ESAB Aristo Mig C3000i User manual

Aristo®, Origo™
Instruction manual
0459 825 301 GB 20180918 Valid for: serial no. 039-, 209-xxx-xxxx
Mig C3000i

TABLE OF CONTENTS
0459 825 301 © ESAB AB 2018
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 7
2.1 Equipment ............................................................................................... 7
2.2 Control panel .......................................................................................... 7
3TECHNICAL DATA ...................................................................................... 8
4INSTALLATION............................................................................................ 10
4.1 Lifting instruction ................................................................................... 10
4.2 Location................................................................................................... 10
4.3 Mains power supply ............................................................................... 10
5OPERATION ................................................................................................ 12
5.1 Connections and control devices ......................................................... 14
5.2 Fan control .............................................................................................. 14
5.3 Overheating protection .......................................................................... 14
5.4 Welding without gas............................................................................... 15
5.5 Wire feed pressure ................................................................................. 15
5.6 Replacing and inserting wire................................................................. 16
5.7 Changing feed rollers............................................................................. 16
6MAINTENANCE........................................................................................... 17
6.1 Inspection and cleaning......................................................................... 17
7TROUBLESHOOTING ................................................................................. 18
8ORDERING SPARE PARTS ........................................................................ 19
DIAGRAM ............................................................................................................ 20
ORDERING NUMBERS....................................................................................... 22
WEAR PARTS...................................................................................................... 23
ACCESSORIES ................................................................................................... 25
Rights reserved to alter specifications without notice.

1 SAFETY
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1 SAFETY
1.1 Meaning of symbols
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).
1.2 Safety 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

1 SAFETY
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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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
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MOVING PARTS - Can cause injuries
• 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.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
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.

2 INTRODUCTION
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2 INTRODUCTION
Mig C3000i is a welding power source intended for MIG/MAG welding with solid wire made
of steel, stainless steel, aluminium as well as cored wire with or without shielding gas. It is
also possible to weld with coated electrodes (MMA welding).
The power sources comes in different variants, see chapter "ORDERING NUMBERS".
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The welding power source is supplied with:
• Instruction manual for the welding power source
• Instruction manual in english for the control panel
• Decal with recommended wear parts
• 5 metre return cable
2.2 Control panel
The welding power source is supplied with one of the following control panels:
U6
With knobs for setting the voltage and wire feed speed
/ current. Other settings by pushbuttons, with text
indication on the display panel.
A Mig C3000i power source equipped with a U6 control
panel also enables TIG welding.
MA24 With knobs for setting the voltage / QSet™ and wire
feed speed / current. Other settings by pushbuttons.
Detailed descriptions of the control panels can be found in separate Instruction manual.
Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

3 TECHNICAL DATA
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3 TECHNICAL DATA
Mig C3000i
Mains voltage 400 V ±10 %, 3 ~ 50/60 Hz
Mains supply Ssc min 1.4 MVA
Primary current
Imax MIG/MAG 17 A
Imax MMA 18 A
Imax TIG 3) 14 A
No-load power demand when in the
energy-saving mode, 6.5 min. after welding
30 W
Setting range
MIG/MAG 16A/14.8V - 300A/29.0V
MMA 16A/20.6V - 300A/32.0V
TIG 3) 4A/10.2V - 300A/22.0V
Permissible load at MIG/MAG
35 % duty cycle 300 A / 29 V
60 % duty cycle 240 A / 26 V
100 % duty cycle 200 A / 24 V
Permissible load at MMA
30 % duty cycle 300 A / 32 V
60 % duty cycle 230 A / 29.2 V
100 % duty cycle 190 A / 27.6 V
Permissible load at TIG 3)
35 % duty cycle 300 A / 22 V
60 % duty cycle 240 A / 19.6 V
100 % duty cycle 200 A / 18 V
Power factor at maximum current
MIG/MAG 0.90
MMA 0.87
TIG 3) 0.89
Efficiency at maximum current
MIG/MAG 82.3 %
MMA 85.7 %
TIG 3) 75.9 %
Open-circuit voltage U0max
MIG/MAG without VRD function 1) 70 - 80 V
MMA without VRD function 1) 57 - 67 V
VRD function deactivated 2) 60 V
VRD function activated 2) < 35 V

