ESAB ARC 601i User manual

ARC 601i
INVERTER MMA / GOUGING
Welding Power Source
Instruction manual
Ver: 1.0 0421

1
ARC 601i
INVERTER WELDING POWER SOURCE
Instruction manual
For
Installation, Operation & General maintenance

2
CONTENTS
Item
Page No.
SAFETY
3-4
RATING AND INSTALLATION
5-6
CAUTIONS FOR INSTALLATION
7
WELDING OPERATIONS
8-9
WIRING DIAGRAM
10
GENERAL MAINTENANCE
11
PARTS LIST AND EXPLODED VIEW
12-15
ESAB INDIA CONTACT DETAIL
16

3
SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety
precautions. Safety precautions must meet the requirements that apply to this type of
welding equipment. The following recommendations should be observed in addition to
the standard regulations that apply to the workplace.
Trained personnel well acquainted with the operation of the welding equipment must
carry out all the work. Incorrect operation of the equipment may lead to hazardous
situations, which can result in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding
2. The operator must ensure that:
• no unauthorized person is stationed within the working area of the equipment
when it is started up.
• no one is unprotected when the arc is struck
3. The workplace must:
• be suitable for the purpose
• be free from drafts
4. Personal safety equipment
• Always wear recommended personal safety equipment, such as safety glasses,
flameproof clothing, and safety gloves.
• Do not wear loose—fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns.
5. General precautions
• Make sure the return cable is connected securely.
• Only a qualified electrician may carry out work on high voltage equipment.
• Appropriate fire extinguishing equipment must be clearly marked and close at
hand.
• Lubrication and maintenance must not be carried out on the equipment during
operation.
Read and understand the instruction manual before installing or operating.
ESAB can provide you with all necessary welding protection and accessories.

4
WARNING
Arc welding and cutting can be injurious to yourself and others. Take
precautions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’
hazard data.
ELECTRIC SHOCK –Can kill
• Install and earth the welding unit in accordance with applicable
standards.
• Do not touch live electrical parts or electrodes with bare skin, wet
gloves or wet clothing.
• Insulate yourself from earth and the workpiece.
• Ensure your working stance is safe.
FUMES AND GASES –Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS –Can injure eyes and burn skin.
• Protect your eyes and body. Use the correct welding screen and filter
lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE –Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk.
MALFUNCTION –Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding
Do not dispose of electrical equipment together with normal waste!
In accordance with national law, electrical equipment that has
reached the end of its life must be collected separately and returned
to an environmentally compatible recycling facility. As the owner of
the equipment, you should get information on approved collection
systems from the local representative. By applying this Directive you
will improve the environment and human health

5
RATING
RATING OF ARC 601i INVERTER WELDING POWER SOURCE
Contents of parameters
Unit
ARC601i
Output
No-load voltage
V
82
Working voltage
V
22-44
Rated welding current
A
600
Welding current
regulating range
A
50-600
Rated load duty cycle
100%
60%
520A
600A
Input
Number of phases
Phase
3
Frequency
Hz
50/60
Power supply voltage
V
415
Rated input current
A
45
Maximum effective
input current
A
34.8
Rated input capacity
KVA
31.63
η
≥85%
Insulation level
H
Enclosure protection grade
IP21S
Characteristics
Drooping characteristic
Weight
Kg
50
Dimensions (L* W* H)
mm
680×320×581

6
INSTALLATION
Input wiring
oEnsure that the voltage, number of phases, frequency and capacity of the input
power are consistent with the calibration values on the nameplate of the welding
machine.
oWiring shall be performed by professional electrician.
oThe input cable and air inlet are located on the back panel of the welding machine.
Please refer to the structure diagram of welding machine for detailed location.
oConnect the input cable to the power to ensure the reliable connection.
oThe casing must be grounded, and the grounding bolt is located at the lower right
corner of the back panel of the welding machine and marked with a grounding
mark.
oThe recommended specifications of ground wire, fuse protector or breaker are as
follows:
Specifications for input cables, grounding wires and input fuse protectors or circuit
breakers at 3-phase /50Hz rated load duty cycle
Welding
machine
model
Duty cycle
Input
voltage
Input
current
Most
effective
Input
current
Cable specification
Fuse
protector
or
circuit
breaker
Three-phase
input cable
Grounding
wire
ARC601i
60%
415V
45A
34.8A
>4 mm2
>2.5 mm2
63A
Output connection
oThe positive and negative electrodes of the output terminal are located at the
lower part of the front panel and marked with "+" and "-" symbols.
oConnect one end of the negative output cable to the negative terminal, and the
other end to the job.
oConnect one end of the positive output cable to the positive terminal, and the
other end to the electrode holder.

