ESAB ES 300i User manual

Instruction manual
0463 417 001 US 20161208 Valid for: serial no. 643-xxx-xxxx
ES300i
Weldingpowersource Stick300A

TABLE OF CONTENTS
0463 417 001 © ESAB AB 2016
1SAFETY ......................................................................................................... 3
1.1 Meaning of symbols ................................................................................. 3
1.2 Safety precautions ................................................................................... 3
1.3 User responsibility ................................................................................... 7
2INTRODUCTION............................................................................................ 10
2.1 Overview ................................................................................................... 10
2.2 Equipment ................................................................................................. 10
3TECHNICAL DATA ........................................................................................ 11
4INSTALLATION.............................................................................................. 13
4.1 Location..................................................................................................... 13
4.2 Lifting instructions ................................................................................... 13
4.3 Electrical supply....................................................................................... 14
5OPERATION .................................................................................................. 17
5.1 Overview ................................................................................................... 17
5.2 Connections and control devices .......................................................... 17
5.3 Connecting welding and return cables .................................................. 17
5.4 Turning the power on/off ......................................................................... 18
5.5 Fan control ................................................................................................ 18
5.6 Thermal protection ................................................................................... 18
5.7 Functions and symbols ........................................................................... 18
5.8 Setting panel ............................................................................................. 20
5.8.1 Navigation .............................................................................................. 20
5.9 Remote control ......................................................................................... 21
5.10 USB connection........................................................................................ 21
6MAINTENANCE............................................................................................. 22
6.1 Routine maintenance ............................................................................... 22
6.2 Cleaning instructions............................................................................... 22
7TROUBLESHOOTING ................................................................................... 26
8ERROR CODES............................................................................................. 27
8.1 List of error codes ................................................................................... 27
8.2 Error code descriptions .......................................................................... 27
9ORDERING SPARE PARTS ......................................................................... 29
DIAGRAM ............................................................................................................. 30
ORDERING NUMBERS........................................................................................ 31
ACCESSORIES .................................................................................................... 32
Rights reserved to alter specifications without notice.

1 SAFETY
0463 417 001 -3- © ESAB AB 2016
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
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in the Additional Safety Information section.
Before performing any installation or operating procedures, be sure to read and
follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe the Safety Precautions could
result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require
hearing protection. The arc, like the sun, emits ultraviolet (UV) and
other radiation and can injure the skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes and equipment is
essential to prevent accidents. Therefore:
1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
2. Always wear safety glasses with side shields in any work area, even if welding
helmets, face shields and goggles are also required.
3. Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to look at the arc and not to expose themselves to
the rays of the electric-arc or hot metal.

1 SAFETY
0463 417 001 -4- © ESAB AB 2016
4. Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
high-topped shoes, and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.
5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of the
clothing.
6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly for long distances. Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS
The heat from flames and arcs can start fires. Hot slag or sparks can
also cause fires and explosions. Therefore:
1. Protect yourself and others from flying sparks and hot metal.
2. Move all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.
3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
4. Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.
5. Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.
6. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
7. After completing work, inspect the work area to make sure there are no hot sparks or
hot metal that could cause a fire later. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact between live electrical parts and earth can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the earth system of the
input power.
2. Connect the workpiece to a good electrical earth.
3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged 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 from both the work piece and from
the ground.
7. Do not stand directly on metal or the ground while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

1 SAFETY
0463 417 001 -5- © ESAB AB 2016
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 for specific grounding recommendations. Do not
mistake the work lead for a earth cable.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor
causes localised Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:
1. Welders with pacemakers fitted should consult their doctor before welding. EMF may
interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimise exposure 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 the welding power source and cables as far away from your body as
possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therefore:
1. Keep your head out of the fumes. Do not breathe the fumes and gases.
2. Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe in the fumes from these materials.
3. Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other
irritant gases.
4. If you develop momentary eye, nose or throat irritation while operating, this is an
indication that the ventilation is not adequate. Stop work and take the necessary steps
to improve ventilation in the work area. Do not continue to operate if physical
discomfort persists.
5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
6. WARNING: This product when used for welding or cutting, produces fumes or gases
that contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:

1 SAFETY
0463 417 001 -6- © ESAB AB 2016
1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
2. Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.
3. Always secure cylinders in an upright position, by chain or strap, to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
4. When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause
injury. Therefore:
1. Keep all doors, panels, guards, and covers closed and securely in place.
2. Stop the engine or drive systems before installing or connecting a unit.
3. Have only qualified people remove covers for maintenance and troubleshooting as
necessary
4. To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
5. Keep hands, hair, loose clothing and tools away from moving parts.
6. Reinstall panels or covers and close doors when service is finished and before starting
engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or
any other accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend
beyond opposite side of unit.
• Keep cables and cords away from moving vehicles when working from
an aerial location.

