con arena, o extintor portátil. Asegúrese que
usted esta entrenado para su uso.
esté
conectado a tierra através del sistema de electricidad primario.
Conecte la pieza de trabajo a un buen sistema de tierra física.
Conecte el cable de retorno a la pieza de trabajo. Cables y
conductores expuestos o con malas conexiones pueden exponer
al operador u otras personas a un choque eléctrico fatal.
Use el equipo solamente si está en buenas condiciones.
Reemplaze cables rotos, dañados o con conductores expuestos.
Mantenga todo seco, incluyendo su ropa, el área de trabajo, los
cables, antorchas, pinza del electrodo, y la fuente de poder.
Asegúrese que todas las partes de su cuerpo están insuladas
de ambos, la pieza de trabajo y tierra.
No se pare directamente sobre metal o tierra mientras trabaja en
lugares estrechos o áreas húmedas; trabaje sobre un pedazo de
madera seco o una plataforma insulada y use zapatos con suela
de goma.
Use guantes secos y sin agujeros antes de energizar el equipo.
Apage el equipo antes de quitarse sus guantes.
Use como referencia la publicación ANSI/ASC Standard Z49.1
(listado en la próxima página) para recomendaciones específicas
de como conectar el equipo a tierra. No confunda el cable de
soldar a la pieza de trabajo con el cable a tierra.
1. Soldadores u Operadores que use marca-pasos para el corazón
deberán consultar a su médico antes de soldar. El Campo
Electromagnético (EMF) puede interferir con algunos marcapasos.
2. Exponerse a campos electromagnéticos (EMF) puede causar
otros efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para
minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de trabajo juntos,
hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno
junto al otro con cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza
de trabajo. Mantega los cables a un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo lo más
cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar lo más
lejos posible de su cuerpo.
9
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios sin
ventilación. No inhale el humo o
gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:
1. Siempre provea ventilación adecuada en el área de
trabajo por medio natural o mecánico. No solde, corte,
o ranure materiales con hierro galvanizado, acero
inoxidable, cobre, zinc, plomo, berílio, o cadmio a
menos que provea ventilación mecánica positiva . No
respire los gases producidos por estos materiales.
2. No opere cerca de lugares donde se aplique substancias
químicas en aerosol. El calor de los rayos del arco
pueden reaccionar con los vapores de hidrocarburo
clorinado para formar un fosfógeno, o gas tóxico, y
otros irritant es.
3. Si momentáneamente desarrolla inrritación de ojos,
nariz
o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada. Pare
de trabajar y tome las medidas necesarias para
mejorar la ventilación en el área de trabajo. No
continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones
específicas en la ventilación.
5. ADVERTENCIA-- Este producto cuando se utiliza para
soldaduras o cortes, produce
humos
o gases, los cuales
contienen químicos c o n o c i d o s
por el Estado de California de
causar defectos en el nacimiento,
o en algunos casos, Cancer. (California Health & Safety Code
§25249.5 et seq.)
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
1. Siempre tenga personal cualificado para efectuar l
a
instalación, diagnóstico, y mantenimiento
del
equipo. No ejecute ningún trabajo eléctrico a menos
que usted esté cualificado para hacer el trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder del
suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones, cable
primario, y cualquier otra fuente de poder en buen
estado operacional. No opere ningún equipo en
malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga el
equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos de
agua , aceite o grasa, atmósferas corrosivas y las
inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y coverturas
del equipo en su posición y en buenas condiciones.
6. Use el equipo sólo para el propósito que fue diseñado.
No modifique el equipo en ninguna manera.
INFORMACION ADICIONAL DE SEGURIDAD
-- Para más información sobre las prácticas de
seguridad de los equipos de arco eléctrico
para soldar y cortar, pregunte a su suplidor por
una copia de "Precautions and Safe Practices
for Arc Welding, Cutting and Gouging-Form 52529.
Las siguientes publicaciones, disponibles através de la
American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse
y liberar violentamente gases.
Rotura repentina del cilindro,
válvula, o válvula de escape puede
causar daño o muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize un
regulador diseñado para operar y reducir la presión
del cilindro de gas . No utilice adaptadores. Mantenga
las mangueras y las conexiones en buenas condiciones.
Observe las instrucciones de operación del manufacturero
para montar el regulador en el cilindro
de gas
comprimido.
2. Asegure siempre los cilindros en posición vertical y
amárrelos con una correa o cadena adecuada para
asegurar el cilindro al carro, transportes, tablilleros,
paredes, postes, o armazón. Nunca asegure los cilindros
a la mesa de trabajo o las piezas que son parte del
circuito de soldadura . Este puede ser parte del circuito
elélectrico.
3. Cuando el cilindro no está en uso, mantenga la válvula
del cilindro cerrada. Ponga el capote de protección
sobre la válvula si el regulador no está conectado.
