ESAB 350mpiPOWER SOURCE

P/N 36975 - 208-230/460 Vac 3-phase, 230 Vac 1-phase, 60 HzP/N 36977 - 400/440 Vac 3-phase 50/60 HzP/N 36976 - 575 Vac 3-phase, 60 Hz

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safepractices 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 attemptto install or operate this equipment until you have read and fully understand these instructions. If you do not fully understandthese instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing oroperating this equipment.

Be sure this information reaches the operator.You can get extra copies through your supplier.

F15-481-KNovember, 2008

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USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labelsand/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. Thisequipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Partsthat are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair orreplacement become necessary, the manufacturer recommends that a telephone or written request for service advicebe 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 userof this equipment shall have the sole responsibility for any malfunction which results from improper use, faultymaintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facilitydesignated by the manufacturer.

PREFACE

The purpose of this manual is to provide the operator with information required to install and operate thepower source. Some technical reference material is also provided to assist in basic troubleshooting thepower source. If it is determined that the power supply is not operating properly, the operator shouldcontact 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)

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SECTION TITLE PAGEPARAGRAPH

USER RESPONSIBILITY ............................................................................................................... 2

SAFETY ................................................................................................................ 5

SECTION 1 DESCRIPTION ....................................................................................... 111.1 General .................................................................................................... 111.2 Duty Cycle .............................................................................................. 111.3 Volt-Ampere Curves................................................................................ 11

SECTION 2 INSTALLATION ...................................................................................... 132.1 General .................................................................................................... 132.2 Required Tools ........................................................................................ 132.3 Unpacking and Placement ...................................................................... 132.4 Input Connections ................................................................................... 142.5 Output Connections ................................................................................ 15

SECTION 3 OPERATION .......................................................................................... 193.1 General .................................................................................................... 193.2 Welding Controls / Indicators .................................................................. 193.3 MIG / GMAW (CV) Operation ................................................................. 213.4 TIG / GTAW (CC) Operation................................................................... 213.5 Stick / SMAW (CC) Operation ................................................................ 223.6 Overview of Error Codes and Programs Updates .................................. 23

SECTION 4 MAINTENANCE...................................................................................... 254.1 General .................................................................................................... 254.2 Inspection and Cleaning .......................................................................... 25

SECTION 5 TROUBLESHOOTING .......................................................................... 275.1 General .................................................................................................... 275.2 Functionality Check (Table 5-1) .............................................................. 27

SECTION 6 REPLACEMENT PARTS ....................................................................... 33

TABLE OF CONTENTS

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TABLE OF CONTENTS

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WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before

performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.

PROTECT YOURSELF AND OTHERS --Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.Training in the proper use of the processes and equip-ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any workarea, even if welding helmets, face shields, and gogglesare also required.

2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc andnot to expose themselves to the rays of the electric-arcor hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing

5. Protect other personnel from arc rays and hot sparkswith a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and ex-plosions. Therefore:

1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.“

3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.

SAFETY PRECAUTIONS

10/98

5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.

6. After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when neces-sary.

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 Asso-ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.

1. Be sure the power source frame (chassis) is connectedto 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 fatalshock.

4. Use well-maintained equipment. Replace worn or dam-aged 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 fromwork and from ground.

7. Do not stand directly on metal or the earth while workingin tight quarters or a damp area; stand on dry boards oran 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 mistakethe work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —May be dangerous. Electric current flow-ing through any conductor causes lo-calized Electric and Magnetic Fields(EMF). Welding and cutting current cre-ates EMF around welding cables andwelding machines. Therefore:

1. Welders having pacemakers should consult their physi-cian before welding. EMF may interfere with some pace-makers.

2. Exposure to EMF may have other health effects which areunknown.

3. Welders should use the following procedures to minimizeexposure 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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FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can cause asphyxiation.Therefore:

1. Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel,copper, zinc, lead, beryllium, or cadmium unless positivemechanical ventilation is provided. Do not breathe fumesfrom these materials.

2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene, a highly toxicgas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation is notadequate. Stop work and take necessary steps to im-prove ventilation in the work area. Do not continue tooperate 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 orcutting, produces fumes or gases whichcontain chemicals known to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety Code §25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, ifmishandled, can rupture and violentlyrelease gas. Sudden rupture of cylin-der, valve, or relief device can injure orkill. Therefore:

1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition. Followmanufacturer's operating instructions for mounting regu-lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chainor strap to suitable hand trucks, undercarriages, benches,walls, post, or racks. Never secure cylinders to worktables or fixtures where they may become part of anelectrical circuit.

3. When not in use, keep cylinder valves closed. Havevalve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitablehand 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 inCylinders", which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington,VA 22202.

EQUIPMENT MAINTENANCE -- Faulty orimproperly maintained equipment cancause injury or death. Therefore:

1. Always have qualified personnel perform the installa-tion, troubleshooting, and maintenance work. Do notperform any electrical work unless you are qualified toperform such work.

2. Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.

3. Maintain cables, grounding wire, connections, powercord, and power supply in safe working order. Do notoperate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keepequipment 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 positionand in good repair.

6. Use equipment only for its intended purpose. Do notmodify it in any manner.

ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices for elec-tric arc welding and cutting equipment, askyour supplier for a copy of "Precautions andSafe Practices for Arc Welding, Cutting andGouging", Form 52-529.

The following publications, which are available from theAmerican Welding Society, 550 N.W. LeJuene Road, Mi-ami, 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 Hand-

book.8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have HeldHazardous Substances."

MEANING OF SYMBOLS - As used through-out this manual: Means Attention! Be Alert!Your safety is involved.

Means immediate hazards which, ifnot avoided, will result in immediate,serious personal injury or loss of life.

Means potential hazards which couldresult in personal injury or loss of life.

Means hazards which could result inminor personal injury.

SP98-10

SAFETY PRECAUTIONS

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a. Éloigner suffisamment tous les matériaux combus-tibles du secteur où l’on exécute des soudures ou descoupes à l’arc, à moins de les recouvrir complètementd’une bâche non-inflammable. Ce type de matériauxcomprend notamment le bois, les vêtements, la sciure,l’essence, le kérosène, les peintures, les solvants, legaz naturel, l’acétylène, le propane et autres sub-stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-cent peuvent tomber dans des fissures du plancher oudans des ouvertures des murs et y déclencher uneignition lente cachée. Veiller à protéger ces ouverturesdes étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérationsde gougeage ou autres travaux à chaud à la surfacede barils, bidons, réservoirs ou autres contenantsusagés, avant de les avoir nettoyés de toute trace desubstance susceptible de produire des vapeursinflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, ilconvient de disposer d’un matériel d’extinction prêt àservir immédiatement, tel qu’un tuyau d’arrosage, unseau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteurde façon à vous assurer qu’aucune étincelle ou projec-tion de métal incandescent ne risque de provoquerultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arcau plasma exige l’emploi de tensions à viderelativement importantes; or, celles-ci risquent decauser des dommages corporels graves et mêmemortels en cas d’utilisation inadéquate. La gravité duchoc électrique reçu dépend du chemin suivi par lecourant 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 devêtements humides. Veillez à porter des gants biensecs.

