ESAB 350mpi
POWER SOURCE
P/N 36975 - 230 (208-230) / 460 (440) V ac, 1- or 3-phase, 50/60 Hz
F-15-481-B
July, 1999
INSTRUCTION MANUAL
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 TITLE PAGE
PARAGRAPH
USER RESPONSIBILITY ............................................................................................................... 2
SAFETY ................................................................................................................ 4
SECTION 1 DESCRIPTION ........................................................................................ 8
1.1 General.................................................................................................... 8
1.2 Duty Cycle ............................................................................................... 8
1.3 Volt-Ampere Curves ................................................................................ 8
SECTION 2 INSTALLATION ...................................................................................... 10
2.1 General.................................................................................................... 10
2.2 Required Tools ........................................................................................ 10
2.3 Unpacking and Placement ...................................................................... 11
2.4 Input Connections ................................................................................... 11
2.5 Output Connections................................................................................. 12
SECTION 3 OPERATION ........................................................................................... 15
3.1 General.................................................................................................... 15
3.2 Welding Controls / Indicators .................................................................. 15
3.3 MIG / GMAW (CV) Operation .................................................................. 17
3.4 TIG / GTAW (CC) Operation ................................................................... 17
3.5 Stick / SMAW (CC) Operation ................................................................. 18
SECTION 4 MAINTENANCE ...................................................................................... 19
4.1 General.................................................................................................... 19
4.2 Inspection and Cleaning .......................................................................... 19
SECTION 5 TROUBLESHOOTING ............................................................................ 20
5.1 General.................................................................................................... 20
5.2 Functionality Check (Table 5-1) .............................................................. 20
SECTION 6 REPLACEMENT PARTS ........................................................................ 23
3
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.
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.
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 Pro-
--
cesses", 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:
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.
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SAFETY PRECAUTIONS
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 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
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.
§25249.5 et seq.)
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. 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.
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."
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.
5
SP98-10
PRÉCAUTIONS DE SÉCURITÉ
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 incandes-
cent 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:
a. Éloigner suffisamment tous les matériaux combus-
tibles 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 incandes-
cent 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 ten-
sion 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
6
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 qua-
lifié 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 Cut-
ting” AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Weld-
ing” 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.
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SECTION 1 DESCRIPTION
1.1 GENERAL
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.
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.
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.
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.
1.2 DUTY CYCLE
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.
1.3 VOLT-AMPERE CURVES
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.
Table 1-1. Technical Specifications
RATED OUTPUT
100% Duty Cycle (3-phase input) 300 A @ 32 V dc
100% Duty Cycle (1-phase input) 225 A @ 29 V dc
60% Duty cycle (3-phase input) 350 A @ 34 V dc
Open-circuit Voltage (max) 70 V dc
PHYSICAL
Height 16.4 in. (417 mm)
Width 11.5 in. (292 mm)
Depth 29.8 in. (757 mm)
Weight 101 lbs (39 kg)
INPUT VOLTAGE AND CURRENT @ RATED 60% DUTY CYCLE LOAD
230/460 V ac models 3-phase 50/25 amps
1-phase 50/38
8
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
9
SECTION 2 INSTALLATION
2.1 GENERAL
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.
2.2 REQUIRED TOOLS
Some procedures require use of the following tools:
3/8" wrench, and a Phillips or Robertson screwdriver.
The use of socket wrenches or nutdrivers are recommended over straight wrenches due to the location of
attaching hardware.
2.3 UNPACKING AND PLACEMENT
NOTE
When lifting the ESAB 350mpi, apply direct upward
pressure to both of the carrying handles. Do not trans-
port the ESAB 350mpi with only one handle or apply
outward pressure to the handles. See Figure 2-1.
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 ship-
ping container(s), check the container for any
loose parts. Remove all packing materials.
WRONG!
Figure 2-1. Correct and Wrong Lifting Techniques
WRONG!
10
SECTION 2 INSTALLATION
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 immedi-
ately, store it in a clean, dry, well-ventilated
area.
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.
fore, 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.
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.
2.4 INPUT CONNECTIONS
ELECTRIC SHOCK CAN KILL! Precautionary measures should be taken to provide maximum protection against electrical shock.
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.
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.
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. There-
Table 2-1. Recommended Input Conductors and
Fuse Sizes
Rated Load
(3-phase input)
Volts
208
230
460
* 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.