Asegure y mueva los cilindros utilizando un carro o
transporte adecuado. Evite el manejo brusco de los
SIGNIFICADO DE LOS SIMBOLOS -- Según
usted avanza en la lectura de este folleto:
Los Símbolos Significan ¡Atención! ¡Esté
Alerta! Se trata de su seguridad.
Significa riesgo inmediato que, de no
ser evadido, puede resultar
inmediatamente en serio daño personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en serio
daño personal o la muerte.
Significa el posible riesgo que puede
resultar en menores daños a la persona.
10
SECTION 1
DESCRIPTION
1.1 GENERAL
1.2 DUTY CYCLE
The ESAB 350mpi is a high performance constant
voltage (CV) and constant current (CC) inverter power
source designed to provide multi-process welding capabilities with dependability and ease of use. The
ESAB 350mpi is a self-contained unit which will produce power for Gas Metal Arc (MIG), Gas Tungsten
Arc (TIG) and Shielded Metal Arc (Stick) welding
without the use of optional apparatus.
The ESAB 350mpi power source will operate on a 60%
duty cycle with a load of 350 amperes at 34 V dc (with
3-phase input). Duty cycle is defined as the ratio of
operating time to total time. Ratings are based on a 10minute cycle. The 60% duty cycle rating means that the
350 ampere, 34 volt rated load can be applied for a total
of 6 minutes and shut off for a total of 4 minutes in a 10minute period. If the welding current (or voltage) is
reduced, the duty cycle increases. Conversely, if the
welding current (or voltage) is increased, the duty cycle
will decrease. Refer to Table 1-1 and Figure 1-2.
For MIG (CV) welding, the ESAB 350mpi supports
welding a wide selection of ferrous and non-ferrous
alloys by utilizing Fixed Slope and inductance controls.
1.3 VOLT-AMPERE CURVES
A special "Touch Tig" circuit eliminates the need for
high frequency or "scratch" starting when using the
TIG (CC) welding process. This feature provides smooth
starts without contaminating the electrode or the work.
Figure 1-2 illustrates the static volt-ampere characteristics for the power source in the MIG (CV), TIG (CC),
and Stick (CC) modes. The slant of these curves is
referred to as the slope and is generally defined as the
voltage drop per 100 amperes of current rise. These
curves show the output voltage available at any given
output current between the minimum and maximum
settings of the output control. Values for other settings
fall between the minimum and maximum curves.
The Stick (CC) welding mode provides adequate open
circuit voltage (70 V dc) for easy starts and re-starts as
well as an adjustable arc force which controls arc
penetration and wetting action.
The "Auto Fan" feature operates the cooling fan only
when the contactor is energized or when the internal
temperature exceeds the safe operating level. During
normal operation, the fan shuts down about 5 minutes
after the contactor disengages.
Table 1-1. Technical Specifications
RATED OUTPUT
100% Duty Cycle (3-phase input)
100% Duty Cycle (1-phase input)
60% Duty cycle (3-phase input)
Open-circuit Voltage (max)
300 A @ 32 V dc
225 A @ 29 V dc
350 A @ 34 V dc
70 V dc
PHYSICAL
Height
Width
Depth
Weight
16.4 in. (417 mm)
11.5 in. (292 mm)
29.8 in. (757 mm)
101 lbs (39 kg)
INPUT VOLTAGE AND CURRENT @ RATED 60% DUTY CYCLE LOAD
230/460 V ac models
3-phase
1-phase
11
50/25 amps
50/38
SECTION 1
DESCRIPTION
NOTE:
These measurements are made at the output terminals of the power source. Additional voltage "drops"
will occur in the welding cable, torch cable, and in the
workpiece. The use of proper size welding cable and
secure electrical connections for the electrode and
ground circuits will minimize these effects which adversely affect welding conditions and waste electrical
energy.
cv mode Volt-Amp Curve
F
M
S
Figure 1-2. Volt-Ampere Characteristics and Duty Cycles
12
SECTION 2
INSTALLATION
2.1 GENERAL
2.3 UNPACKING AND PLACEMENT
This section provides detailed instructions for the proper
installation of the ESAB 350mpi power source from initial
receipt of the equipment to output welding connections.
It is recommended that these instructions be followed
carefully to allow for the best possible operating environment.
NOTE
When lifting the ESAB 350mpi, apply direct upward
pressure to both of the carrying handles. Do not
transport the ESAB 350mpi with only one handle or
apply outward pressure to the handles. See Figure 21.
2.2 REQUIRED TOOLS
A. Immediately upon receipt of the ESAB 350mpi,
inspect for damage which may have occurred
in transit. Notify the carrier of any defects or
damage at once.
B. After removing the components from the shipping container(s), check the container for any
loose parts. Remove all packing materials.
C. Check air passages of power source for any
packing materials that may obstruct air flow
through the power source.
D. If the equipment is not to be installed immediately, store it in a clean, dry, well-ventilated
area.