1 SAFETY
0463 417 001 -7- © ESAB AB 2016
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1. Always have qualified personnel perform the installation, troubleshooting
and maintenance work. Do not perform any electrical work unless you
are qualified to perform such work.
2. Before performing any maintenance work inside a power source,
disconnect the power source from the incoming electrical power.
3. Maintain cables, earthing wire, connections, power cord and power
supply in safe working order. Do not operate any equipment in faulty
condition.
4. Do not abuse any equipment or accessories. Keep equipment 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 position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any
manner.
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices
for Arc Welding, Cutting and Gouging.” Form 52-529.
The following publications are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding"
3. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"
4. AWS SP - "Safe Practices" - Reprint, Welding Handbook
5. ANSI/AWS F4.1 - "Recommended Safe Practices for Welding and
Cutting of Containers That Have Held Hazardous Substances"
6. OSHA 29 CFR 1910 - "Safety and Health Standards"
7. CSA W117.2 - "Code for Safety in Welding and Cutting"
8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and
Other Hot Work"
9. CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”
1
0.
ANSI Z87.1, "Occupational and Educational Personal Eye and Face
Protection Devices"
1.3 User responsibility
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
could result in injury to the operator and damage to the equipment.

1 SAFETY
0463 417 001 -8- © ESAB AB 2016
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorized person is within the working area of the equipment when it is
started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting may cause injury 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 - Pose health risks
• Welders with pacemakers fitted should consult their doctor 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 the 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.

1 SAFETY
0463 417 001 -9- © ESAB AB 2016
FUMES AND GASES - Can be dangerous to your 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 ear defenders or other hearing protection.
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 a fire. Make sure 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!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
This product is solely intended for arc welding.
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
0463 417 001 - 10 - © ESAB AB 2016
2 INTRODUCTION
2.1 Overview
The ES300i is an inverter-based power source intended for coated electrode (stick) and
tungsten inert gas (TIG) welding.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.2 Equipment
The power source is supplied with:
• Instruction manual
• Power cable

3 TECHNICAL DATA
0463 417 001 - 11 - © ESAB AB 2016
3 TECHNICAL DATA
ES300i (0445100881)
Outlet voltage 220–480V ±10%, 3~
50/60Hz
220-230V ±10%, 1~
50/60Hz
Primary current
Imax Stick (SMAW) 32.0A 29.0A
Imax GTAW (TIG) 21.0A 20.0A
No-load power demand
when in energy-saving mode
91W 91W
Setting range
Stick (SMAW) 5A/20.2V – 300A/32.0V 5A/20.2V – 300A/32.0V
GTAW (TIG) 5A/10.2V – 300A/22.0V 5A/10.2V – 300A/22.0V
Permissible load at Stick (SMAW)
40% duty cycle 300A/32.0V
60% duty cycle 250A/30.0V
100% duty cycle 200A/28.0V 200A/28.0V
Permissible load at GTAW (TIG)
40% duty cycle 300A/22.0V
60% duty cycle 250A/20.0V
100% duty cycle 200A/18.0V 200A/18.0V
Power factor at maximum current
GTAW (TIG) 0.96 0.96
Stick (SMAW) 0.96 0.96
Efficiency at maximum current
Stick (SMAW) 89% 89%
GTAW (TIG) 85% 85%
Open-circuit voltage U0max
VRD 35V deactivated 48V 48V
VRD 35V activated 32V 32V
Operating temperature +14 to +104°F (−10 to +40°C) +14 to +104°F (−10 to +40°C)
Transportation temperature −4 to +131°F (−20 to +55°C) −4 to +131°F (−20 to +55°C)
Continual sound pressure
at no-load
<70db (A) <70db (A)
Dimensions l × w × h 18.1 x 7.9 x 12.6in. (460 x
200 x 320mm)
18.1 x 7.9 x 12.6in. (460 x
200 x 320mm)
Weight 33lb (15kg) 33lb (15kg)
Insulation class transformer F F
Enclosure class IP23 IP23
Application class

3 TECHNICAL DATA
0463 417 001 - 12 - © ESAB AB 2016
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 104°F (40°C) 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
0463 417 001 - 13 - © ESAB AB 2016
4 INSTALLATION
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment, this
product may cause radio interference. It is the user's responsibility to take
adequate precautions.
4.1 Location
Position the power source so that its cooling air inlets and outlets are not obstructed.
A. Minimum 8in. (200mm)
B. Minimum 8in. (200mm)
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.
4.2 Lifting instructions
Mechanical lifting must be done with both outer handles.

