ESAB MIG400iCCCV User manual

MIG400iCCCV

INVERTER MIG/MMA

Welding Power Source

Instruction manual

MIG400iCCCV

INVERTER WELDING POWER SOURCE

Instruction manual

For

Installation, Operation & General maintenance

CONTENTS

Item

Page No.

SAFETY

3-4

RATING AND INSTALLATION

CAUTIONS FOR INSTALLATION

WELDING OPERATIONS

7-9

WIRING DIAGRAM

TROUBLESHOOTING

PARTS LIST AND EXPLODED VIEW

12-14

ESAB INDIA LOCATIONS AND CONTACT DETAILS

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

RATING

RATING OF MIG400iCCCV INVERTER WELDING POWER SOURCE

CHARACTERISTICS

CONSTANT VOLTAGE/

CURRENT TYPE

Input:

SUPPLY VOLTAGE, PHASE & FREQUENCY

415V± 15%, 3Phase, 50 Hz, AC

MAXIMUM INPUT CURRENT

26.6 A

Output:

OUTPUT CURRENT RANGE

DC 40-400A

VOLTAGE RANGE

16-34 V DC

TYPE OF WELDING CURRENT CONTROL

STEPLESS

CLASS OF INSULATION

‘H’

COOLING

FORCED AIR COOLED

APPROX DIMENSION (LxWxH) IN MM

654 x 322 x 671

WEIGHT (APPROX)

50.5 KG.

INSTALLATION

The complete installation for MIG application should consist the following items:

Description

Type

Quantity

Welding Power Source

MIG400iCCCV

Wire feeder with

Interconnections, Wire

spool

MIG400i wire

feeder

MIG Torch for MIG

Earth cable with Clamp

Heater - optional

110V A.C. for CO2

GAS with regulator

The complete installation for MMA application should consist the following items:

Description

Type

Quantity

Welding Power Source

MIG400iCCCV

Welding Cable with

Electrode Holder.

Earth cable with Clamp

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

1. Current meter

2. Voltage meter

3. Crater Current

4. Crater Voltage

5. MMA/ MIG switch

6. Wire feeder control circuit socket

7. Power Socket +

8. Power indicating light

9. Protection indicating light

10. Current Inductance control

11. Welding mode selection switch

12. Crater OFF/ON (2T/4T) selection switch

13. Power Socket —

1. Power switch

2. Heater socket AC110V）

3. Controlling power trip (3A)

4. Fan

5. Earthing bolt

6. Cable fixed head

7. Power input cable

8. Nameplate

Indicating light

Only Green light on: The power is on.

Green light on, Red light on: The machine is overheated. The machine will go back to

working condition, if the inner temperature of machine returns to the allowed level.

MIG MODE

Put MMA/ MIG switch on power source in MIG mode.

Crater Control (2T/4T)

Usually there is a crater at the end of welding. Adjust Crater Voltage and Current to fill

up the crater by arc ending current (less than 40%-70% of welding current) and

improve the welding quality. It also selects 2T/4T operation of the machine.

Soft wire feeding

In order to get the satisfying welding quality, the machine feed the wire at preset low

speed before wire touch the work piece. The speed will reach the normal level after

striking arc. It means striking arc fail if the current is not detected during this stage.

This kind of striking arc mode can improve the success of striking arc and ensure the

reliable and stable arc.

Burn back time

When the trigger of torch is switched off, the wire feeding will continue because of

inertia. So the wire will go out to the top end of torch after the welding. It will cause the

stick of wire to the work piece, thus bring the difficulty to the next welding. The burn

back is set in the machine to solve this problem. The machine will keep output voltage

during certain time to keep wire burning.

Current Inductance control

It means electronic reactor. It can adjust wire burning power by changing the current

changing speed, and reduce the spatter.

Ball cutting

Usually there is a big droplet at the end of wire after welding. And slag will stick on the

low surface of the droplet. It will cause difficulty of striking arc. The ball cutting circuit is

designed to cut the droplet automatically after welding.

Post-gas

3 seconds post-gas time is set to protect the welding area after welding.

Control on wire Feeder

1. Welding Current Setting.

2. Wire Inch Push Button.

3. Welding Voltage Setting.

MMA MODE

Put MMA/MIG switch on power source in MMA mode.

Welding current can be set by MMA current setting knob on the power source.

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