Some procedures require use of the following tools:
3/8" wrench, Phillips or Robertson, and a screwdriver.
The use of socket wrenches or nutdrivers are recommended over straight wrenches due to the location of
attaching hardware.
WRONG!
WRONG!
Figure 2-1. Correct and Wrong Lifting Techniques
13
SECTION 2
INSTALLATION
E. The location of the power source should be
carefully selected to ensure satisfactory and
dependable service. Choose a location relatively close to a properly fused source of
electrical power.
F. The machine components are maintained at
proper operating temperatures by forced air
which is drawn through the cabinet by the fan
unit. For this reason, it is important that the
machine be located in an open area where air
can circulate freely at front and rear openings.
If space is at a premium, leave at least 1 foot
(300 mm) of clearance between the rear of
the power source and wall or other obstruction. The area around the unit should be
relatively free of dust, fumes, and excessive
heat. It is also desirable to locate the unit so
the cover can be removed easily for cleaning
and maintenance.
2.4.3
NOTE
As shipped from the factory, the ESAB 350mpi, 400/
440 V model, is set for 440 volts input. If you will be
operating the machine from a 400 V source, open
the switch access panel on the rear panel on the
machine and flip the Voltage Selector Switch to the
400 V position.
2.4 INPUT CONNECTIONS
ELECTRIC SHOCK CAN KILL! Precautionary measures should be taken to provide maximum protection against electrical shock.
The ESAB 350mpi is designed to compensate for line
voltage variations of plus or minus 10 percent from the
rated level while maintaining rated output, without damage to internal components. If line voltage fluctuations
exceed this range, serious damage could occur. Therefore, prior to installation, it is recommended that the line
voltage of the supply circuit be measured at several
times during the day. If fluctuations beyond the +/-10%
level are detected, another supply circuit should be
selected, or the local power company should be asked
to adjust the supply. In addition, certain types of factory
equipment can cause rapid voltage swings (transients)
which can cause the ESAB 350mpi safety circuits to
“trip”. Examples of such equipment are resistance
welders, punch presses, and starting of large electric
motors.
Be sure that all power is OFF by opening the line
(wall) disconnect switch when primary electrical
connections are made to the power source.
To be doubly safe, check your input leads with a
voltmeter to make sure all power is OFF.
2.4.1
230/460V Model
NOTE
As shipped from the factory, the ESAB 350mpi, 230/
460 V model, is set for 460 volts input. If you will be
operating the machine from a 230 V source, open
the switch access panel on the rear panel on the
machine and flip the Voltage Selector Switch to the
230 V position.
2.4.2
400/440V Model
Input Power Cable (Figure 2-3). Before installing the
power cable, make sure there is a line (wall) disconnect
switch with fuses or circuit breakers at the main power
panel. You may either use the factory-installed input
power cable (No. 8 AWG, 4/c, type SO (90 °C), 12 ft (3.7
m) length) or provide your own input power leads. If you
choose to provide your own, make sure they are insulated copper conductors. You must have two (singlephase) or three (three-phase) power leads and one
ground wire. The wires may be heavy rubber covered
cable or may be run in a solid or flexible conduit. Refer
to Table 2-1 for recommended input conductors and
line fuse sizes.
575V Model
575 Vac input models are single voltage units and
therefore do not require any installation preparation for input line voltage.
14
SECTION 2
INSTALLATION
Table 2-1. Recommended Input Conductors and
Fuse Sizes
Rated Load
(3-phase input)
Volts
Amps
208
230
460
575
40
38
21
17
Input &
Ground
Conductor*
CU/AWG (mm )
8 (10)
8 (10)
10 (6)
10 (6)
ELECTRIC SHOCK CAN KILL! After the red wire
has been removed from L2, its center conductor is
exposed. This conductor must be covered with an
insulating material. Failure to do so properly could
cause a serious electrical shock hazard.
Time-Delay
Fuse Size
Amps
60
60
30
30
5. Re-attach the top cover with hardware removed in step 1.
* Sizes per National Electric Code for 90 °C rated copper conductors
@ 30 °C ambient. Not more than three conductors in raceway or
cable. Local codes should be followed if they specify larger sizes
other than those listed above.
2.5 OUTPUT CONNECTIONS
Use the following procedure to disconnect the factory-installed
cable and connect your own input power leads/cable.
ELECTRIC SHOCK CAN KILL! Before making any
connections to the power source output terminals,
make sure that all primary power input power is
deenergized (OFF) at the line (wall) disconnect
switch or circuit breaker.
ELECTRIC SHOCK CAN KILL! Make sure the ground
lead is at least twice as long as the input power
leads on the inside of the power source (see Figure
2-3). Ensure the strain relief and ground connection are securely tightened.
Two male plug connectors (P/N 13792513) are supplied with the ESAB 350mpi (see Figure 2-3). To
assemble the connectors onto each of your welding
cables, refer to the following instructions:
1. Slip the insulating boot over the end of the
cable.