b. Si vous devez effectuer un travail sur une surfacemétallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secset des chaussures à semelles de caoutchouc et envous tenant sur une planche ou une plate-formesèche.

c. Mettez toujours à la terre le poste de soudage/coupageen le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Nesurchargez jamais le câble. Utilisez toujours unéquipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas enservice. une mise à la masse accidentelle peut eneffet provoquer une surchauffe de l’équipement et undanger d’incendie. Ne pas enrouler ou passer le câbleautour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce enun point aussi proche que possible de la zone detravail. Le branchement des câbles de masse àl’ossature du bâtiment ou en un point éloigné de lazone de travail augmente en effet le risque depassage d’un courant de sortie par des chaînes de

PRÉCAUTIONS DE SÉCURITÉAVERTISSEMENT: Ces règles de sécurité ont pour objetd’ assurer votre protection. Veillez à lire et à observer lesprécautions énoncées ci-dessous avant de monter l’équipement ou de commercer à l’utiliser. Tout défautd’observation de ces précautions risque d’entraîner desblessures graves ou mortelles.1. PROTECTION INDIVIDUELLE-- Les brûlures de la

peau et des yeux dues au rayonnement de l’arcélectrique ou du métal incandescent, lors du soudageau plasma ou à l’électrode ou lors du gougeage àl’arc, peuvent s’avérer plus graves que cellesrésultant d’une exposition prolongée au soleil. Aussiconvient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaquesprotectrices et des verres filtrants appropriés afin devous protéger les yeux, le visage, le cou et les oreillesdes étincelles et du rayonnement de l’arc électriquelorsque vous effectuez des soudures ou des coupesou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximitéde façon à ce qu’elles ne regardent pas l’arc et à cequ’elles ne s’exposent pas à son rayonnement, ni àcelui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tuniqueépaisse à manches longues, des pantalons sansrebord, des chaussures à embout d’acier et uncasque de soudage ou une calotte de protection, afind’éviter d’exposer la peau au rayonnement de l’arcélectrique ou du métal incandescent. ll est égalementsouhaitable d’utiliser un tablier ininflammable defaçon à se protéger des étincelles et du rayonnementthermique.

c. Les étincelles ou les projections de métal incandes-cent risquent de se loger dans des manchesretroussées, des bords relevés de pantalons ou dansdes poches. Aussi convient-il de garder boutonnés lecol et les manches et de porter des vêtements sanspoches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arcélectrique les autres personnes travaillant à proximitéà l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécuritélorsque vous vous trouvez dans un secteur où l’oneffectue des opérations de soudage ou de coupage àl’arc. Utilisez des lunettes de sécurité à écrans ouverres latéraux pour piquer ou meûler le laitier. Lespiquetures incandescentes de laitier peuvent êtreprojetées à des distances considérables. Lespersonnes se trouvant à proximité doivent égalementporter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasmaproduisent un niveau de bruit extrêmement élevé (de100 à 114 dB) et exigent par conséquent l’emploi dedispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections delaitier incandescent ou d’étincelles peuventprovoquer de graves incendies au contact dematériaux combustibles solides, liquides ou gazeux.Aussi faut-il observer les précautions suivantes:

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levage, des câbles de grue ou divers cheminsélectriques.

g. Empêchez l’apparition de toute humidité, notammentsur vos vêtements, à la surface de l’emplacement detravail, des câbles, du porte-électrode et du poste desoudage/coupage. Réparez immédiatement toutefuite d’eau.

4. VENTILATION-- La respiration prolongée des fuméesrésultant des opérations de soudage/coupage, àl’intérieur, d’un local clos, peut provoquer des mal-aises et des dommages corporels. Aussi convient-ild’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate del’emplacement de travail en maintenant une ventila-tion naturelle ou à l’aide de moyens mécaniques.N’effectuez jamais de travaux de soudage ou decoupage sur des matériaux de zinc, de plomb, deberyllium ou de cadmium en l’absence de moyensmécaniques de ventilation capables d’empêcherl’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou decoupage à proximité de vapeurs d’hydrocarburechloré résultant d’opérations voisines de dégraissageou de pulvérisation. La chaleur dégagée ou lerayonnement de l’arc peut déclencher la formation dephosgène -- gaz particulièrement toxique -- et d’autresgaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de lagorge constatée au cours de l’utilisation del’équipement dénote un défaut de ventilation. Arrêtez-vous de travailler afin de prendre les mesures néces-saires à l’amélioration de la ventilation. Ne poursuivezpas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisationsoù circule de l’hydrogène. L’armoire de commande estmunie d’un ventilateur destiné à empêcher la forma-tion de poches d’hydrogène, lesquelles présentent undanger d’explosion; ce ventilateur ne fonctionne quesi l’interrupteur correspondant du panneau avant setrouve placé en position ON (Marche). Veillez àmanœuvrer cette commande en vérifiant si lecouvercle est bien en place, de façon à assurerl’efficacité de la ventilation ainsi réalisée. Ne jamaisdébrancher le ventilateur.

e. Les fumées produites par l’opération de soudage oude coupage peuvent s’avérer toxiques. Aussi est-ilnécessaire de disposer en permanence d’un dispositifadéquat de ventilation de type aspirant, afin d’élimi-ner du voisinage de l’opérateur tout dégagement defumée visible.

f. Consultez les recommandations particulières enmatière de ventilation indiquées à l’alinéa 6 de lanorme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipemententretenu de façon défectueuse ou inadéquate risquenon seulement de réaliser un travail de mauvaise

qualité mais, chose plus grave encore, d’entraîner desdommages corporels graves, voire mortels endéclenchant 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 postede soudage et de coupage. N’effectuez aucuneréparation électrique sur l’équipement à moins d’êtrequa-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretienquelconque à l’intérieur du poste de soudage/coupage, avant d’avoir débranché l’alimentationélectrique.

c. Maintenez en bon état de fonctionnement les câbles,le câble de masse, les branchements, le cordond’alimentation et le poste de soudage/coupage.N’utilisez jamais le poste ou l’équipement s’il présenteune défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage etdes équipements accessoires. Gardez-les à l’écartdes sources de charleur, notamment des fours, del’humidité, des flaques d’eau maintenez-les à l’abri destraces d’huile ou de graisse, des atmosphères corro-sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tousles panneaux de l’armoire de commande en veillant àles garder en bon état.

