ESAB Buddy Mig 500i User manual

GB
Buddy
™
Mig 500i
Instruction manual
0463 335 074 GB 20120507
Valid for serial no. 209-xxx-xxxx

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© ESAB AB2012
1 SAFETY .…………………………………………………………………….. 3
2 INTRODUCTION .………………………………………………………..… 5
2.1 Equipment ..…………………………………………………………………….….. 5
3 TECHNICAL DATA …………………………………………………………5
4 INSTALLATION ……………………………………………………………6
4.1 Lifting instructions ………………………………………………………………….6
4.2 Location ……………………………………………………………………………..6
4.3 Mains supply ..……………………………………………………………………….6
5 OPERATION …………………………………………………………………8
5.1 Connections and control devices ………………………………………………….8
5.2 Fault indication light ………………………………………………...………………8
5.3 Inductance ………………………………………………………………………….. 8
5.4 Wire feed speed / Ammeter……………………………………………………….. 8
5.5 Gas check / Weld mode ..……………………….………………………………….9
5.6 2S / 4S (Crater on / off) .…………………….…………………………………….. 9
5.7 Crater filling .…………………………………………………………………………9
5.8 Creep start ..………………………………………………………………………… 9
5.9 Burnback …………………….……………………………………………………… 9
5.10 Turning on the power source……………………………………………….……...10
5.11 Connection of welding and return cable ………………………………………….10
5.12 MIG/MAG and FCAW-S welding…………………………………………………..10
6 MAINTENANCE ……………………………………………………………. 10
6.1 Power source ...………………………………………………………………….…. 10
6.2 Welding leads and clamps.……………………………………………………..…. 10
7 FAULT TRACING ..………………………………………………………… 11
8 ORDERING OF SPARE PARTS .………………………………………… 11
DIAGRAM …………………………………………………………….……..… 12
ORDERING NUMBERS ………………………………………….……..…… 13
ACCESSORIES ……..…………………………………………………………14
Rights reserved to alter specifications without notice.

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© ESAB AB2012
1 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.
All work must be carried out by trained personnel well-acquainted with the operation of the welding
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 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, 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 qualified electricians.
● 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.

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© ESAB AB2012
WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precautions when welding &
cutting.
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 work-piece.
●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!
Read and understand the instruction manual before installing or operating.
CAUTION!
This product is solely intended for arc welding only.
WARNING!
Do not use the power source for thawing frozen pipes.
ESAB can provide you with all necessary welding protection and accessories.
CAUTION!
Read and understand the instruction manual before
installing or operating.

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© ESAB AB2012
2 INTRODUCTION
Mig 500i is a welding power source intended for MIG/MAG welding as well as for welding with
powder filled cored wire (FCAW-S) when coupled with Feed 402 wire feeder and associated
accessories.
ESAB's accessories for the product can be found on page 14.
2.1 Equipment
The power source is supplied with an instruction manual, 3m mains cable and 5m return cable with
clamp.
3 TECHNICAL DATA
Mig 500i
Mains voltage
Primary current
Imax
Ieff
Setting range
MIG/MAG
Permissible load at MIG/MAG
60% duty cycle
100 % duty cycle
Power factor at maximum current
Efficiency at maximum current (MIG/MAG)
Open-circuit voltage U0 max
Preset gas pre-flow
Preset gas post-flow
Preset creep start
Preset burn-back
Operating temperature
Transportation temperature
Dimensions lxwxh
Weight
Insulation class
Enclosure class
Application class
400 V ± 15%, 3 ~ 50/60 Hz
37 A
29 A
50 A / 16.5 V – 500 A / 39 V
500 A / 39 V
387 A / 33.4 V
0.93
85%
70 V DC
0.5 sec
2.0 sec
Built-in
0.3 sec
-10 to +40°C
-20 to +55°C
650 x 350 x 650 mm
58 kg
F
IP21
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a
certain load without overloading. The duty cycle is valid for temperatures up to 40°C
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid
objects or water. Equipment marked IP21 is designed for indoor use.

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© ESAB AB2012
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
4 INSTALLATION
The installation must be executed by a professional
4.1 Lifting instructions
4.2 Location
Place the power source such that its cooling air inlets and outlets are not obstructed.
4.3 Mains supply
Note!
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence
the power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case 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 may be connected.
WARNING!
The handles are meant for manual handling of the power source only. For
mechanized handling, please use the lifting eyes.
WARNING!
The lifting eyes are meant for mechanized lifting of the power source only. Do
not attach any accessories such as welding cables, wire feeder or gas cylinder
when lifting the power source using these lifting eyes.