2. Strip the wire approximately 1-1/2" (37 mm)
from the end.
3. Place the ferrule over the stripped wire end.
4. Place the male connector over the ferrule and
tighten the two Allen screws until they are flush
with the connector.
5. Slide the insulating boot over the assembly.
If these conditions are not met, the power source
chassis may become electrically "hot" if excessive
stress is placed on the input power cable.
If it is necessary to move the power source after it
has been connected to primary power, ensure that
the power source is turned OFF, and that an adequate amount of "slack" is maintained in the input
power cable.
If you have single-phase input power and are using the
factory-installed power cable, you must change the
ON-OFF switch cable connections from three-phase to
single-phase configuration as follows:
Refer to Tables 2-2 and 2-3 and Figures 2-4, 2-5, 2-6,
and 2-7 when attaching welding cables and optional
equipment to the ESAB 350mpi.
1. Remove the 1/4" screws securing the top cover
and place them in a safe place.
2. Remove the top cover and set aside.
3. Loosen the ON-OFF switch cable connection
T3 located inside the power source.
4. Remove the red wire from cable connection T3.
Particular attention should be paid to the electrical
resistance in the welding circuit; especially, the work
and work cable and when using a water-cooled torch.
High resistance in the welding circuit can cause performance deterioration (loss of "heat" input, popping of
weld puddle, bushy arcs, etc.). It is recommended that
the power source/wire feeder and workpiece be placed
15
SECTION 2
INSTALLATION
Table 2-2. Typical Output Connections
as close together as possible to limit this resistance.
Make sure that the work cable (ground) is large enough,
kept as short as possible, properly insulated, securely
connected to the workpiece, and that all connections
are clean and tightly secured. If the work circuit includes
mechanical fixtures, ship structure, robot fixtures, etc.,
make sure that the circuit is secure and presents a low
resistance path to the flow of weld current. Also, the
power cable on a water-cooled torch is normally subject
to gradual deterioration and increasing resistance due
to corrosion which leads to the poor performance
described above. To assure good torch performance,
the water-cooled power cable should be replaced periodically.
MIG Welding
(DCRP)
TIG Welding
(DCSP)
Stick Welding
(DCSP or DCRP)
Electrode
positive (+)
negative (-)
positive (+) DCRP
negative (-) DCSP
Work
negative (-)
positive (+)
negative (-) DCRP
positive (+) DCSP
Table 2-3. Recommended Welding
Cable Sizes - AWG (mm2 )
Total Length (Feet) of Cable in Welding Circuit*
Welding
Current
100
150
200
250
300
*
**
16
50
(13 m)
6 (16)**
4 (25)**
3 (30)**
2 (35)
1 (50)
100
(25 m)
4 (25)**
3 (30)**
1 (50)
1/0 (50)
2/0 (70)
150
(38 m)
200
(51 m)
250
(64 m)
3 (30)**
1 (50)
1/0 (50)
2/0 (70)
3/0 (95)
2 (35)
1/0 (50)
2/0 (70)
3/0 (95)
4/0 (120)
1 (50)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
Total cable length includes work and electrode cables. Cable size is based on direct
current, insulated copper conductors, 100% duty cycle, and a voltage drop of 4 or
less volts. The welding cable insulation must have a voltage rating that is high
enough to withstand the open circuit voltage of the machine.
The supplied male output connectors will not accept anything smaller than #2 gauge
(35 mm ) cable.
SECTION 2
INSTALLATION
Figure 2-4. Male Output Cable Connectors (P/N 13792513)
(REMOTE CONTROL
HC-5, P/N 34838)
Figure 2-5. MIG (GMAW) Interconnection Diagram
17
SECTION 2
INSTALLATION
(REMOTE CONTROL
HC-5, P/N 34838)
Figure 2-6. TIG (GTAW) Interconnection Diagram
(REMOTE CONTROL
HC-5, P/N 34838)
REVERSE
PORALITY
(electrode positive)
STRAIGHT
PORALITY
(electrode
negative)
ELECTRODE
(+)
ELECTRODE ()
Figure 2-7. Stick (SMAW) Interconnection Diagram
18
SECTION 3
OPERATION
B. REMOTE RECEPTACLE - For connecting remote
output control devices such as hand pendant (HC5, P/N 34838), foot, and torch controls.
C. PANEL / REMOTE SWITCH - Selects the point of
machine control.
3.1 GENERAL
Never, under any circumstances, operate the power
source with the cover removed. In addition to the
safety hazard, improper cooling may cause damage to internal components.
1. PANEL position - Machine is controlled by
the local front panel controls.
2. REMOTE position - Machine control is
switched to the device plugged into the
REMOTE RECEPTACLE.
D. APPLICATION SELECT SWITCH - This switch
selects specific application characteristics when
the PROCESS CONTROL SWITCH is in the
MIG position regardless of the PANEL/REMOTE
SWITCH position. Each selection fine-tunes the
specific arc characteristics to provide superior
performance by enhancing stability and reducing
spatter.