f. Utilisez le poste de soudage/coupage conformément àson usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVESÀ LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur lesrègles de sécurité à observer pour le montage etl’utilisation d’équipements de soudage et de coupageélectriques et sur les méthodes de travailrecommandées, demandez un exemplaire du livret N°52529 “Precautions and Safe Practices for Arc Weld-ing, Cutting and Gouging” publié par ESAB. Nousconseillons également de consulter les publicationssui-vantes, tenues à votre disposition par l’AmericanWelding Society, 550 N.W. LeJuene Road, Miami, FL32126:

a. “Safety in Welding and Cutting” AWS Z49.1b. “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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ADVERTENCIA: Estas Precauciones de Seguridadson para su protección. Ellas hacen resumen deinformación proveniente de las referencias listadas

en la sección "Información Adicional Sobre La Seguridad". Antes dehacer cualquier instalación o procedimiento de operación , asegúresede leer y seguir las precauciones de seguridad listadas a continuaciónasí como también todo manual, hoja de datos de seguridad delmaterial, calcomanias, etc. El no observar las Precauciones deSeguridad puede resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS--Algunos procesos de soldadura, cortey ranurado son ruidosos y requirenprotección para los oídos. El arco, comoel sol , emite rayos ultravioleta (UV) y

otras radiaciones que pueden dañar la piel y los ojos.El metal caliente causa quemaduras. EL entrenamientoen el uso propio de los equipos y sus procesos esesencial para prevenir accidentes. Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados siempreque esté en el área de trabajo, aún cuando esté usando caretade soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente para protegersus ojos, cara, cuello, y oídos de las chispas y rayos del arcocuando se esté operando y observando las operaciones. Alertea todas las personas cercanas de no mirar el arco y no exponersea los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada demangas largas, pantalón de ruedo liso, zapato alto al tobillo, ycareta de soldar con capucha para el pelo, para proteger elcuerpo de los rayos y chispas calientes provenientes del metalfundido. En ocaciones un delantal a prueba de fuego esnecesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse en lasmangas enrolladas de la camisa , el ruedo del pantalón o losbolsillos. Mangas y cuellos deberán mantenerse abotonados,bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chispas calientescon una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de seguridadcuando esté removiendo escoria o puliendo. La escoria puedeestar caliente y desprenderse con velocidad. Personas cercanasdeberán usar gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor delas flamas y el arco pueden ocacionarfuegos. Escoria caliente y las chispaspueden causar fuegos y explosiones.Por lo tanto:

1. Remueva todo material combustible lejos del área de trabajo ocubra los materiales con una cobija a prueba de fuego. Materialescombustibles incluyen madera, ropa, líquidos y gases flamables,solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietasy agujeros de pisos y paredes causando fuegos escondidos enotros niveles o espacios. Asegúrese de que toda grieta y agujeroesté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hastaque la pieza de trabajo esté totalmente limpia y libre desubstancias que puedan producir gases inflamables o vaporestóxicos. No trabaje dentro o fuera de contenedores o tanquescerrados. Estos pueden explotar si contienen vapores inflamables.

4. Tenga siempre a la mano equipo extintor de fuego para usoinstantáneo, como por ejemplo una manguera con agua, cubetacon agua, cubeta con arena, o extintor portátil. Asegúrese queusted esta entrenado para su uso.

PRECAUCION DE SEGURIDAD

5. No use el equipo fuera de su rango de operación. Por ejemplo, elcalor causado por cable sobrecarga en los cables de soldarpueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el áreade trabajo para cerciorarse de que las chispas o metal calienteocasionen un fuego más tarde. Tenga personal asignado paravigilar si es necesario.

7. Para información adicional , haga referencia a la publicaciónNFPA Standard 51B, "Fire Prevention in Use of Cutting andWelding Processes", disponible a través de la National FireProtection Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto conlas partes eléctricas energizadas y tierrapuede causar daño severo o muerte. NOuse soldadura de corriente alterna (AC)en áreas húmedas, de movimientoconfinado en lugares estrechos o si hayposibilidad de caer al suelo.

1. Asegúrese de que el chasis de la fuente de poder estéconectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.3. Conecte el cable de retorno a la pieza de trabajo. Cables y

conductores expuestos o con malas conexiones pueden exponeral operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones.Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, loscables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladasde ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja enlugares estrechos o áreas húmedas; trabaje sobre un pedazo demadera seco o una plataforma insulada y use zapatos con suelade goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC Standard Z49.1(listado en la próxima página) para recomendaciones específicasde como conectar el equipo a tierra. No confunda el cable desoldar a la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETICOS- Son peligrosos. La corriente eléctricafluye através de cualquier conductorcausando a nivel local Campos Eléctricosy Magnéticos (EMF). Las corrientes en elárea de corte y soldadura, crean EMFalrrededor de los cables de soldar y lasmaquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para el corazóndeberán consultar a su médico antes de soldar. El CampoElectromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede causarotros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos paraminimizar exponerse al EMF:A. Mantenga el electrodo y el cable a la pieza de trabajo juntos,

hasta llegar a la pieza que usted quiere soldar. Asegúrelos unojunto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor de su cuerpo.C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza

de trabajo. Mantega los cables a un sólo lado de su cuerpo.D. Conecte el cable de trabajo a la pieza de trabajo lo más

cercano posible al área de la soldadura.E. Mantenga la fuente de poder y los cables de soldar lo más

lejos posible de su cuerpo.

10

HUMO Y GASES -- El humo y losgases, pueden causar malestar odaño, particularmente en espacios sinventilación. No inhale el humo ogases. El gas de protección puedecausar falta de oxígeno.

Por lo tanto:

1. Siempre provea ventilación adecuada en el área detrabajo por medio natural o mecánico. No solde, corte,o ranure materiales con hierro galvanizado, aceroinoxidable, cobre, zinc, plomo, berílio, o cadmio amenos que provea ventilación mecánica positiva . Norespire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique substanciasquímicas en aerosol. El calor de los rayos del arcopueden reaccionar con los vapores de hidrocarburoclorinado para formar un fosfógeno, o gas tóxico, yotros irritant es.

3. Si momentáneamente desarrolla inrritación de ojos,nariz o garganta mientras est á operando, esindicación de que la ventilación no es apropiada. Parede trabajar y tome las medidas necesarias paramejorar la ventilación en el área de trabajo. Nocontinúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC StandardZ49.1 (Vea la lista a continuación) para recomendacionesespecíficas en la ventilación.

5. ADVERTENCIA-- Este producto cuando se utiliza parasoldaduras o cortes, producehumos o gases, los cualescontienen químicos c o n o c i d o spor el Estado de California decausar defectos en el nacimiento,o en algunos casos, Cancer. (Cali-fornia Health & Safety Code§25249.5 et seq.)

