As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2Safety precautions
Users of ESAB 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 equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. 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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2.The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
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,
flame-proof clothing, 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
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ 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
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
•Install and ground the unit in accordance with instruction manual.
•Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
•Insulate yourself from work and ground.
•Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
•Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
•Exposure to EMF may have other health effects which are unknown.
•Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
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.
0463 415 101
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
•Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
•Stop engine before installing or connecting unit.
•Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
•Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
•Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
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.
Equipment marked IP23 is intended for indoor and outdoor use.
Application class
The symbolindicates that the power source is designed for use in areas with increased
electrical hazard.
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.
4.1Location
Position the power source so that its cooling air inlets and outlets are not obstructed.
A. Minimum 200 mm (8”)
B. Minimum 200 mm (8”)
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.
4.2Lifting instructions
Mechanical lifting must be done with both outer handles.
This equipment complies with IEC 61000-3-12 provided that the short-circuit
power is greater than or equal to S
at the interface point between the user's
scmin
supply and the public system. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply with a short-circuit
power greater than or equal to S
. Refer to the technical data in the
scmin
TECHNICAL DATA chapter.
The power source will automatically adjust to the supplied input voltage; make sure it is
protected by the correct fuse rating. A protective earth connection must be made, in
accordance with regulations.
Different variants of ES 300i are certified for different mains voltage. Always refer
to the rating plate for the specification of the power source in use.
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. Use the power source in accordance with the relevant
national regulations.
1-phase 230V mains voltage with 16A mains fuse
See table below for informative data for use at 1-phase 230V mains voltage with 16A mains
fuse. A 16A mains fuse may enable the use of a 16A mains plug in combination with a
*) Porcelain fuses are recommended to achieve 200A in MMA and TIG mode. MCB fuses
break the circuit faster than porcelain fuses.
Supply from power generators
The power source can be supplied from different types of generators. However, some
generators may not provide sufficient power for the welding power source to operate
correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better
type of regulation, with rated power 20 kW, are recommended.
Installation of mains cable
NOTE!
The power source is delivered with mains cable approved for 380-480V and plug
for 380-415V. If other mains voltage is required, the mains cable and plug may
be changed according to relevant national regulations.
1.Remove the side panel.
2.If tightened, release the stopping block (A).
3.If a cable is connected, disconnect all wires, cut the cable tie (D), and remove the
cable.
4.Optional: The fan with foam can at this point be removed to simplify the installation.
Note the direction of the fan (the sticker towards the inside).
5.Strip the new wire according to specification (B).
6.Insert the cable with about 1 cm (0.4 in.) of isolation inside the stopping block. Tighten
the stopping block by using 1.5–2Nm (13.3–17.7in.lb) (A).
7.Use a cable tie to fasten the cables (D).
8.Optional: If the fan with foam has been removed it shall now be re-installed. A symbol
on the side of the fan (G) shows the air flow direction.
9.Install the ferrites and connect the earth wire (C). A toothed washer should be located
closest to the heat sink. Tighten the screw to a torque of 6.0±0.6Nm (53.1±5.3in.lb).
10. Connect all wires. Tighten the screw to a torque of 1.0±0.2Nm (8.9±1.8in.lb).
11. Ensure that the IP shield is correctly mounted on the inside of the side panel (E).
General safety regulations for handling the equipment can be found in the chapter
"Safety". Read it through before you start the equipment.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
5.2Connections and control devices
1. Setting panel5. Mains power supply switch, O/I
2. Positive welding terminal6. USB connection
3. Negative welding terminal7. Mains cable
4. Connection for remote control unit
NOTE!
Always use the cover when the USB connection is not in use.
5.3Connection of welding and return cables
The power source has two outputs, a positive welding terminal (+) and a negative welding
terminal (-), for connecting welding and return cables. The output to which the welding cable
is connected depends on the welding method or type of electrode used.
Connect the return cable to the other output 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.
•For TIG welding, the negative welding terminal (-) is used for the welding torch and the
positive welding terminal (+) is used for the return cable.
•For MMA welding, the welding cable can be connected to the positive welding terminal
(+) or negative welding terminal (-) depending on the type of electrode used. The
connecting polarity is stated on the electrode packaging.
5.4Turning the mains power on/off
Turn on the mains power by turning switch to the ”I” position.
Turn the unit off by turning the switch to the ”O” position.
Whether the mains power supply is interrupted or the power source is switched off in the
normal manner, weld programs will be stored so that it is available next time the unit is
started.
CAUTION!
Do not turn off the power source during welding (with load).
5.5Fan control
The power source has an automatic thermal control. The fan continues to run during a few
minutes after welding has stopped while the power source switches to energy-saving mode.