To prevent serious injury, never touch any torch
parts forward of the handle (nozzle, electrode, etc.)
unless the power switch is in the off position.
Wear proper protective gloves, clothing, safety
glasses, and helmet. A helmet with filter lens shade
No. 11-14 should provide adequate protection for
your eyes. Refer to the Safety Precautions in the
beginning of this manual for additional operating
precautions.
Selections include:
Steel CO2
Stainless Steel
Cored Wires
Medium Slope
3.2 WELDING CONTROLS / INDICATORS
(FIGURE 3-1)
A. WIRE FEEDER RECEPTACLE - For connecting
ESAB 42 & 115 vac wire feeders.
J. OUTPUT VOLTAGE / CURRENT CONTROL
Steel Argon Mix
Aluminum
Spray
Steep Slope
NOTE: When the PROCESS CONTROL SWITCH is
set to the STICK, TIG, or TOUCH TIG
modes,
the
APPLICATION
SELECT
SWITCH has no effect on the welding output
characteristics
K. PRESET SWITCH
I. DIGITAL AMPS DISPLAY
L. STICK ARC FORCE / MIG ARC TRIM
M. PROCESS SELECT SWITCH
H. POWER INDICATOR
G. TEMP INDICATOR
F. FAULT INDICATOR
E. DIGITAL VOLTS DISPLAY
D. APPLICATION SELECT SWITCH
C. PANEL / REMOTE SWITCH
B. 14 PIN REMOTE RECEPTACLE
A. 19 PIN WIRE FEEDER RECEPTACLE
Figure 3-1. Controls / Indicators
19
N. POWER ON/OFF SWITCH
SECTION 3
E. DIGITAL VOLTS DISPLAY - In the normal
mode, this large, easy to read digital display
indicates actual output voltage or preset voltage
level when the PRESET SWITCH is depressed.
If a machine error occurs this display will
automatically switch to the error mode and
display "Err".
F. FAULT INDICATOR - Indicates an improper
input line condition. The machine will not
energize. The machine must be reset by turning
the POWER “ON/OFF” SWITCH to "OFF" and
then back to “ON”, after the proper input voltage
is selected.
a. Indicator illuminated - A primary input overcurrent condition has occurred.
b. Indicator blinking - The INPUT VOLTAGE
SELECT SWITCH at the rear of the
machine is set incorrectly for the primary
input voltage applied.
G. TEMP INDICATOR - Indicates that an overtemperature condition has occurred and the
machine will cease to function. "Err 4" will
appear in the digital displays. The machine will
return to normal operation once the temperature
decreases to a safe operating level.
H. POWER INDICATOR - Indicates power is
present in the machine and that control circuits
are energized.
I. DIGITAL AMPS DISPLAY - In the normal mode,
this large, easy to read digital display indicates
actual output amperage or preset amperage
level when the PRESET SWITCH is depressed.
If a machine error occurs this display will
automatically switch to the error mode and
display the error code number.
J. OUTPUT CURRENT/VOLTAGE CONTROL Sets the welding power output of the machine.
When in the STICK, TIG, and Touch TIG modes,
this knob controls the output welding current
(amperes). When in the MIG mode, this knob
controls the welding voltage (volts).
K. PRESET SWITCH - When depressed, the digital
meters will display the adjustment level of the
OUTPUT CURRENT/VOLTAGE control. This
allows the welder the ability to quickly and easily
preset the desired output level before attempting
to weld. This greatly reduces the “trail & error”
approach to adjusting proper welding conditions.
1. PROCESS SELECT SWITCH in the MIG
mode - Depressing the PRESET SWITCH
displays the output voltage level in the
VOLTS window for the given OUTPUT
CONTROL setting.
2. PROCESS SELECT SWITCH in the STICK,
OPERATION
TIG, Touch TIG modes - - Depressing the
PRESET SWITCH displays the output current
level in the AMPS window for the given
OUTPUT CONTROL setting.
L. STICK ARC FORCE / MIG ARC TRIM - This
control allows the welder to fine tune arc
characteristics to suit specific applications and
individual preferences.
1. PROCESS SELECT SWITCH in the STICK
mode - the STICK ARC FORCE control
adjusts the amount of “digging” action when
the arc length is shortened. This adjustment
is based mostly on personal preference of the
welder.
a. Settings
from
0 mid point toward
negative (-). The welding arc becomes
softer and has less penetrating power as
the welding arc length is shortened.
b. Settings from 0 mid point toward positive
(+). The welding arc becomes stiff and
has more penetrating power when the arc
length is held short.