MANEJO DE CILINDROS-- Loscilindros, si no son manejadoscorrectamente, pueden rompersey liberar violentamente gases.Rotura repentina del cilindro,válvula, o válvula de escape puedecausar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize unregulador diseñado para operar y reducir la presióndel cilindro de gas . No utilice adaptadores. Mantengalas mangueras y las conexiones en buenas condiciones.Observe las instrucciones de operación del manufactureropara montar el regulador en el cilindro de gascomprimido.

2. Asegure siempre los cilindros en posición vertical yamárrelos con una correa o cadena adecuada paraasegurar el cilindro al carro, transportes, tablilleros,paredes, postes, o armazón. Nunca asegure los cilindrosa la mesa de trabajo o las piezas que son parte delcircuito de soldadura . Este puede ser parte del circuitoelélectrico.

3. Cuando el cilindro no está en uso, mantenga la válvuladel cilindro cerrada. Ponga el capote de protecciónsobre la válvula si el regulador no está conectado.Asegure y mueva los cilindros utilizando un carro otransporte adecuado. Evite el manejo brusco de los

Las siguientes publicaciones, disponibles através de laAmerican Welding Society, 550 N.W. LeJuene Road, Mi-ami, FL 33126, son recomendadas para usted:1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have HeldHazardous Substances."

Significa riesgo inmediato que, de noser evadido, puede resultarinmediatamente en serio daño per-sonal o la muerte.

Significa el riesgo de un peligropotencial que puede resultar en seriodaño personal o la muerte.

Significa el posible riesgo que puederesultar en menores daños a la per-sona.

MANTENIMIENTO DEL EQUIPO -- Equipodefectuoso o mal mantenido puedecausar daño o muerte. Por lo tanto:

1. Siempre tenga personal cualificado para efectuar la instalación, diagnóstico, y mantenimiento delequipo. No ejecute ningún trabajo eléctrico a menosque usted esté cualificado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de lafuente de poder, desconecte la fuente de poder delsuministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cableprimario, y cualquier otra fuente de poder en buenestado operacional. No opere ningún equipo enmalas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga elequipo lejos de cosas que generen calor comohornos, también lugares húmedos como charcos deagua , aceite o grasa, atmósferas corrosivas y lasinclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturasdel equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado.No modifique el equipo en ninguna manera.

INFORMACION ADICIONAL DE SEGURIDAD-- Para más información sobre las prácticas deseguridad de los equipos de arco eléctricopara soldar y cortar, pregunte a su suplidor poruna copia de "Precautions and Safe Practicesfor Arc Welding, Cutting and Gouging-Form 52-529.

SIGNIFICADO DE LOS SIMBOLOS -- Segúnusted avanza en la lectura de este folleto:Los Símbolos Significan ¡Atención! ¡EstéAlerta! Se trata de su seguridad.

11

1.1 GENERAL

The ESAB 350mpi is a high performance constantvoltage (CV) and constant current (CC) inverter powersource designed to provide multi-process welding ca-pabilities with dependability and ease of use. TheESAB 350mpi is a self-contained unit which will pro-duce power for Gas Metal Arc (MIG), Gas TungstenArc (TIG) and Shielded Metal Arc (Stick) weldingwithout the use of optional apparatus.

For MIG (CV) welding, the ESAB 350mpi supportswelding a wide selection of ferrous and non-ferrousalloys by utilizing Fixed Slope and inductance controls.

A special "Touch Tig" circuit eliminates the need forhigh frequency or "scratch" starting when using theTIG (CC) welding process. This feature provides smoothstarts without contaminating the electrode or the work.

The Stick (CC) welding mode provides adequate opencircuit voltage (70 V dc) for easy starts and re-starts aswell as an adjustable arc force which controls arcpenetration and wetting action.

The "Auto Fan" feature operates the cooling fan onlywhen the contactor is energized or when the internaltemperature exceeds the safe operating level. Duringnormal operation, the fan shuts down about 5 minutesafter 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 (with3-phase input). Duty cycle is defined as the ratio ofoperating time to total time. Ratings are based on a 10-minute cycle. The 60% duty cycle rating means that the350 ampere, 34 volt rated load can be applied for a totalof 6 minutes and shut off for a total of 4 minutes in a 10-minute period. If the welding current (or voltage) isreduced, the duty cycle increases. Conversely, if thewelding current (or voltage) is increased, the duty cyclewill decrease. Refer to Table 1-1 and Figure 1-2.

1.3 VOLT-AMPERE CURVES

Figure 1-2 illustrates the static volt-ampere character-istics for the power source in the MIG (CV), TIG (CC),and Stick (CC) modes. The slant of these curves isreferred to as the slope and is generally defined as thevoltage drop per 100 amperes of current rise. Thesecurves show the output voltage available at any givenoutput current between the minimum and maximumsettings of the output control. Values for other settingsfall between the minimum and maximum curves.

Table 1-1. Technical Specifications

RATED OUTPUT

100% Duty Cycle (3-phase input) 300 A @ 32 V dc100% Duty Cycle (1-phase input) 225 A @ 29 V dc60% Duty cycle (3-phase input) 350 A @ 34 V dcOpen-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 amps1-phase 50/38

SECTION 1 DESCRIPTION

12

Figure 1-2. Volt-Ampere Characteristics and Duty Cycles

NOTE:These measurements are made at the output termi-nals of the power source. Additional voltage "drops"will occur in the welding cable, torch cable, and in theworkpiece. The use of proper size welding cable andsecure electrical connections for the electrode andground circuits will minimize these effects which ad-versely affect welding conditions and waste electricalenergy.

cv mode Volt-Amp Curve

F

M

S

SECTION 1 DESCRIPTION

13

2.3 UNPACKING AND PLACEMENT

NOTEWhen lifting the ESAB 350mpi, apply direct upwardpressure to both of the carrying handles. Do nottransport the ESAB 350mpi with only one handle orapply outward pressure to the handles. See Figure 2-1.

A. Immediately upon receipt of the ESAB 350mpi,inspect for damage which may have occurredin transit. Notify the carrier of any defects ordamage at once.

B. After removing the components from the ship-ping container(s), check the container for anyloose parts. Remove all packing materials.

C. Check air passages of power source for anypacking materials that may obstruct air flowthrough the power source.

D. If the equipment is not to be installed immedi-ately, store it in a clean, dry, well-ventilatedarea.

2.1 GENERAL

This section provides detailed instructions for the properinstallation of the ESAB 350mpi power source from initialreceipt of the equipment to output welding connections.It is recommended that these instructions be followedcarefully to allow for the best possible operating environ-ment.

2.2 REQUIRED TOOLS

Some procedures require use of the following tools:3/8" wrench, Phillips or Robertson, and a screwdriver.The use of socket wrenches or nutdrivers are recom-mended over straight wrenches due to the location ofattaching hardware.

WRONG! WRONG!

Figure 2-1. Correct and Wrong Lifting Techniques

SECTION 2 INSTALLATION

14

E. The location of the power source should becarefully selected to ensure satisfactory anddependable service. Choose a location rela-tively close to a properly fused source ofelectrical power.