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© ESAB AB2012
Rating plate with supply connection data
Note! The welding power source is designed for connection to a 400 (380 - 415V) volt system with
four conductors. If the power source is to be used in countries with a higher or lower supply voltage,
the power source must be connected via a safety transformer.
Recommended fuse sizes and minimum cable area
Mig 500i
Mains voltage
Mains cable area mm2
Phase current I1eff
Fuse
Anti-surge
Type C MCB
400 V ± 15%, 3 ph
4 G 6
29A
32A
32A
Note!
Use the welding power source in accordance with the relevant national regulations.
(Check with relevant national regulations)
Make sure that the welding power source is connected to the correct supply voltage and that it is
protected by the correct fuse rating. Please refer to the rating plate at the back of the machine for
the mains supply requirement. A protective earth connection must be made in accordance with
regulations.

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© ESAB AB2012
5 OPERATION
General safety regulations for the handling of the equipment can be found
on page 3. Read through before you start using the equipment!
5.1 Connections and control devices
5.2 Fault Indication Light (Yellow LED) ( ) (Pos 9)
The power source has a fault indication light that operates when one of the following events occur:-
1) Thermal overload - operates when machine has been used beyond its intended duty cycle. Fault
indication resets automatically when the temperature has fallen to a suitable temperature
2) Over/under voltage protection - operates when the mains input voltage exceeds the tolerance of
the machine. Fault indication would need to be reset manually by turning the main switch to off and
then back on again.
3) Internal machine fault - operates if there are faults in the machine. Please contact ESAB Service
technician for assistance.
5.3 Inductance ( ) (Pos 3)
Higher inductance results in a wider weld pool and less spatter. Lower inductance produces a
harsher sound but a stable, concentrated arc.
Control of the inductance is especially important when short arc welding.
5.4 Wire feed speed display / Ammeter (Pos 2)
During preset, the meter will show wire feed speed in m/min. When welding, the meter will show
the welding amperage.
1Voltmeter
2Wire feed speed display / ammeter
3Inductance control ( )
4Connection for wire feed unit ( )
5 Connection (-)
6Connection (+)
4
5
6
7
12
11
10
9
8
1
2
3
15
14
13
7Crater voltage control ( )
8Crater current control ( )
9Fault indication light (Yellow LED) ( )
10 Power indication light (White LED)
11 Switch for 2-stroke / 4-stroke (Crater on/off)
12 Gas check / weld mode
13 Mains power supply switch, 1 / 0
14 CO2heater regulator socket (110Vac)
15 Resettable breaker for heater socket

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© ESAB AB2012
5.5 Gas Check / Weld mode (Pos 12)
Gas check is used to measure that gas flow or to flush the gas hoses to clean them of any air and
moisture before commencing welding. Gas check is carried out with the voltage and wire feed
switched off.
5.6 2-stroke /4-stroke (Crater on/off) (Pos 11)
With 2 stroke, wire feed starts when the trigger switch is pressed in and ends when it is released.
With 4 stroke, the gas flow starts when the trigger switch is pressed in and the wire feed starts
when it is released. The welding process continues until the switch is pressed in again, the wire
feed stops and when the switch is released the post-flow starts. By switching to 4 stroke, it also
turns on the crater filling function. The crater voltage & current can be adjusted on the panel of the
power source.
5.7 Crater filling (Pos 7 & 8)
Crater filling helps to avoid pores, thermal cracking and crater formation in the weld when welding
stops.
The crater voltage & current control on the machine panel controls the full voltage and current
range of the machine. It is generally recommended that the crater voltage & current is set lower
than the welding voltage & current.
5.8 Creep start
Creep start means that the wire is fed at low speed until it comes into electrical contact with the
workpiece and then the speed increases to the set speed. The creep start timing has been preset
and cannot be changed.
5.9 Burnback
Burnback time is a delay between the time when the wire starts to brake until the time when the
power source switches off the welding voltage. The burnback timing has been preset and cannot
be changed.
5.10 Turning on the power source (Pos 13)
Turn on the mains power by turning the mains switch to the “1” position.
If the mains power supply should be interrupted while welding is in progress, and then be restored,
the power source will be energised.
Turn the unit off by turning the switch to the “0” position.
5.11 Connection of welding and return cable
The power source has two outputs, a positive terminal (+) and a negative terminal (-), for
connecting welding and return cables. The output to which the welding cable is connected depends
on the welding method or type of electrode used.
For MIG/MAG/FCAW-S welding, one end of the welding cable can be connected to the positive
terminal (+) or negative terminal (-) depending on the type of electrode used (The connecting
polarity is stated on the electrode packaging) and the other end of the welding cable is connected
to the wire feeder.
Connect the return cable to the other output on the power source. Secure the return cable’s
contact clamp to the work piece and ensure that there is good contact between the work piece and
the output for the return cable on the power source.