2. PROCESS SELECT SWITCH in the MIG mode
- the MIG ARC TRIM control adjusts the arc
dynamic characteristics primarily for short arc
welding. This adjustment is based mostly on
personal preference of the welder.
a. Settings
from
0 mid point toward
negative (-). The welding arc becomes
crisp with a higher buzzing sound. The
weld pool becomes less fluid and the
weld bead may become more crowned.
b. Settings from 0 mid point toward positive
(+).The welding arc becomes softer with
a more crackling sound. The weld pool
becomes more fluid and the weld bead
may be flatter.
M. PROCESS SELECT SWITCH - Selects the
desired welding process to be performed. Switch
selections and associated process are as follows:
Mig Position - Output is always energized
Contactor on - Gas Metal Arc Welding (GMAW)
- Short Circuiting Arc Welding
- Spray Arc Welding
- Flux Cored Arc Welding
Stick Position - Output is always energized
Contactor on - Shielded Metal Arc Welding (SMAW)
- Air Carbon Arc Gouging (ACAG)
Mig Position - Gas Metal Arc Welding (GMAW)
- Short Circuiting Arc Welding
- Spray Arc Welding
- Flux Cored Arc Welding
TIG Position - Gas Tungsten Arc Welding
(GTAW) scratch start
Touch TIG
- Gas Tungsten Arc Welding
Position
(GTAW) with Lift Arc
20
SECTION 3
OPERATION
N. POWER ON/OFF SWITCH - Controls the main
input power into the welding machine. In the “ON”
position the machine is energized and power is
available to all of the control circuits. In the “OFF”
position the machine is de-energized and no
power is supplied to the control circuits.
I. Set the ARC TRIM potentiometer to the center
position. The microprocessor will provide the
optimum arc characteristics for each APPLICATION setting. Additional adjustment may
be made to suit specific needs or preferences
and can be particularly effective in short circuiting arc applications.
3.3 MIG / GMAW (CV) OPERATION
NOTE
When the HC-5 remote hand control (P/N 34838) is
plugged into the power source, the ARC TRIM potentiometer on the power source is disabled even when the power
source's CONTROL switch is placed in the PANEL
position.
A. Make all secondary output connections to the
power source output receptacles as described
in section 2 and as shown in the appropriate
wire feeder and/or control instruction literature.
J. Commence welding operations by energizing
the torch switch.
B. After the primary input connections have been
made in accordance with section 2, close the
main wall disconnect switch or circuit breaker.
K. For remaining wire feeder or control operations, refer to the appropriate instruction literature supplied with your particular system.
C. Place the primary power switch in the ON
position. This will apply power to the control
circuitry as indicated by the MAIN POWER
light on the front panel. If the MAIN POWER
light does not lite, check the position of the
INPUT VOLTAGE SELECT SWITCH for
proper setting.
3.4 TIG / GTAW (CC) OPERATION
A. Make all secondary output connections to the
power source output receptacles as described
in section 2 and as shown in the appropriate
accessory instruction literature.
D. Place the PANEL/REMOTE switch in the
desired position. Use the PANEL position for
control from the power source's front panel
(typical for conventional MIG wire feeders), or
the REMOTE position for remote voltage control wire feeders and/or accessories. If REMOTE position is selected, set the PANEL
potentiometer to maximum for full range from
remote.
B. After the primary input connections have been
made in accordance with section 2, close the
main wall disconnect switch or circuit breaker.
C. Place the primary power switch in the ON
position. This will apply power to the control
circuitry as indicated by the MAIN POWER
light on the front panel.
E. Place the PROCESS SELECTOR switch in
the MIG position.
F. Set the APPLICATION SELECT SWITCH to
the appropriate material/gas/application setting.
ELECTRIC SHOCK CAN KILL! Make sure that the
contactor control switch on the remote control
accessory is in the "off" position until you are ready
to weld. Otherwise, the electrode in the torch will be
"electrically-hot" and could shock you.
G. Set a wire feed speed and begin welding.
H. If operating in the PANEL mode, adjust the
VOLTAGE potentiometer to the desired welding voltage by depressing the PRESET
SWITCH and reading the value in the VOLTS
DISPLAY. The PRESET SWITCH is only
functional with the PANEL settings.
D. Place the PROCESS SELECT switch in the
TIG or TOUCH TIG position.
F. Place the PANEL/REMOTE switch in the
appropriate position. Use the PANEL position
for control from the power source's front panel,
or the REMOTE position for control from a
remote control accessory.
21
SECTION 3
OPERATION
G. Adjust the PANEL CURRENT potentiometer
to the desired welding current by depressing
the PRESET SWITCH and reading the value
in the AMPS DISPLAY.
3.5 STICK / SMAW (CC) OPERATION
A. Make all secondary output connections to the
power source output receptacles as described
in section 2 and as shown in the appropriate
accessory instruction literature.
Note
In the remote position, the max output for MIG, TIG and
STICK is limited by the position of the "Panel" potentiometer; i.e., for maximum output, the PANEL potentiometer must be set to maximum.
B. After the primary input connections have
been made in accordance with section 2,
close the main wall disconnect switch or
circuit breaker.