F. The machine components are maintained atproper operating temperatures by forced airwhich is drawn through the cabinet by the fanunit. For this reason, it is important that themachine be located in an open area where aircan 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 ofthe power source and wall or other obstruc-tion. The area around the unit should berelatively free of dust, fumes, and excessiveheat. It is also desirable to locate the unit sothe cover can be removed easily for cleaningand maintenance.

2.4 INPUT CONNECTIONS

ELECTRIC SHOCK CAN KILL! Precautionary mea-sures should be taken to provide maximum protec-tion against electrical shock.

Be sure that all power is OFF by opening the line(wall) disconnect switch when primary electricalconnections are made to the power source.

To be doubly safe, check your input leads with avoltmeter to make sure all power is OFF.

2.4.1 230/460V Model

NOTEAs shipped from the factory, the ESAB 350mpi, 230/460 V model, is set for 460 volts input. If you will beoperating the machine from a 230 V source, openthe switch access panel on the rear panel on themachine and flip the Voltage Selector Switch to the230 V position.

2.4.2 575V Model

575 Vac input models are single voltage units andtherefore do not require any installation prepara-tion for input line voltage.

2.4.3 400/440V Model

NOTEAs shipped from the factory, the ESAB 350mpi, 400/440 V model, is set for 440 volts input. If you will beoperating the machine from a 400 V source, openthe switch access panel on the rear panel on themachine and flip the Voltage Selector Switch to the400 V position.

The ESAB 350mpi is designed to compensate for linevoltage variations of plus or minus 10 percent from therated level while maintaining rated output, without dam-age to internal components. If line voltage fluctuationsexceed this range, serious damage could occur. There-fore, prior to installation, it is recommended that the linevoltage of the supply circuit be measured at severaltimes during the day. If fluctuations beyond the +/-10%level are detected, another supply circuit should beselected, or the local power company should be askedto adjust the supply. In addition, certain types of factoryequipment can cause rapid voltage swings (transients)which can cause the ESAB 350mpi safety circuits to“trip”. Examples of such equipment are resistancewelders, punch presses, and starting of large electricmotors.

Input Power Cable (Figure 2-3). Before installing thepower cable, make sure there is a line (wall) disconnectswitch with fuses or circuit breakers at the main powerpanel. You may either use the factory-installed inputpower cable (No. 8 AWG, 4/c, type SO (90 °C), 12 ft (3.7m) length) or provide your own input power leads. If youchoose to provide your own, make sure they are insu-lated copper conductors. You must have two (single-phase) or three (three-phase) power leads and oneground wire. The wires may be heavy rubber coveredcable or may be run in a solid or flexible conduit. Referto Table 2-1 for recommended input conductors andline fuse sizes.

SECTION 2 INSTALLATION

15

SECTION 2 INSTALLATION

Rated Load(3-phase input)

Volts Amps

Input &GroundConductor*CU/AWG (mm )

Time-DelayFuse SizeAmps

208 40230 38460 21575 17

8 (10)8 (10)10 (6)10 (6)

60603030

Table 2-1. Recommended Input Conductors and Fuse Sizes

* Sizes per National Electric Code for 90 °C rated copper conductors@ 30 °C ambient. Not more than three conductors in raceway orcable. Local codes should be followed if they specify larger sizesother than those listed above.

Use the following procedure to disconnect the factory-installedcable and connect your own input power leads/cable.

ELECTRIC SHOCK CAN KILL! Make sure the groundlead is at least twice as long as the input powerleads on the inside of the power source (see Figure2-3). Ensure the strain relief and ground connec-tion are securely tightened.

If these conditions are not met, the power sourcechassis may become electrically "hot" if excessivestress is placed on the input power cable.

If it is necessary to move the power source after ithas been connected to primary power, ensure thatthe power source is turned OFF, and that an ad-equate amount of "slack" is maintained in the inputpower cable.

If you have single-phase input power and are using thefactory-installed power cable, you must change theON-OFF switch cable connections from three-phase tosingle-phase configuration as follows:

1. Remove the 1/4" screws securing the top coverand 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 wirehas been removed from L2, its center conductor isexposed. This conductor must be covered with aninsulating material. Failure to do so properly couldcause a serious electrical shock hazard.

5. Re-attach the top cover with hardware re-moved in step 1.

2.5 OUTPUT CONNECTIONS

ELECTRIC SHOCK CAN KILL! Before making anyconnections to the power source output terminals,make sure that all primary power input power isdeenergized (OFF) at the line (wall) disconnectswitch or circuit breaker.

Two male plug connectors (P/N 13792513) are sup-plied with the ESAB 350mpi (see Figure 2-3). Toassemble the connectors onto each of your weldingcables, refer to the following instructions:

1. Slip the insulating boot over the end of thecable.

2. Strip the wire approximately 1-1/2" (37 mm)from the end.

3. Place the ferrule over the stripped wire end.4. Place the male connector over the ferrule and

tighten the two Allen screws until they are flushwith 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 optionalequipment to the ESAB 350mpi.

Particular attention should be paid to the electricalresistance in the welding circuit; especially, the workand work cable and when using a water-cooled torch.High resistance in the welding circuit can cause perfor-mance deterioration (loss of "heat" input, popping ofweld puddle, bushy arcs, etc.). It is recommended thatthe power source/wire feeder and workpiece be placed

16

Table 2-2. Typical Output Connections

MIG Welding(DCRP)

TIG Welding(DCSP)

Stick Welding(DCSP or DCRP)

Electrode positive (+) negative (-)positive (+) DCRPnegative (-) DCSP

Work negative (-) positive (+)negative (-) DCRPpositive (+) DCSP

Table 2-3. Recommended WeldingCable Sizes - AWG (mm2 )

WeldingCurrent

Total Length (Feet) of Cable in Welding Circuit*

50(13 m)

100(25 m)

150(38 m)

200(51 m)

250(64 m)

100150200250300

6 (16)**4 (25)**3 (30)**2 (35)1 (50)

4 (25)**3 (30)**1 (50)1/0 (50)2/0 (70)

3 (30)**1 (50)1/0 (50)2/0 (70)3/0 (95)

2 (35)1/0 (50)2/0 (70)3/0 (95)4/0 (120)

1 (50)2/0 (70)3/0 (95)4/0 (120)4/0 (120)

* Total cable length includes work and electrode cables. Cable size is based on directcurrent, insulated copper conductors, 100% duty cycle, and a voltage drop of 4 orless volts. The welding cable insulation must have a voltage rating that is highenough 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.

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, securelyconnected to the workpiece, and that all connectionsare clean and tightly secured. If the work circuit includesmechanical fixtures, ship structure, robot fixtures, etc.,make sure that the circuit is secure and presents a lowresistance path to the flow of weld current. Also, thepower cable on a water-cooled torch is normally subjectto gradual deterioration and increasing resistance dueto corrosion which leads to the poor performancedescribed above. To assure good torch performance,the water-cooled power cable should be replaced peri-odically.