Amps
40
38
21
Inpu t &
Ground
Conductor*
CU/AWG (mm)
8 (10)
8 (10)
10 (6)
Time-Delay
Fuse Size
Amps
60
60
30
Use the following procedure to disconnect the factoryinstalled cable and connect your own input power leads/
cable.
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.
11
SECTION 2 INSTALLATION
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 ONOFF switch cable connections from three-phase to singlephase configuration as follows:
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.
ELECTRIC SHOCK CAN KILL! After the red wire has
been removed from T3, its center conductor is exposed. This conductor must be fully covered with an
insulating material. Failure to do so properly could
cause a serious electrical shock hazard.
5. Re-attach the top cover with hardware removed in step 1.
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.
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.
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 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.
Table 2-2. Typical Output Connections
MIG Welding
(DCRP)
TIG Welding
(DCSP)
Stick Welding
(DCSP or DCRP)
2.5 OUTPUT CONNECTIONS
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.
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.
Electrode positive (+) negative (-)
Work negative (-) positive (+)
positive (+) DCRP
negative (-) DCSP
negative (-) DCRP
positive (+) DCSP
Table 2-3. Recommended Welding
Cable Sizes - AWG (mm2 )
Welding
Current
100
150
200
250
300
* 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.
Total Length (Feet) of Cable in Welding Circuit*
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)
3 (30)**
1 (50)
1/0 (50)
2/0 (70)
3/0 (95)
200
(51 m)
2 (35)
1/0 (50)
2/0 (70)
3/0 (95)
4/0 (120)
12
250
(64 m)
1 (50)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
SECTION 2 INSTALLATION
Figure 2-4. Male Output Cable Connectors (P/N 13792513)
Figure 2-5. MIG (GMAW) Interconnection Diagram
13
SECTION 2 INSTALLATION
Figure 2-6. TIG (GTAW) Interconnection Diagram
REVERSE PORALITY
(electrode positive)
ELECTRODE (+)
STRAIGHT PORALITY
(electrode negative)
ELECTRODE (-)
Figure 2-7. Stick (SMAW) Interconnection Diagram
14
SECTION 3 OPERATION
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.
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.
3.2 WELDING CONTROLS / INDICATORS
(Figure 3-1)
A. WIRE FEEDER RECEPTACLE - For connecting
ESAB 42 & 115 vac wire feeders.
B. REMOTE RECEPTACLE - For connecting remote
output control devices such as hand pendant, foot,
and torch controls.
C. PANEL / REMOTE SWITCH - Selects the point of
machine control.
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.
Selections include:
Steel CO
2
Steel Argon Mix
Stainless Steel Aluminum
Cored Wires Spray
Medium Slope 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
J. OUTPUT VOLTAGE / CURRENT CONTROL
I. DIGITAL AMPS DISPLAY
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
K. PRESET SWITCH
Figure 3-1. Controls / Indicators
L. STICK ARC FORCE / MIG ARC TRIM
M. PROCESS SELECT SWITCH
N. POWER ON/OFF SWITCH
15
SECTION 3 OPERATION
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 over-
current condition has occurred.
b. Indicator blinking - The INPUT VOLTAGE SE-
LECT SWITCH at the rear of the machine is set
incorrectly for the primary input voltage applied.
G. TEMP INDICATOR - Indicates that an over-tem-
perature 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 - S e t s
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,
Figure 3.2 - ERROR CODES
ERROR CODES
Err 1 - Hi Line
Err 2 - Lo Line
Err 3 - Hi OCV
Err 4 - Over temp
Err 5 - Over 250 Amps
Err 6 - Secondary
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
16
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.
3.3 MIG / GMAW (CV) Operation
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.
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. If the MAIN POWER
light does not lite, check the position of the
INPUT VOLTAGE SELECT SWITCH for
proper setting.
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.
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.
NOTE
When the HC-5 remote hand control 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.
J. Commence welding operations by energizing
the torch switch.
K. For remaining wire feeder or control opera-
tions, refer to the appropriate instruction literature supplied with your particular system.
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.
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.
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.
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.
D. Place the PROCESS SELECT switch in the
TIG or TOUCH TIG position.
F. Place the PANEL/REMOTE switch in the ap-
propriate 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.
17
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.
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.
NOTE
When the HC-5 remote hand control 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. Make sure you have a good clean ground and
a secure workpiece. Also, ensure that shielding gas is turned on and flowing.
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 willl increase to the
value as controlled by the potentiometer.
L. For remaining accessory operations, refer to
the appropriate instruction literature supplied
with your particular system.
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.
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.
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.
D. Place the PANEL/REMOTE switch in the de-
sired 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.