3 TECHNICAL DATA
0459 825 301 -9- © ESAB AB 2018
Mig C3000i
Operating temperature -10 to +40°C
Constant A-weighed sound pressure < 70 db
Dimensions l × w × h 652 x 412 x 423 mm
Weight 43 kg
Insulation class transformer H
Enclosure class IP23
Application class
Torch connection EURO
Wire feed speed 0.8 - 25.0 m/min
Max. diameter wire bobbin 300 mm
Wire dimension
Fe
Ss
Al
Cored wire

0.6 - 1.2 mm
0.6 - 1.2 mm
1.0 - 1.2 mm
0.8 - 1.2 mm
Shielding gas
max pressure
All types intended for MIG/MAG welding
5 bar
Motor current Imax 3.5 A
1) Valid for power sources without VRD specification on the rating plate.
2) Valid for power sources with VRD specification on the rating plate. The VRD function is
explained in the instructions for the control panel, if the panel has that function.
3) Valid for a power source controlled from a U6 control panel
Mains supply, Ssc min
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 symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION
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4 INSTALLATION
The installation must be carried out by a professional.
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit power is
greater than or equal to Sscmin at the interface point between the user's 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 Sscmin. Refer to the technical data in the TECHNICAL DATA chapter.
4.1 Lifting instruction
4.2 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
4.3 Mains power supply
 Check that the welding power source is connected to the correct
mains power supply voltage, and that it is protected by the correct
fuse size. A protective earth connection must be made in
accordance with regulations.
Rating plate with supply connection data





4 INSTALLATION
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
Recommended fuse sizes and minimum cable area
Mig C3000i MIG/MAG MMA
Mains voltage 400 V 3 ~ 50 Hz 400 V 3 ~ 50 Hz
Mains cable area mm24G4 4G4
Phase current, Ieff 10 A 10 A
Fuse
Anti-surge
Type C MCB

16 A
16 A

16 A
16 A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. For other regions, supply cables must be suitable for the
application and meet local and national regulations.
NOTE!
This welding power source is designed for connection to a four wire 230/400 volt
system.
If the power source is to be used in a country with a higher mains voltage, the power
source shall be connected via a safety transformer.

5 OPERATION
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5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
NOTE!
When moving the equipment, use handle intended for transportation. Never pull the
equipment by the welding torch.
WARNING!
Assure that the side panels are closed during operation.
WARNING!
To prevent the reel from sliding off
the hub: Lock the reel in place by
turning the red knob as shown on
the warning label attached next to
the hub.
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
Risk of crushing when replacing the wire bobbin! Do not use safety gloves when
inserting the welding wire between the feed rollers.

5 OPERATION
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5 OPERATION
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5.1 Connections and control devices
1Control panel, see separate instruction
manual
4Connection"+"
MMA:Weldingcurrentcable
TIG:Returncable
2CAN connection for cooling unit or remote
control unit
5Connection for welding torch
3Connection"-"
MIG/MAGandMMA:Returncable
TIG:Weldingtorch
6Mains voltage switch
7Connection for shielding gas
5.2 Fan control
The power source has a time control that means that the fans continue to run for 6.5 minutes
after welding has stopped, and the unit switches to energy-saving mode. The fans start again
when welding restarts.
The fans run at reduced speed for welding currents up to 110 A, and at full speed for higher
currents.
5.3 Overheating protection
The welding power source has overheating protection which operate if the temperature
becomes too high, When this occurs the welding current is interrupted and a fault code is
displayed on the control panel.
The overheating protection resets automatically when the temperature has fallen.