The fan starts again when welding restarts.
During energy-saving mode the fan will start occasionally and run for a few minutes.
5.6Thermal protection
The power source includes thermal protection against overheating. When
overheating occurs the welding is stopped and overheating indicator on the
panel will be lit and an error message shows in the display. The protection is
automatically reset when the temperature has been sufficiently reduced.
5.7Functions and symbols
Hot start
The hot start function temporarily increases the current in the beginning of the
weld. Use this function to reduce risk of insufficient fusion and electrode sticking
and scratching.
Hot start only applies to MMA welding.
Cel 6010
Optimised arc characteristics for cellulosic electrodes such as 6010 and similar.
TIG welding melts the metal of the workpiece, using an arc struck from a
tungsten electrode that does not melt. The weld pool and electrode are
protected by shielding gas.
For TIG welding, the welding power source shall be supplemented with:
•a TIG torch with gas valve
•an argon gas cylinder
•an argon gas regulator
•tungsten electrode
This power source performs Live TIG start.
The tungsten electrode is placed against the workpiece. When lifted away from
workpiece the arc is struck at a limited current level.
Voltage Reduction Device (VRD)
The VRD function ensures that the open-circuit voltage does not exceed 35V
when welding is not being carried out. This is indicated by a lit VRD indicator on
the panel. Contact an authorised ESAB service technician to activate this
function.
The set indicator (8) will be lit when a value can be changed. It cannot be changed from the
panel when a remote control is activated. Trying to change a value while in measured value
mode will result in automatically move to set current value mode.
5.8.2Weld program
For each welding process (MMA/TIG) three different weld programs can be stored in the
setting panel memory (1). Press selection button 1, 2 or 3 for 3 seconds to store a weld
program in the memory. The memory indicator will be lit when finished.
To switch between the different weld programs press button 1, 2 or 3.
5.9Remote control
Connect the remote control on the rear side of the power source and activate the
remote control by pressing the remote control button on the panel (remote
control indicator being lit when activated). When the remote control is activated
the control panel is locked for interaction but displays welding data.
5.10USB connection
Always use the USB cover when the USB connection is not in use.
Do not use for charging units such as mobile phones.
The welding process is blocked when a USB flash drive is connected. The USB
connection can be used to retrieve welding statistics. The statistics contains of
total number of welds performed, total welding time and average current.
Retrieving welding statistics
Always make sure that the power source is not used for welding when retrieving
welding statistics.
1.Insert an empty USB flash drive into the power source USB connector.
2.To confirm that the power source has read the USB flash drive, the text
"USB" flashes in the display for a moment, after which the text "USB" is
shown with fixed light.
3.When the text "USB" is shown with fixed light: Remove the USB flash drive
from the USB connector.
4.The USB flash will contain a text file (.txt) with the welding statistics.
5.Recommended program for opening the text file is Microsoft WordPad or
Microsoft Word.
The error code is used to indicate that a fault has occurred in the equipment. Errors are
indicated by the text "Err" followed by the error code number shown in the display.
If several errors have been detected only the code for the last occurring error is displayed.
7.1Error code descriptions
Error codes that the user can handle are listed below. If any other error code appears,
contact an authorised ESAB service technician.
Error code Description
Err 1Temperature fault
The temperature of the power source is too high. A LED indicating
temperature fault is also lit on the panel.
Action: The error code will automatically disappear and the LED indicating
temperature fault will be turned off when the power source has cooled off and
is ready for use again.
Err 3Power supply fault
The power supply to the power source is too low or too high.
Action: Make sure the power supply is stable, all leads are connected, that
the mains voltage (all 3 phases) are OK and restart the system. If the error
persists, contact a service technician.
Err 4Communication fault
The communication in the power source has been disrupted.
Action: Restart the power source. If the error persists, contact a service
technician.
Err 5Memory fault
The program memory is damaged. This fault can disable preset functions or
other functions where values are stored.
Action: Remove the error indication from the display by pressing a button on
the panel. Restart the power source. If the error persists, contact a service
technician.
Err 6Timing fault
The power source electronics are not able to execute all functions in a timely
fashion.
Action: Restart the power source. If the error persists, contact a service
technician.
Err 7OCV fault
The OCV is too high or the electronic control of the OCV has been disrupted.
0463 415 101
Action: Restart the power source. If the error persists, contact a service
technician.
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The ES 300i is designed and tested in accordance with international and european
standards IEC/EN 60974-1 and IEC/EN 60974-10. On completion of service or repair work,
it is the responsibility of the person(s) performing the work to ensure that the product still
complies with the requirements of the above standard.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.