18
J. For remaining accessory operations, refer to
the appropriate instruction literature supplied
with your system.
SECTION 4 MAINTENANCE
4.1 GENERAL
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.
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.
4.2 INSPECTION AND CLEANING
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.
19
SECTION 5 TROUBLESHOOTING
5.1 GENERAL
5.2 FUNCTIONALITY CHECK (Table 5-1)
The 350mpi Functionality Check should be used to verify
proper power source operation. Before performing the
following checks, disconnect the remote connections
ELECTRIC SHOCK CAN KILL! Before attempting
inspection or work inside the power source, be sure
that all primary power to the machine has been
(WIRE FEEDER and REMOTE CONTROL) from rear of
power source and make sure there is no load attached
to the output terminals.
externally disconnected and the line (wall) disconnect switch or circuit breaker is open.
Table 5-1. 350mpi Functionality Check
YES NO
1. Are input power supply connections properly secured? Go to next
2. If using 3-phase power, are all three primary leads securely connected to Go to next Refer to
primary power switch. step. Section 2.
If using single-phase power, are black and white leads securely connected to
primary power switch?
.
3. Position power source controls as follows: --- --
PROCESS SELECTOR - STICK
CURRENT - MINIMUM
ARC FORCE - MINIMUM
step
4. Turn primary power switch to ON position. Does MAIN POWER light Go to next
illuminate? step.
5. Do digital meters show about 68.0 volts and 00.0 amps? Go to next
7. Fan is not energized. Go to next
8. Place PANEL/REMOTE switch in the PANEL position. Do digital meters Go to next Power source
show 00.0 volts and 00.0 amps? step. faulty.
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? Go tonext
11. Rotate ARC FORCE fully clockwise. Does digital meter show about 150 Go to next
amps? step.
12. Rotate CURRENT fully clockwise. Does digital meter show about 500 Go to next
amps? 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.
step.
step.
step.
20
SECTION 5 TROUBLESHOOTING
37504-B
Figure 5-1. Schematic Diagram - 350mpi, 230 (208-230)/ 460 (440) Vac
21
SECTION 5 TROUBLESHOOTING
37844-B
Figure 5-2. Wiring Diagram - ESAB 350mpi Power Source
22
SECTION 6
REPLACEMENT PARTS
View 1 of ESAB 350mpi Bill of Materials
23
SECTION 6
REPLACEMENT PARTS
View 2 of ESAB 350mpi Bill of Materials
24
SECTION 6
REPLACEMENT PARTS
View 3 of ESAB 350mpi Bill of Materials
View 4 of ESAB 350mpi Bill of Materials
25
SECTION 6
REPLACEMENT PARTS
View 5 of ESAB 350mpi Bill of Materials
78
142
1
1
View 6 of ESAB 350mpi Bill of Materials
26
SECTION 6
REPLACEMENT PARTS
View 7 of ESAB 350mpi Bill of Materials
View 8 of ESAB 350mpi Bill of Materials
27
SECTION 6
REPLACEMENT PARTS
View 9 of ESAB 350mpi Bill of Materials
28
SECTION 6
REPLACEMENT PARTS
View 10 of ESAB 350mpi Bill of Materials
29
SECTION 6
REPLACEMENT PARTS
Bill of Materials
ESAB 350mpi Power Source
ITEM PART OR
NO. CODE NO. QTY. DESCRIPTION SYMBOL
1 34916 4 BUSBAR TAB
2 36107 1 SWITCH POWER 600V 63 AMP S1
4 37584 1 BAFFLE FRONT
5 37585 1 BAFFLE MIDDLE
6 37590 1 BUS CAP A+
7 37591 1 BUS CAP A-
8 37592 1 BUS CAP B-
9 37593 2 BUSBAR RESISTOR
10 37594 1 BRACKET CAP KYDEX
11 37595 2 HEAT SINK RESISTOR BRACKET
12 37596 1 BUS CAP B+