NOTE
When the HC-5 remote hand control (P/N 34838) is
plugged into the power source, the ARC FORCE potentiometer (used for stick welding) on the power source is
disabled even when the power source's CONTROL
switch is placed in the PANEL position.
J.
C. Place the primary power switch in the ON
position. This will apply power to the control
circuitry as indicated by the MAIN POWER
light on the front panel.
Make sure you have a good clean ground
and a secure workpiece. Also, ensure that
shielding gas is turned on and flowing.
ELECTRIC SHOCK CAN KILL! When the PROCESS
SELECTOR SWITCH is set to the STICK position
the welding output will be energized and the electrode in the holder will be "electrically-hot" and
could shock you.
K. To establish the welding arc;
1. TOUCH TIG - When selected, the voltmeter will indicate a voltage of 4 to 5
volts. As the tungsten is touched to the
work piece the contactor will automatically be energized and a limited short
circuit current of 25 amps will start to flow
in the welding circuit. Rock the torch
away from the workpiece and the welding arc will be established. The amperage will automatically increase to the
pre-set value.
2. TIG (scratch) Select PANEL or REMOTE
mode switch on the front panel.
3. Touch tungsten to work. Operate either
the foot or the hand operated torch switch.
Contactor will energize, and a limited
short circuit current of 28 amps will flow.
Back the torch away from the work piece
and the welding current will increase to
the value as controlled by the potentiometer.
D. Place the PANEL/REMOTE switch in the
desired position. Panel setting limits max
current in either mode. Use the PANEL position for control from the power source's front
panel, or the REMOTE position for control
from a remote control accessory.
E. Place the PROCESS SELECT switch in the
STICK position. The welding output will be
energized and the electrode holder will be
"electrically-hot".
G. Set the ARC FORCE CONTROL to the mid
position.
I. Adjust the CURRENT for the stick electrode
type and diameter, as specified by the electrode manufacturer, being used by depressing the PRESET SWITCH and reading the
value in the AMPS DISPLAY. PRESET
SWITCH can only be used in the PANEL
position of the power source.
L. For remaining accessory operations, refer to
the appropriate instruction literature supplied
with your particular system.
J. For remaining accessory operations, refer to
the appropriate instruction literature supplied
with your system.
22
SECTION 3
3.6
OPERATION
OVERVIEW OF ERROR CODES
AND PROGRAM UPDATES
Program Updates
ERR 1: High input voltage. Over 264 VAC in 230
mode, over 529 VAC in 460 mode, and over 661 VAC
for 575.
The current program is “PRG 1.04”. The program has
undergone 2 changes. The first was to reduce the
low-line voltage referred to in “ERR 2”. The reason for
this was that the MIG35 wire feeder was causing the
machine to shut off due to its heavy draw on the
control transformer. This heavy load caused the
control voltages to sag, which resulted in the error
message, even though acceptable line voltages were
present on the primary. By adjusting for this sag in
control voltage, the machine will now operate over its
entire intended range.
ERR 2: Low input voltage. The low line is 161 VAC
for 230, 322 VAC for 460 and 403 VAC for 575.
ERR 3: Over-voltage at the output. If the output
voltage exceeds 80V, the machine will shut off the
contactor. This was implemented to prevent a
snubber failure from causing a dangerous voltage to
appear at the output terminals.
The second modification was to the handling of short
circuit time. The original short circuiting time allowed
was 160 milliseconds. The short circuit time allowed
was increased to 320 milliseconds and the handling
of this timer in the program was improved.
ERR 4: Over temperature. One of the thermal
switches has opened.
ERR 5: Over current in single-phase operation. In
MIG welding, if an operator draws more than 250
amps for more than 5 seconds, this error will occur.
In STICK or TIG modes, the machine will display this
error if the control pot is turned up above 250 amps in
single phase.
Control Board Modifications
The MIG contactor circuits were modified to decrease
holding time after trigger release to correct cases
where the increased time was causing minor “burnback” problems.
ERR 6: Extended secondary short circuit. The
machine will allow a full short circuit condition
(secondary current of more than 500 amps) to exist
for 320 milliseconds before this error occurs.
The output capability of the machine was modified to
handle a 12 volt, 60 amp short arc aluminum MIG
welding condition. Before the modification, this low
power condition was not stable.
ERR 7: Primary Over-current. This may indicate a
failure of an output diode, the Hall Effect current
sensor or a magnetic short to chassis.
23
SECTION 3
OPERATION
24
SECTION 4
MAINTENANCE
4.1 GENERAL
4.2 INSPECTION AND CLEANING
If this equipment does not operate properly, stop work
immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean,
or repair this equipment. Use only recommended replacement parts.