4 INSTALLATION
0463 417 001 - 14 - © ESAB AB 2016
4.3 Electrical supply
The power source will automatically adjust to the supplied input voltage. Make sure that it is
protected by the correct fuse rating. A protective ground connection must be made, in
accordance with regulations.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable area for the ES300i
Power cable for heavy-duty applications (SOOW type) must be used
Outlet voltage 220 V 3~
50/60 Hz
400 V 3~
50/60 Hz
480 V 3~
50/60 Hz
220 V 1~
60 Hz
230 V 1~
60 Hz
Electrical cable area 4 × 4mm2/
4 ×
12AWG
4 ×
2.5mm2/ 4
× 16AWG
4 ×
2.5mm2/ 4
× 16AWG
3 × 6mm2/
3 ×
10AWG
3 × 6mm2/
3 ×
10AWG
Maximal current rating Imax
MMA/Stick (SMAW) 30.2 A 16.0 A 14.0 A 29.0 A 28.0 A
I1eff
MMA/Stick (SMAW) 18.5 A 10.0 A 9.0 A 29.0 A 28.0 A
Fuse
anti-surge
type C MCB
20 A
20 A
10 A
10 A
10 A
10 A
35 A
35 A
35 A
35 A

4 INSTALLATION
0463 417 001 - 15 - © ESAB AB 2016
Recommended fuse sizes and minimum cable area for the ES300i
Power cable for heavy-duty applications (SOOW type) must be used
Outlet voltage 220 V 3~
50/60 Hz
400 V 3~
50/60 Hz
480 V 3~
50/60 Hz
220 V 1~
60 Hz
230 V 1~
60 Hz
Maximum recommended
extension cord length
330 ft (100
m)
330 ft (100
m)
330 ft (100
m)
330 ft (100
m)
330 ft (100
m)
Minimum recommended
extension cord size
4 ×
12AWG
(4 ×
4mm²)
4 ×
12AWG
(4 ×
4mm²)
4 ×
12AWG
(4 ×
4mm²)
3 ×
10AWG
(3 × 6
mm²)
3 ×
10AWG
(3 × 6
mm²)
NOTE!
Different variants of ES300i are certified for different outlet voltages. Always refer
to the rating plate for the specification of the power source in use.
NOTE!
The power cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. Use the power source in accordance with the relevant
national regulations.
Installation of electrical cable
NOTE!
This power source is delivered with a power cable approved for 220–480V
three-phase power. If other outlet voltages are required, the power cable can be
changed in accordance with local regulations.
1. Remove the side panel.
2. If tightened, release the stopping block (A).
3. If a cable is connected, disconnect all wires, cut the cable tie (C), and remove the
cable.
4. Optional: The fan with foam can now be removed to simplify installation. Note the
direction of the fan (sticker toward the inside).
5. Strip the new wire in accordance with specifications (B).

4 INSTALLATION
0463 417 001 - 16 - © ESAB AB 2016
6. Insert the cable with about 0.4in. (1 cm) of isolation inside the stopping block. Tighten
the stopping block to 13.3–17.7lb-in. (1.5–2.0N·m) (A).
7. Use a cable tie to fasten the cables (C).
8. Optional: If the fan with foam was removed, it must now be reinstalled. A symbol on
the side of the fan (G) shows the airflow direction.
9. Connect the ground wire (C). A toothed washer should be located closest to the heat
sink. Tighten the screw to a torque of 53.1lb-in.±5.3 (6.0N·m ±0.6).
10. Connect all wires. The right position, L3, will only be used for three-phase power (D).
Tighten the screw to a torque of 8.6lb-in.±17.7(1.0N·m±0.2).
11. Make sure that the IP shield is correctly mounted on the inside of the side panel (E).
12. Reassemble the side panel (F).
13. Tighten the screws on the side panel to 26.6lb-in.±2.6(3N·m±0.3).