13 37598 1 XFMR MAIN T1
14 37599 1 INDUCTOR L1
16 37602 1 INDUCTOR DC L2
20 38012 1 PC BRD IGBT DRIVER PCB3
21 38150 1 PCB CONTROL PCB1
22 38152 1 PCB METER PCB4
23 38154 1 PCB LINE MONITOR PCB2
25 634515 1 SW TGGL SPDT 2 POS 15A 125V S4
27 634818 1 BUSHING SNAP .25 ID .38 MH .41L
32 950228 1 FUSE 4A 500V TIME DELAY F1
35 950710 1 SWITCH THERMAL 15A 120V 131 TS3
37 951085 2 SWITCH THERMAL 15A 120V TS1
38 951161 4 CAPC METPOLY 20uf 400 VDC C2,3,6,7
39 951191 2 PAD THERMAL IGBT 1200V (INCL. WITH-)
40 951340 1 PLUG 14 POS P1
41 951474 1 SWITCH SEAL BLACK
42 951567 2 STDF NYL 1.25 LG #6-32
43 951635 2 CAP ALUM 1900uf 450VDC C1,5
44 951939 1 FAN BLADE C13
45 951940 2 CAPC 1uf 600 VDC
46 951997 1 TRANSDUCER CURRENT
50 952136 1 FUSE HOLDER PANEL MOUNT
51 952209 1 RECPT PNL MNT 19 PIN 22-14S J1
52 952235 1 MODULE INPUT BRIDGE/SCR IBR
53 952280 1 PAD THERMAL INPUT BRIDGE
54 952873 2 MODULE DUAL IGBT 200A 600V Q1,2
55 952888 2 HANDLE
56 952889 1 HEATSINK PRIMARY
57 952890 1 HEATSINK SECONDARY
58 952892 1 SW ROTARY 2 POLE 5 POS S3
30
SECTION 6
REPLACEMENT PARTS
Bill of Materials
ESAB 350mpi Power Source (Cont'd)
ITEM PART OR
NO. CODE NO. QTY. DESCRIPTION SYMBOL
59 952894 1 SW ROTARY 1 POLE 8 POS S1
60 952895 1 SWITCH PB NORMALLY OPEN S5
61 952896 1 DUAL BREAKER W/2 AUX SW
62 952897 1 TRANSFORMER CONTROL T2
63 952898 2 DIODE OUTPUT D1,2
64 952899 1 POWER CABLE INPUT
65 952900 1 DIODE 1/2 BRIDGE D3
66 952937 1 RECPT PNL MNT 14 PIN 22-14S J2
67 952938 1 SCR 480V 12A PNL MNT SCR1
68 952986 2 CURRENT TRANSDUCER T3 4
69 954292 2 LABEL ESAB 2.7 X 4.5
70 954506 1 LABEL ISO 9002
71 954699 1 LABEL WARNING FAN HAZARD
72 954802 1 LABEL ELECTRIC SHOCK
73 954803 1 LABEL DO NOT SWITCH W/POWER ON
74 954805 1 LABEL DISCONNECT POWER
75 954808 1 OVERLAY
76 954816 1 NAMEPLATE 350 MPI
77 954820 1 LABEL 4A 600VAC SLOW BLOW FUSE
78 2017483 1 FUSE 1A 250V N-T DELAY
79 2091514 1 LABEL WARNING WELD & CUT
81 13730611 4 KNOB
82 13730632 2 POT LIN 10K 2W .88L R11,12
85 13732226 1 FAN MOTOR 1/16 HP M1
87 13733935 2 PANEL RECEPT 2-1/0 NEG, POS
88 17240225 4 RES WW 25W 3% R2,3,6,7
89 17250005 1 RES WW 50W 5% R1
90 17725005 2 RES 2.5K OHM 25W R9,10
91 17750020 4 RES 20 OHM 50W 3% NON-INDUCT R4,8,13,14
125 99511578 AR SNAP IN TIE BASE .218
133 182W12 4 FOOT
134 37581GY 1 BASE
135 37582GY 1 PNL FRONT
136 37583YL 1 COVER
137 37586GY 1 BAFFLE REAR
138 37587GY 1 SHELF PCB
139 37588GY 1 BRACKET FAN
140 37840GY 1 BOX CIRCUIT BREAKER
141 37875GY 2 BRACKET INDUCTOR
142 96W10 1 FUSE BLOCK 1 POLE QUICK CONNECT
143 97W63 1 CONNECTOR CABLE GRIP
31
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Order Entry Product Availability Pricing D elivery
Order Changes Saleable Goods Returns Shipping Information
Telephone: (800)362-7080 / Fax: (800) 634-7548
Telephone: (800)783-5360 / Fax: (800) 783-5362
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
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 / Fax: (843) 664-4454 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
Eastern Distribution Center
Central Distribution Center
Western Distribution Center
Hours: 7:30 AM to 4:00 PM EST
Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
F-15-481-B 7/99 Printed in U.S.A
IF YOU DO NOT KNOW WHOM TO CALL
Hours: 7:30 AM to 5:00 PM EST
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