5 OPERATION
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5.4 Welding without gas
It is possible to switch between welding with a solid wire and shielding gas, or welding with
self shielded cored wire without gas.
Solid wire Self shielded core wire without gas
• Disconnect the welding power source from the mains
current supply.
• Open the side panel. Remove the protective cover.
• Rechuck the positive connection (+) and negative
connection (-) on the terminal block above the feed
mechanism.
• Reinstall the protective cover. Close the side panel.
• Move the return cable from the negative outlet (-) to the
positive outlet (+).
5.5 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then set the
pressure of the wire feeder's pressure rollers. It is important that the pressure is not too high.
Figure A Figure B
To check that the feed pressure is set correctly, you can feed out the wire against an
insulated object, e.g. a piece of wood.
When you hold the welding torch approx. 5 mm from the piece of wood (figure A) the feed
rollers should slip.
If you hold the welding torch approx. 50 mm from the piece of wood, the wire should be fed
out and bend (figure B).

5 OPERATION
0459 825 301 - 16 - © ESAB AB 2018
5.6 Replacing and inserting wire
• Open the side panel.
• Disconnect the pressure sensor by folding it backwards, the pressure rollers slide up.
• Straighten out the new wire 10-20 cm. File away burrs and sharp edges from the end of
the wire before inserting it into the wire feed unit.
• Make sure that the wire goes properly into the feed roller's track and into the outlet
nozzle and the wire guide.
• Secure the pressure sensor.
• Close the side panel.
5.7 Changing feed rollers
• Open the side panel.
• Disconnect the pressure sensor (1) by folding it
backwards, the pressure rollers slide up.
• Disconnect the pressure rollers (2) by turning the axle
(3) 1/4 turn clockwise and pulling out the axle. The
pressure rollers disconnect.
• Disconnect the feed rollers (4) by unscrewing the nuts
(5) and pulling out the rollers.
During installation, repeat the above in the reverse order.
Choice of tracks in the feed rollers
Turn the feed roller with the dimensioning mark for the required track towards you.

6 MAINTENANCE
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6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.
Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
6.1 Inspection and cleaning
Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on: the welding process, arc times,
placement, and the surrounding environment. It is normally sufficient to blow the dust out of
the power source with dry compressed air (reduced pressure) once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
• Cleaning and replacement of the wire feed unit mechanism's worn parts should take
place at regular intervals in order to achieve trouble-free wire feed. Note that if
pre-tensioning is set too hard, this can result in abnormal wear on the pressure roller,
feed roller and wire guide.
The brake hub
The hub is adjusted when delivered, if readjustment is required, follow the instructions below.
Adjust the brake hub so that wire is slightly slack when wire feed stops.
•Adjusting the braking torque:
○ Turn the red handle to the locked
position.
○ Insert a screwdriver into the
springs in the hub.
Turn the springs clockwise to reduce
the braking torque.
Turn the springs counter-clockwise to
increase the braking torque.
Note: Make sure you turn both springs
the same amount.
Welding torch
• Cleaning and replacement of the welding torch's wear parts should take place at
regular intervals in order to achieve trouble-free wire feed. Blow the wire guide clean
regularly and clean the contact tip.

7 TROUBLESHOOTING
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7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorised service
technician.
Type of error Action
No arc. • Check that the mains power supply switch is turned
on.
• Check that the welding current supply and return
cables are correctly connected.
• Check that the correct current value is set.
The welding current is
interrupted during welding.
• Check whether the overheating protection has
operated (fault code E6 is displayed on the control
panel).
• Check the mains power supply fuses.
The overheating protection
trips frequently.
• Make sure that you are not exceeding the rated data
for the welding power source (i.e. that the unit is not
being overloaded).
Poor welding performance. • Check that the welding current supply and return
cables are correctly connected.
• Check that the correct current value is set.
• Check that the correct wire is being used.
• Check the mains power supply fuses.

8 ORDERING SPARE PARTS
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8 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Mig C3000i is designed and tested in accordance with the international and European
standards IEC/EN 60974-1,IEC/EN 60974-5 and IEC/EN 60974-10 Class A. It is the
obligation of the service unit which has carried out the service or repair work to make sure
that the product still conforms to the said standard.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. 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.

DIAGRAM
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DIAGRAM