5 OPERATION
0463 417 001 - 17 - © ESAB AB 2016
5 OPERATION
5.1 Overview
General safety regulations for handling the equipment can be found in the chapter
"Safety." Read it before you start using the equipment.
NOTE!
When moving the equipment, use the handle. Never pull the cables.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
5.2 Connections and control devices
1. Setting panel 5. Mains power supply switch, I/O
2. Positive welding terminal 6. USB connection
3. Negative welding terminal 7. Power cable
4. Connection for remote control unit
NOTE!
Always use the cover when the USB connection is not in use.
5.3 Connecting welding and return cables
The power source has two outputs, a positive welding terminal (+) and a negative welding
terminal (-), for connecting welding and return cables. The output to which the welding cable
is connected depends on the welding method or type of electrode used.

5 OPERATION
0463 417 001 - 18 - © ESAB AB 2016
Connect the return cable to the other output on the power source. Secure the return cable’s
contact clamp to the workpiece, and make sure that there is a good contact between the
workpiece and the output for the return cable on the power source.
• For TIG (GTAW) welding, the negative welding terminal (-) is used for the welding
torch and the positive welding terminal (+) is used for the return cable.
• For stick (SMAW) welding, the welding cable can be connected to the positive welding
terminal (+) or negative welding terminal (-), depending on the type of electrode used.
The connection polarity is stated on the electrode packaging.
5.4 Turning the power on/off
Turn on the power by turning the switch to the “ON” (I) position.
Turn the unit off by turning the switch to the “O” position.
Whether the power supply is interrupted or the power source is switched off in the normal
manner, weld programs are stored so that they are available the next time the unit is started.
CAUTION!
Do not turn off the power source during welding (with load).
5.5 Fan control
The power source has automatic thermal control. The fan continues to run for a few minutes
after welding has stopped while the power source switches to energy-saving mode. The fan
starts again when welding restarts.
In energy-saving mode, the fan starts occasionally and runs for a few minutes.
5.6 Thermal protection
The power source includes thermal protection against overheating. When
overheating occurs, welding stops, the overheating indicator on the panel
illuminates, and an error message appears on the display screen. The protection
is automatically reset once the temperature has decreased to a safe level.
5.7 Functions and symbols
Stick (SMAW) welding
Stick (SMAW) welding can also be referred to as welding with coated electrodes.
Striking the arc melts the electrode, and its coating forms protective slag.
For Stick (SMAW) welding, the power source must be supplemented with the following:
• Welding cable with electrode holder
• Return cable with clamp
Soft/Crisp
The arc force function determines how the current changes in response to
variations in arc length during welding. Use a low value (Soft) to get a calm arc
with little spatter, and use a high value (Crisp) to get a hot and digging arc.
Soft/Crisp only applies to stick (SMAW) welding.

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Cel 6010
Optimized arc characteristics for cellulose electrodes, such as 6010.
TIG (GTAW) welding
TIG welding, also called gas tungsten arc welding (GTAW), melts the metal of
the workpiece using an arc struck from a tungsten electrode that does not melt.
The weld pool and electrode are protected by shielding gas.
For TIG (GTAW) welding, the welding power source must be supplemented with
the following:
• TIG (GTAW) torch with gas valve
• Argon gas cylinder
• Argon gas regulator
• Tungsten electrode
This power source performs Live TIG (GTAW) start.
The tungsten electrode is placed against the workpiece. When lifted from
workpiece, the arc is struck at a limited current level.
Voltage Reduction Device (VRD)
The VRD function ensures that the open-circuit voltage does not exceed 35V
when welding is not being carried out. This is indicated by a lit VRD indicator on
the panel. Contact an authorized ESAB service technician to activate this
function.

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5.8 Setting panel
1. VRD function (reduced open-circuit
voltage) indicator.
6. Display, shows set or measured value.
2. Overheating indication. 7. Display parameter indicator.
3. Indication of welding method: stick
(SMAW) with cellulose electrode or TIG
(GTAW).
8. Set indicator.
4. Select welding method, indicated by (3). 9. Select parameter to show in display,
indicated by (7).
5. Knob for setting data.
5.8.1 Navigation
Parameter selection
By pressing the button (9), different values can be shown and changed. Use the knob (5) to
change the values. Sequence:
1. Set current values.
2. Measure current values.
3. Soft/Crisp, 0–100%. (only stick (SMAW))
Set parameter
The set indicator (8) illuminates when a value can be changed. It cannot be changed from
the panel when a remote is activated. Trying to change a value while in measured value
mode results in automatically switching to set current value mode.