SECTION 2 INSTALLATION

17

Figure 2-4. Male Output Cable Connectors (P/N 13792513)

Figure 2-5. MIG (GMAW) Interconnection Diagram

SECTION 2 INSTALLATION

(REMOTE CONTROLHC-5, P/N 34838)

18

Figure 2-7. Stick (SMAW) Interconnection Diagram

Figure 2-6. TIG (GTAW) Interconnection Diagram

ELECTRODE (-)

STRAIGHTPORALITY

(electrodenegative)

REVERSEPORALITY(electrode positive)

ELECTRODE(+)

SECTION 2 INSTALLATION

(REMOTE CONTROLHC-5, P/N 34838)

(REMOTE CONTROLHC-5, P/N 34838)

19

Figure 3-1. Controls / Indicators

3.1 GENERAL

Never, under any circumstances, operate the powersource with the cover removed. In addition to thesafety hazard, improper cooling may cause dam-age to internal components.

To prevent serious injury, never touch any torchparts forward of the handle (nozzle, electrode, etc.)unless the power switch is in the off position.

Wear proper protective gloves, clothing, safetyglasses, and helmet. A helmet with filter lens shadeNo. 11-14 should provide adequate protection foryour eyes. Refer to the Safety Precautions in thebeginning of this manual for additional operatingprecautions.

3.2 WELDING CONTROLS / INDICATORS(FIGURE 3-1)

A. WIRE FEEDER RECEPTACLE - For connectingESAB 42 & 115 vac wire feeders.

B. REMOTE RECEPTACLE - For connecting remoteoutput control devices such as hand pendant (HC-5, P/N 34838), foot, and torch controls.

C. PANEL / REMOTE SWITCH - Selects the point ofmachine control.

1. PANEL position - Machine is controlled bythe local front panel controls.

2. REMOTE position - Machine control isswitched to the device plugged into theREMOTE RECEPTACLE.

D. APPLICATION SELECT SWITCH - This switchselects specific application characteristics whenthe PROCESS CONTROL SWITCH is in theMIG position regardless of the PANEL/REMOTESWITCH position. Each selection fine-tunes thespecific arc characteristics to provide superiorperformance by enhancing stability and reducingspatter.

Selections include:Steel CO

2Steel Argon Mix

Stainless Steel AluminumCored Wires SprayMedium Slope Steep Slope

NOTE: When the PROCESS CONTROL SWITCH isset to the STICK, TIG, or TOUCH TIGmodes, the APPLICATION SELECTSWITCH has no effect on the welding outputcharacteristics

C. PANEL / REMOTE SWITCH

D. APPLICATION SELECT SWITCH

E. DIGITAL VOLTS DISPLAY

F. FAULT INDICATOR

G. TEMP INDICATOR

H. POWER INDICATOR

I. DIGITAL AMPS DISPLAY

J. OUTPUT VOLTAGE / CURRENT CONTROLK. PRESET SWITCH L. STICK ARC FORCE / MIG ARC TRIM

B. 14 PIN REMOTE RECEPTACLE

M. PROCESS SELECT SWITCH

A. 19 PIN WIRE FEEDER RECEPTACLE

N. POWER ON/OFF SWITCH

SECTION 3 OPERATION

20

E. DIGITAL VOLTS DISPLAY - In the normalmode, this large, easy to read digital displayindicates actual output voltage or preset voltagelevel when the PRESET SWITCH is depressed.If a machine error occurs this display willautomatically switch to the error mode anddisplay "Err".

F. FAULT INDICATOR - Indicates an improperinput line condition. The machine will notenergize. The machine must be reset by turningthe POWER “ON/OFF” SWITCH to "OFF" andthen back to “ON”, after the proper input voltageis selected.a. Indicator illuminated - A primary input over-

current condition has occurred.b. Indicator blinking - The INPUT VOLTAGE

SELECT SWITCH at the rear of themachine is set incorrectly for the primaryinput voltage applied.

G. TEMP INDICATOR - Indicates that an over-temperature condition has occurred and themachine will cease to function. "Err 4" willappear in the digital displays. The machine willreturn to normal operation once the temperaturedecreases to a safe operating level.

H. POWER INDICATOR - Indicates power ispresent in the machine and that control circuitsare energized.

I. DIGITAL AMPS DISPLAY - In the normal mode,this large, easy to read digital display indicatesactual output amperage or preset amperagelevel when the PRESET SWITCH is depressed.If a machine error occurs this display willautomatically switch to the error mode anddisplay the error code number.

J. OUTPUT CURRENT/VOLTAGE CONTROL -Sets the welding power output of the machine.When in the STICK, TIG, and Touch TIG modes,this knob controls the output welding current(amperes). When in the MIG mode, this knobcontrols the welding voltage (volts).

K. PRESET SWITCH - When depressed, the digitalmeters will display the adjustment level of theOUTPUT CURRENT/VOLTAGE control. Thisallows the welder the ability to quickly and easilypreset the desired output level before attemptingto weld. This greatly reduces the “trail & error”approach to adjusting proper welding conditions.1. PROCESS SELECT SWITCH in the MIG

mode - Depressing the PRESET SWITCHdisplays the output voltage level in theVOLTS window for the given OUTPUTCONTROL setting.

2. PROCESS SELECT SWITCH in the STICK,

TIG, Touch TIG modes - - Depressing thePRESET SWITCH displays the output currentlevel in the AMPS window for the givenOUTPUT CONTROL setting.

L. STICK ARC FORCE / MIG ARC TRIM - Thiscontrol allows the welder to fine tune arccharacteristics to suit specific applications andindividual preferences.

1. PROCESS SELECT SWITCH in the STICKmode - the STICK ARC FORCE controladjusts the amount of “digging” action whenthe arc length is shortened. This adjustmentis based mostly on personal preference of thewelder.

a. Settings from 0 mid point towardnegative (-). The welding arc becomessofter and has less penetrating power asthe welding arc length is shortened.

b. Settings from 0 mid point toward positive(+). The welding arc becomes stiff andhas more penetrating power when the arclength is held short.

2. PROCESS SELECT SWITCH in the MIG mode- the MIG ARC TRIM control adjusts the arcdynamic characteristics primarily for short arcwelding. This adjustment is based mostly onpersonal preference of the welder.

a. Settings from 0 mid point towardnegative (-). The welding arc becomescrisp with a higher buzzing sound. Theweld pool becomes less fluid and theweld bead may become more crowned.

b. Settings from 0 mid point toward positive(+).The welding arc becomes softer witha more crackling sound. The weld poolbecomes more fluid and the weld beadmay be flatter.