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5.12 MIG/MAG and FCAW-S welding
An arc melts a continuously supplied wire. The weld pool is protected by shielding gas.
For MIG/MAG and FCAW-S welding, the power source is to be supplemented with:
●wire feed unit
●welding gun
●connection cable between power source and wire feed unit
●gas bottle with suitable regulator
6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized staff)
may remove the safety plates.
6.1 Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on:
●welding process
●arc time
●placement
●surrounding environment
It is normally sufficient to blow down the power source with dry compressed air (reduced pressure)
once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.
6.2 Welding gun and clamp
Wear parts should be cleaned and replaced at regular intervals in order to achieve trouble-free
welding.
CAUTION!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.

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7 FAULT - TRACING
Try these recommended checks and inspections before sending for an authorized
service technician.
Type of fault Corrective action
No arc. ●Check that the mains power supply switch is turned on.
●Check that the welding and return cables are correctly
connected.
●Check that the correct current value is set.
●Check the mains power supply fuses.
The welding current is
interrupted during welding ●Check whether the thermal cut-outs have tripped (a fault light is displayed on the control panel).
●Check the mains power supply fuses.
The thermal cut-out trips
frequently ●Check to see whether the air inlets & outlets are being blocked. ●Make sure that you are not exceeding the rated data for the
welding power source (i.e. that the unit is not being overloaded)
●Check that the welding power source is not clogged with dirt.
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 electrodes are being used.
8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
To find the required spare part, please refer to the Spare Parts List as shown on page 13.
Spare parts may be ordered through your nearest ESAB dealer. See the last page of this publication
to find the nearest ESAB office or dealers.

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© ESAB AB2012
Mig 500i
Diagram

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© ESAB AB2012
Mig 500i
Ordering Numbers
Ordering no. Description Type
0700 301 000
0459 839 079
Welding power source
Spare parts list
Buddy™ Mig 500i, 400V
Buddy™ Mig 500i, 400V
The spare parts list is available on the internet at www.esab.com

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© ESAB AB2012
Mig 500i
Accessories
Connection Set, 70mm2
15m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0700 301 300
25m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0700 301 301
Comprises of welding cable, gas hose & control cable
Wheel Kit, 10m . . . . . . . . . . . . . . . . . . . . . . . 0700 301 010
Comprises of 2 fixed & 2 swivel castor wheels
Buddy™Feed 402. . . . . . . . . . . . . .. . . . . . . . 0700 301 200
Trolley with Gas Tray. . . . . . . . . . . . . . . . . . 0700 301 011

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© ESAB AB2012
Notes

© ESAB AB
110915
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: [phone]
Fax: [phone]
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: [phone]
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]
DENMARK
Aktieselskabet ESAB
Herlev
Tel: [phone]
Fax: [phone]
FINLAND
ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]
GERMANY
ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]
ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]
HUNGARY
ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: [phone]
Fax: [phone]
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]
NORWAY
AS ESAB
Larvik
Tel: [phone]
Fax: [phone]
POLAND
ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]
PORTUGAL
ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: [phone]
Fax: [phone]
RUSSIA
LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: [phone]
Fax: [phone]
ESAB international AB
Gothenburg
Tel: [phone]
Fax: [phone]
SWITZERLAND
ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: [phone]
Fax: [phone]
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]
BRAZIL
ESAB S.A.
Contagem-MG
Tel: [phone]
Fax: [phone]
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: [phone]
Fax: [phone]
CHINA
Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]
INDIA
ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]
JAPAN
ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]
MALAYSIA
ESAB (Malaysia) Sdn Bhd
USJ
Tel: [phone]
Fax: [phone]
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: [phone]
Fax: [phone]
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: [phone]
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
www.esab.com