ESAB MIG 301i User manual

MIG 301i / 401i / 501i

INVERTER MIG

Welding Power Source

Instruction manual

MIG 301i / 401i / 501i

INVERTER WELDING POWER SOURCE

MIG 301i MIG 401i MIG 501i

Instruction manual

For

Installation, Operation & General maintenance

CONTENTS

Item Page

SAFETY 3 - 4

TECHNICAL DATA 5

INSTALLATION 6

WELDING OPERATION 7 - 9

TROBULESHOOTING 10

BLOCK DIAGRAM 11

PART LIST AND EXPLODED VIEW 12 - 15

ESAB INDIA LOCATIONS AND CONTACT DETAILS 16

SAFETY

Users of ESAB welding 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

welding equipment. The following recommendations should be observed in addition to

the standard regulations that apply to the workplace.

Trained personnel well acquainted with the operation of the welding equipment must

carry out all the work. Incorrect operation of the equipment may lead to hazardous

situations, which can result in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:

• its operation

• location of emergency stops

• its function

• relevant safety precautions

• welding

2. The operator must ensure that:

• no unauthorized person is stationed within the working area of the equipment

when it is started up.

• no one is unprotected when the arc is struck

3. The workplace must:

• be suitable for the purpose

• be free from drafts

4. Personal safety equipment

• Always wear recommended personal safety equipment, such as safety glasses,

flameproof clothing, and safety gloves.

• Do not wear loose—fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns.

5. General precautions

• Make sure the return cable is connected securely.

• Only a qualified electrician may carry out work on high voltage equipment.

• 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.

Read and understand the instruction manual before installing or operating.

ESAB can provide you with all necessary welding protection and accessories.

WARNING

Arc welding and cutting can be injurious to yourself and others. Take

precautions when welding.

Ask for your employer’s safety practices which should be based on manufacturers’

hazard data.

ELECTRIC SHOCK –Can kill

• Install and earth the welding unit in accordance with applicable

standards.

• Do not touch live electrical parts or electrodes with bare skin, wet

gloves or wet clothing.

• Insulate yourself from earth and the workpiece.

• Ensure your working stance is safe.

FUMES AND GASES –Can be dangerous to health

• 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.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable materials nearby.

NOISE –Excessive noise can damage hearing

• Protect your ears. Use earmuffs or other hearing protection.

• Warn bystanders of the risk.

MALFUNCTION –Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding

Do not dispose of electrical equipment together with normal waste!

In accordance with national law, electrical equipment that has

reached the end of its life must be collected separately and returned

to an environmentally compatible recycling facility. As the owner of

the equipment, you should get information on approved collection

systems from the local representative. By applying this directive you

will improve the environment and human health

TECHNICAL DATA

MIG 301i

MIG 401i

MIG 501i

Mains Voltage, V/Ph, Hz

415(± 15%) /3,50

Rated Input Power, KVA

9.5

26.5

No Load Voltage, V

Current Range MIG, A

60-300

40-440

50-550

Permissible load at 40% Duty

Cycle MIG,

440A/36V

550A/41.5V

Permissible load at 60% Duty

Cycle MIG,

300A/29V

400A/34V

500A/39V

Permissible load at 100%

Duty Cycle MIG,

240A/26V

313A/29.7V

387A/33.4V

Power factor at maximum

current

≥ 0.9

Efficiency at maximum

current

≥89%

Insulation class

Enclosure class

IP 21S

Wire Diameter, mm

0.8-1.2

0.8-1.6

Dimension (LXWXH), mm

687X320X581

Weight, Kg

Duty Cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can

weld or cut at a certain load without overloading. The duty cycle is valid for 40 °C / 104

°F, or below.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against

penetration by solid objects or water.

INSTALLATION

The complete installation for MIG application should consists of the following items:

Sl. No

Description

Type

Quantity

Welding Power Source

MIG 301i / 401i / 501i

Wire feeder with Interconnections,

Wire spool

MIG 301i wire feeder /

MIG 401i wire feeder/

MIG 501i wire feeder

MIG Torch

Earth cable with clamp

Heater - Optional

110V A.C for Co2

GAS with regulator

CAUTIONS FOR INSTALLATION

−Provide a Switch Box for every Welding Power Source, and use designated

fuse

−Tolerance of Power Voltage Variation is 10% of rated input voltage.

a) Installation place

−Install in the place where less moisture and dust exist. Avoid direct sunlight and

rain, and maintain ambient temperature within –10o to +45o C as much as

possible.

−Keep the welding power source at least 20 cm. away from the wall (if any).

−In case of installation of more two units side by side, a distance of more than 20

cm is recommended between the two power sources.

−Use a shield to protect the welding arc in case of excessive air draft.

b) Ventilation

Adequate ventilation is recommended at the place of installation. For example

the following guideline should be followed:

a) In case of the area being more than 300 square meters (per unit), no

ventilation is required, provided the room is not completely airtight.

b) In case of the area being less than 300 square meters and the welding

is continuously performed, adequate ventilation is recommended with

the help of vent fan or exhaust duct.

c) While performing the grounding work, it is recommended that a skilled

electrician does the work.

WELDING OPERATIONS

Front Panel

MIG 301i / 401i

MIG 501i

Rear Panel

To start the power source, switch on the main switch on the front panel. To stop the

power source, switch OFF the main switch.

Depending on the selection, put process switch on MIG/ MMA/ GOUGING mode.

MIG Mode

Welding current and voltage can be set by knobs on the wire feeder remote. INCHING

push switch is on the wire feeder remote for inching wire without voltage. Flow of Gas

can be checked by GAS switch on the front panel.

Selection of wire diameter, type of material and 2 stroke / 4 stroke mode can be

selected on the front panel of the machine.

Crater voltage and current can be set by knobs on the machine front panel.

Control on Wire Feeder

1.Welding Current 2. Wire Inch Push Button 3. Welding Voltage Setting

Main Supply

Make sure that the welding power source is connected to the correct supply voltage

and that it is protected by the correct fuse rating. A protective earth connection must

be made in accordance with regulations.

The power source will automatically adjust to the supplied input voltage.

Recommended specification of input cable, grounding wire and fuse

Power Source

MIG 301i

MIG 401i

MIG 501i

Mains Voltage

415V, 3Ph,50Hz

Input Protector

Fuse

30A

40A

50A

Cross-section

of cable

Welding cable

2.5 mm2

4 mm2

6 mm2

Grounding wire

> 6 mm2

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 specifications of the output cable

Power Source

MIG 301i

MIG 401i

MIG 501i

Cross-section of

Cable (mm2 )

≥ 35

≥ 50

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