M. PROCESS SELECT SWITCH - Selects thedesired welding process to be performed. Switchselections and associated process are as follows:

Mig Position - Output is always energizedContactor on - Gas Metal Arc Welding (GMAW)

- Short Circuiting Arc Welding- Spray Arc Welding- Flux Cored Arc Welding

Stick Position - Output is always energizedContactor 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 WeldingPosition (GTAW) with Lift Arc

SECTION 3 OPERATION

21

N. POWER ON/OFF SWITCH - Controls the maininput power into the welding machine. In the “ON”position the machine is energized and power isavailable to all of the control circuits. In the “OFF”position the machine is de-energized and nopower is supplied to the control circuits.

3.3 MIG / GMAW (CV) OPERATION

A. Make all secondary output connections to thepower source output receptacles as describedin section 2 and as shown in the appropriatewire feeder and/or control instruction litera-ture.

B. After the primary input connections have beenmade in accordance with section 2, close themain wall disconnect switch or circuit breaker.

C. Place the primary power switch in the ONposition. This will apply power to the controlcircuitry as indicated by the MAIN POWERlight on the front panel. If the MAIN POWERlight does not lite, check the position of theINPUT VOLTAGE SELECT SWITCH forproper setting.

D. Place the PANEL/REMOTE switch in thedesired position. Use the PANEL position forcontrol from the power source's front panel(typical for conventional MIG wire feeders), orthe REMOTE position for remote voltage con-trol wire feeders and/or accessories. If RE-MOTE position is selected, set the PANELpotentiometer to maximum for full range fromremote.

E. Place the PROCESS SELECTOR switch inthe MIG position.

F. Set the APPLICATION SELECT SWITCH tothe appropriate material/gas/application set-ting.

G. Set a wire feed speed and begin welding.

H. If operating in the PANEL mode, adjust theVOLTAGE potentiometer to the desired weld-ing voltage by depressing the PRESETSWITCH and reading the value in the VOLTSDISPLAY. The PRESET SWITCH is onlyfunctional with the PANEL settings.

I. Set the ARC TRIM potentiometer to the centerposition. The microprocessor will provide theoptimum arc characteristics for each APPLI-CATION setting. Additional adjustment maybe made to suit specific needs or preferencesand can be particularly effective in short cir-cuiting arc applications.

NOTEWhen the HC-5 remote hand control (P/N 34838) isplugged into the power source, the ARC TRIM potentiom-eter on the power source is disabled even when the powersource's CONTROL switch is placed in the PANELposition.

J. Commence welding operations by energizingthe torch switch.

K. For remaining wire feeder or control opera-tions, refer to the appropriate instruction lit-erature supplied with your particular system.

3.4 TIG / GTAW (CC) OPERATION

A. Make all secondary output connections to thepower source output receptacles as describedin section 2 and as shown in the appropriateaccessory instruction literature.

B. After the primary input connections have beenmade in accordance with section 2, close themain wall disconnect switch or circuit breaker.

C. Place the primary power switch in the ONposition. This will apply power to the controlcircuitry as indicated by the MAIN POWERlight on the front panel.

ELECTRIC SHOCK CAN KILL! Make sure that thecontactor control switch on the remote controlaccessory is in the "off" position until you are readyto weld. Otherwise, the electrode in the torch will be"electrically-hot" and could shock you.

D. Place the PROCESS SELECT switch in theTIG or TOUCH TIG position.

F. Place the PANEL/REMOTE switch in theappropriate position. Use the PANEL positionfor control from the power source's front panel,or the REMOTE position for control from aremote control accessory.

SECTION 3 OPERATION

22

G. Adjust the PANEL CURRENT potentiometerto the desired welding current by depressingthe PRESET SWITCH and reading the valuein the AMPS DISPLAY.

NoteIn the remote position, the max output for MIG, TIG andSTICK is limited by the position of the "Panel" potenti-ometer; i.e., for maximum output, the PANEL potenti-ometer must be set to maximum.

NOTEWhen the HC-5 remote hand control (P/N 34838) isplugged into the power source, the ARC FORCE poten-tiometer (used for stick welding) on the power source isdisabled even when the power source's CONTROLswitch is placed in the PANEL position.

J. Make sure you have a good clean groundand a secure workpiece. Also, ensure thatshielding gas is turned on and flowing.

K. To establish the welding arc;1. TOUCH TIG - When selected, the volt-

meter will indicate a voltage of 4 to 5volts. As the tungsten is touched to thework piece the contactor will automati-cally be energized and a limited shortcircuit current of 25 amps will start to flowin the welding circuit. Rock the torchaway from the workpiece and the weld-ing arc will be established. The amper-age will automatically increase to thepre-set value.

2. TIG (scratch) Select PANEL or REMOTEmode switch on the front panel.

3. Touch tungsten to work. Operate eitherthe foot or the hand operated torch switch.Contactor will energize, and a limitedshort circuit current of 28 amps will flow.Back the torch away from the work pieceand the welding current will increase tothe value as controlled by the potentiom-eter.

L. For remaining accessory operations, refer tothe appropriate instruction literature suppliedwith your particular system.

3.5 STICK / SMAW (CC) OPERATION

A. Make all secondary output connections to thepower source output receptacles as describedin section 2 and as shown in the appropriateaccessory instruction literature.

B. After the primary input connections havebeen made in accordance with section 2,close the main wall disconnect switch orcircuit breaker.

C. Place the primary power switch in the ONposition. This will apply power to the controlcircuitry as indicated by the MAIN POWERlight on the front panel.

ELECTRIC SHOCK CAN KILL! When the PROCESSSELECTOR SWITCH is set to the STICK positionthe welding output will be energized and the elec-trode in the holder will be "electrically-hot" andcould shock you.

D. Place the PANEL/REMOTE switch in thedesired position. Panel setting limits maxcurrent in either mode. Use the PANEL posi-tion for control from the power source's frontpanel, or the REMOTE position for controlfrom a remote control accessory.

E. Place the PROCESS SELECT switch in theSTICK position. The welding output will beenergized and the electrode holder will be"electrically-hot".

G. Set the ARC FORCE CONTROL to the midposition.

I. Adjust the CURRENT for the stick electrodetype and diameter, as specified by the elec-trode manufacturer, being used by depress-ing the PRESET SWITCH and reading thevalue in the AMPS DISPLAY. PRESETSWITCH can only be used in the PANELposition of the power source.

J. For remaining accessory operations, refer tothe appropriate instruction literature suppliedwith your system.

SECTION 3 OPERATION

23

SECTION 3 OPERATION

3.6 OVERVIEW OF ERROR CODESAND PROGRAM UPDATES

ERR 1: High input voltage. Over 264 VAC in 230mode, over 529 VAC in 460 mode, and over 661 VACfor 575.

ERR 2: Low input voltage. The low line is 161 VACfor 230, 322 VAC for 460 and 403 VAC for 575.