7
CAUTIONS FOR INSTALLATION
−Provide a Switch Box for every Welding Power Source, and use designated
fuse
−Tolerance of Power Voltage Variation is 10% of rated input voltage.
a) Installation place
−Install in the place where less moisture and dust exist. Avoid direct sunlight and
rain and maintain ambient temperature within –10o to +45o C as much as
possible.
−Keep the welding power source at least 20 cm. away from the wall (if any).
−In case of installation of more two units’ side by side, a distance of more than
20 cm is recommended between the two power sources.
−Use a shield to protect the welding arc in case of excessive air draft.
b) Ventilation
Adequate ventilation is recommended at the place of installation. For
example, the following guideline should be followed:
a) In case of the area being more than 300 square meters (per unit), no
ventilation is required, provided the room is not completely airtight.
b) In case of the area being less than 300 square meters and the welding
is continuously performed, adequate ventilation is recommended with
the help of vent fan or exhaust duct.
c) While performing the grounding work, it is recommended that a skilled
electrician does the work.

8
WELDING OPERATIONS
oThe power switch of the welding machine is located on the upper part of the
rear panel of the welding machine.
oTurn on the power switch of the welding machine and the welding machine will
be on.
oThe power indicator light of the welding machine on the front panel will be on
(the green light will be on), the digital display will display value, the fan will start
running, and the output voltage will be available.
Front Panel
GOUGING / MMA
MMA or GOUGING mode of operation can be selected, selected LED will be on.
LOCAL / REMOTE
LOCAL MODE: Output current control can be done from panel.
REMOTE MODE: Output current control can be done from remote controller.
CURRENT
Welding / gouging current can be controlled in local mode.
ARC FORCE
Arc force can be controlled by rotating this knob. Droplet transition performance can
be improved.
HOT START
Arc striking performance can be improved.

9
VRD ON / VRD OFF
VRD function can be switched to ON or OFF condition.
Digital display will show output current value in AMP and output voltage value in Volt.

10

11
General maintenance
No additional maintenance for fan is required as all parts of the fan are sealed.
If the welding machine is used where there is a lot of dust, the dust may block the
air duct of the welding machine and cause the welding machine to heat up.
Therefore, it is necessary to use dry compressed air to remove the dust inside the
welding machine at set intervals.
Overload protection
The temperature sensing device in the welding machine can provide effective
protection of the important power devices of the welding machine, which uses the
temperature switch to prevent overload or insufficient cooling. When continuous
overload or power device IGBT and fast recovery diode cannot get adequate heat
dissipation, the overheating indicator light will be ON, and the normal output of the
welding machine will be stopped. When the power devices cool down, the
overheating indicator light will go to OFF state and the output of the welding
machine will automatically return to normal.
The control circuit of the welding machine has undervoltage protection. The too
low input voltage of the welding machine will affect the normal welding work
seriously. When the input voltage of the welding machine is too low, the output of
the welding machine will be stopped. When it is found that there is no voltage at
the output end, the power indicator light is ON, but the overheating indicator light
doesn't work, please check the input power voltage.

12
Parts List and Exploded view
No
PART NO
DESCRIPTION
1
0012001004
4-CORE AVIATION SOCKET ARC601i
2
0040214018
OUTPUT TERMINAL ARC 601i
3
0010603056
WELDING CURRENT KNOB ARC 601i
4
0030101884
CONTROL PANEL ARC 601i
5
0010603057
PUSH CURRENT KNOB ARC 601i
6
0010603057
ARC STRIKE CURRENT KNOB ARC601i
7
0011504006
ROCKER SWITCH ARC 601i

13
8
0011501003
MINIAT.CIRCUIT BREAKER ARC601i
9
0050802003
CABLE CONNECTOR ARC 601i
10
0030501596
INPUT CABLE ARC 601i

14
11
0011702012
AXIAL FLOW FAN ARC 601i
12
0060301221
F.REC'RY DIODE RADIAT.ARC601i
13
0012102033
F.REC'ERY DIODE MODULE ARC601i
14
0030604330
F.REC'RY DIODE MOD (CU B.BAR) ARC601i
15
0030101676
DIODE ABSORPTION BOARD ARC601i
16
0031001123
THREE-PHASE INPUT CABLE ARC601i
17
0060101171
CONTROL TRANSFORMER ARC 601i
18
0030101831
TIMING DRIVE BOARD ARC 601i
19
0031001106
SEC'DARY SIDE INDUCTOR ARC601i
20
0030901137
REACTOR ARC 601i

15
21
0011301005
HALL SENSOR ARC 601i
22
0030101565
ABSORPTION BOARD ARC 601i
23
0030801644
MAIN TRANSFORMER ARC 601i
24
0010227001
CAPACITOR ARC 601i
25
0011303003
CURRENT TRANSFORMER ARC 601i
26
0031001122
PRIMARY SIDE INDUCTOR ARC 601i
27
0010110030
CEMENT RESISTOR ARC 601i
28
0012103002-01
3PH REC'ER BRIDGE MOD. ARC601i
29
0010114003
VOLT.DEPE'NT RESISTOR ARC 601i
30
0011304008
TEMPERATURE SENSOR ARC 601i
31
0060301222
IGBT RADIATOR ARC 601i
32
0012101070
IGBT MODULE ARC 601i
33
0030101618
PWR SUP.DETECTION BRD ARC 601i
34
0030101427
INVERTER BOARD ARC 601i

16
ESAB INDIA LIMITED
Registered and Head Office
13, Industrial Estate, III Main Road
Ambattur, Chennai - 600058
Telephone: + 91 44 42281100
Fax: + 91 44 4228 1107
Email: [email protected]
Web: www.esabindia.com