Since there are no moving parts (other than the fan) in
the power source, maintenance consist mainly of keeping the interior of the cabinet clean. Periodically, remove
the cover from the cabinet, and wearing proper eye
protection, blow accumulated dust and dirt from the air
passages and the interior components, using clean low
pressure air. It is imperative that the air passages, to the
interior of the unit, be free of dirt to ensure adequate
circulation of cooling air, especially over the rectifier
bridge plates. The length of time between cleaning will
depend on the location of the unit, and the amount of
dust in the atmosphere.
ELECTRIC SHOCK CAN KILL! Be sure that the line
(wall) disconnect switch or circuit breaker is open
before attempting any work inside the power source.
Always wear safety goggles with side shields when
blowing out the power source with air.
25
SECTION 4
MAINTENANCE
26
SECTION 5
TROUBLESHOOTING
5.2 FUNCTIONALITY CHECK (TABLE 5-1)
5.1 GENERAL
The 350mpi Functionality Check should be used to
verify proper power source operation. Before performing the following checks, disconnect the remote connections (WIRE FEEDER and REMOTE CONTROL)
from rear of power source and make sure there is no
load attached to the output terminals.
ELECTRIC SHOCK CAN KILL! Before attempting
inspection or work inside the power source, be
sure that all primary power to the machine has
been externally disconnected and the line (wall)
disconnect switch or circuit breaker is open.
Table 5-1. 350mpi Functionality Check
YES
1.
Are input power supply connections properly secured?
Go to next
step
2.
If using 3-phase power, are all three primary leads securely connected to
primary power switch.
If using single-phase power, are black and white leads securely connected to
primary power switch?
.
Position power source controls as follows:
Go to next
step.
3.
NO
Refer to
Section 2.
--
---
PROCESS SELECTOR - STICK
CURRENT - MINIMUM
ARC FORCE - MINIMUM
4.
Turn primary power switch to ON position. Does MAIN POWER light
illuminate?
Go to next
step.
5.
Do digital meters show about 68.0 volts and 00.0 amps?
Go to next
step.
7.
Fan is not energized.
Go to next
step.
8.
Place PANEL/REMOTE switch in the PANEL position. Do digital meters
show 00.0 volts and 00.0 amps?
Go to next
step.
9.
Place PROCESS SELECTOR to MIG position.
10. Short electrode to work table , hold in place and return PROCESS SELECTOR to STICK. Does
digital meter show approximately 50 amps?
Power source
faulty.
Go tonext
step.
11. Rotate ARC FORCE fully clockwise. Does digital meter show about 150
amps?
Go to next
step.
12. Rotate CURRENT fully clockwise. Does digital meter show about 500
amps?
Go to next
step.
ESAB 350mpi has passed the functionality check. Problem may be in interconnection of gas lines or polarity of output
connectors. For technical assistance, refer to the Communication Guide located on the last page of this manual.
27
SECTION 5
TROUBLESHOOTING
28
REPLACEMENT PARTS
SECTION 6
Replacement parts may be ordered from your ESAB
distributor or from:
6.1 General
Replacement parts are illustrated on the following
figures. When ordering replacement parts, order by
part number and part name, as listed. Always provide
the series or serial number of the unit on which the parts
will be used. The serial number is stamped on the unit
nameplate.
ESAB Welding & Cutting Products
Attn.: Customer Service Dept.
PO Box 100545, Ebenezer Road
Florence, SC, 29501-0545
Refer to the Communication Guide located on the last
page of this manual for a list of customer service phone
numbers.
NOTE:
Replacement Parts, Schematics and Wiring Diagrams on
279.4mm x 431.8mm (11” x 17”) paper are included inside the
back cover of this manual.
NOTE:
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
29
SECTION 6
REPLACEMENT PARTS
Revision History
Revision "A" added the Troubleshooting and Parts section.
Revision "B" updated the Volt-Ampere Characteristics and Duty Cycles charts, made corrections in Installation and Operation sections and updated the Troubleshooting section.
Revision "C" added the 575 V ac model.
Revision "D" added parts information for the 575V ac model.
Revision "E" updates the Wiring and Schematic Diagrams.
Revision "F" added parts and Input Connection information for the 400/440V ac model and
updated Replacement Parts list.
Revision "G" added part designation and number for optional remote control HC-5, P/N 34838.
Revision "H" added Error Code and Program Updates in Operation subsection per Customer
Service inputs.
Revision "J" changed BOM Item 63 from 952898 to 0558007860 per ECN #073242.
Revision "K" changed replacement parts and wiring diagram per ECN #083183. Moved schematics, wiring diagrams and replacement parts to back of manual.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Order Entry
Product Availability
Order Changes
Saleable Goods Returns
Pricing
Delivery
Shipping Information
Eastern Distribution Center
Telephone: (800)362-7080 / Fax: (800) 634-7548
Central Distribution Center
Telephone: (800)783-5360 / Fax: (800) 783-5362
Western Distribution Center
Telephone: (800) 235-4012/ Fax: (888) 586-4670
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns
Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications
Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates
Repair Status
Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123
Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
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/ Web:http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
F15-481-K
11 / 2008
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