ERR 3: Over-voltage at the output. If the outputvoltage exceeds 80V, the machine will shut off thecontactor. This was implemented to prevent asnubber failure from causing a dangerous voltage toappear at the output terminals.

ERR 4: Over temperature. One of the thermalswitches has opened.

ERR 5: Over current in single-phase operation. InMIG welding, if an operator draws more than 250amps for more than 5 seconds, this error will occur.In STICK or TIG modes, the machine will display thiserror if the control pot is turned up above 250 amps insingle phase.

ERR 6: Extended secondary short circuit. Themachine will allow a full short circuit condition(secondary current of more than 500 amps) to existfor 320 milliseconds before this error occurs.

ERR 7: Primary Over-current. This may indicate afailure of an output diode, the Hall Effect currentsensor or a magnetic short to chassis.

Program Updates

The current program is “PRG 1.04”. The program hasundergone 2 changes. The first was to reduce thelow-line voltage referred to in “ERR 2”. The reason forthis was that the MIG35 wire feeder was causing themachine to shut off due to its heavy draw on thecontrol transformer. This heavy load caused thecontrol voltages to sag, which resulted in the errormessage, even though acceptable line voltages werepresent on the primary. By adjusting for this sag incontrol voltage, the machine will now operate over itsentire intended range.

The second modification was to the handling of shortcircuit time. The original short circuiting time allowedwas 160 milliseconds. The short circuit time allowedwas increased to 320 milliseconds and the handlingof this timer in the program was improved.

Control Board Modifications

The MIG contactor circuits were modified to decreaseholding time after trigger release to correct caseswhere the increased time was causing minor “burn-back” problems.

The output capability of the machine was modified tohandle a 12 volt, 60 amp short arc aluminum MIGwelding condition. Before the modification, this lowpower condition was not stable.

24

SECTION 3 OPERATION

25

4.1 GENERAL

If this equipment does not operate properly, stop workimmediately and investigate the cause of the malfunc-tion. Maintenance work must be performed by an expe-rienced person, and electrical work by a trained electri-cian. Do not permit untrained persons to inspect, clean,or repair this equipment. Use only recommended re-placement parts.

ELECTRIC SHOCK CAN KILL! Be sure that the line(wall) disconnect switch or circuit breaker is openbefore attempting any work inside the power source.Always wear safety goggles with side shields whenblowing out the power source with air.

4.2 INSPECTION AND CLEANING

Since there are no moving parts (other than the fan) inthe power source, maintenance consist mainly of keep-ing the interior of the cabinet clean. Periodically, removethe cover from the cabinet, and wearing proper eyeprotection, blow accumulated dust and dirt from the airpassages and the interior components, using clean lowpressure air. It is imperative that the air passages, to theinterior of the unit, be free of dirt to ensure adequatecirculation of cooling air, especially over the rectifierbridge plates. The length of time between cleaning willdepend on the location of the unit, and the amount ofdust in the atmosphere.

SECTION 4 MAINTENANCE

26

SECTION 4 MAINTENANCE

27

5.1 GENERAL

ELECTRIC SHOCK CAN KILL! Before attemptinginspection or work inside the power source, besure that all primary power to the machine hasbeen externally disconnected and the line (wall)disconnect switch or circuit breaker is open.

5.2 FUNCTIONALITY CHECK (TABLE 5-1)

The 350mpi Functionality Check should be used toverify proper power source operation. Before perform-ing the following checks, disconnect the remote con-nections (WIRE FEEDER and REMOTE CONTROL)from rear of power source and make sure there is noload attached to the output terminals.

Table 5-1. 350mpi Functionality Check

YES NO

1. Are input power supply connections properly secured? Go to nextstep

2. If using 3-phase power, are all three primary leads securely connected to Go to next Refer toprimary power switch. step. Section 2.If using single-phase power, are black and white leads securely connected toprimary power switch?.

3. Position power source controls as follows: --- --

PROCESS SELECTOR - STICKCURRENT - MINIMUMARC FORCE - MINIMUM

4. Turn primary power switch to ON position. Does MAIN POWER light Go to nextilluminate? step.

5. Do digital meters show about 68.0 volts and 00.0 amps? Go to nextstep.

7. Fan is not energized. Go to nextstep.

8. Place PANEL/REMOTE switch in the PANEL position. Do digital meters Go to next Power sourceshow 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. Doesdigital meter show approximately 50 amps? Go tonext

step.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 nextamps? step.

ESAB 350mpi has passed the functionality check. Problem may be in interconnection of gas lines or polarity of outputconnectors. For technical assistance, refer to the Communication Guide located on the last page of this manual.

SECTION 5 TROUBLESHOOTING

28

SECTION 5 TROUBLESHOOTING

29

Replacement parts may be ordered from your ESABdistributor or from:

ESAB Welding & Cutting ProductsAttn.: Customer Service Dept.PO Box 100545, Ebenezer RoadFlorence, SC, 29501-0545

Refer to the Communication Guide located on the lastpage of this manual for a list of customer service phonenumbers.

6.1 General

Replacement parts are illustrated on the followingfigures. When ordering replacement parts, order bypart number and part name, as listed. Always providethe series or serial number of the unit on which the partswill be used. The serial number is stamped on the unitnameplate.

SECTION 6 REPLACEMENT PARTS

NOTE:Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

NOTE:Replacement Parts, Schematics and Wiring Diagrams on

279.4mm x 431.8mm (11” x 17”) paper are included inside theback cover of this manual.

SECTION 6 REPLACEMENT PARTS

Revision History

Revision "A" added the Troubleshooting and Parts section.

Revision "B" updated the Volt-Ampere Characteristics and Duty Cycles charts, made cor-rections in Installation and Operation sections and updated the Troubleshooting section.

Revision "C" added the 575 V ac model.

Revision "D" added parts information for the 575V ac model.

Revision "E" updates the Wiring and Schematic Diagrams.

Revision "F" added parts and Input Connection information for the 400/440V ac model andupdated Replacement Parts list.

Revision "G" added part designation and number for optional remote control HC-5, P/N 34838.

Revision "H" added Error Code and Program Updates in Operation subsection per CustomerService inputs.

Revision "J" changed BOM Item 63 from 952898 to 0558007860 per ECN #073242.

Revision "K" changed replacement parts and wiring diagram per ECN #083183. Moved sche-matics, wiring diagrams and replacement parts to back of manual.

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

A. CUSTOMER SERVICE QUESTIONS:Order Entry Product Availability Pricing DeliveryOrder Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548

Central Distribution Center Telephone: (800)783-5360 / Fax: (800) 783-5362

Western Distribution Center Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM ESTWarranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM ESTPerformance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:Telephone: (843)664-4428 / Fax: (843) 679-5864Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

ESAB Welding & Cutting Products, Florence, SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES

F15-481-K 11 / 2008

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