ESAB MIG 301i User manual

MIG 301i / 401i / 501i
INVERTER MIG
Welding Power Source
Instruction manual

1
MIG 301i / 401i / 501i
INVERTER WELDING POWER SOURCE
MIG 301i MIG 401i MIG 501i
Instruction manual
For
Installation, Operation & General maintenance

2
CONTENTS
Item Page
SAFETY 3 - 4
TECHNICAL DATA 5
INSTALLATION 6
WELDING OPERATION 7 - 9
TROBULESHOOTING 10
BLOCK DIAGRAM 11
PART LIST AND EXPLODED VIEW 12 - 15
ESAB INDIA LOCATIONS AND CONTACT DETAILS 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.

4
ESAB can provide you with all necessary welding protection and accessories.
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
TECHNICAL DATA
MIG 301i
MIG 401i
MIG 501i
Mains Voltage, V/Ph, Hz
415(± 15%) /3,50
Rated Input Power, KVA
9.5
19
26.5
No Load Voltage, V
70
70
70
Current Range MIG, A
60-300
40-440
50-550
Permissible load at 40% Duty
Cycle MIG,
_
440A/36V
550A/41.5V
Permissible load at 60% Duty
Cycle MIG,
300A/29V
400A/34V
500A/39V
Permissible load at 100%
Duty Cycle MIG,
240A/26V
313A/29.7V
387A/33.4V
Power factor at maximum
current
≥ 0.9
Efficiency at maximum
current
≥89%
Insulation class
H
H
H
Enclosure class
IP 21S
IP 21S
IP 21S
Wire Diameter, mm
0.8-1.2
0.8-1.2
0.8-1.6
Dimension (LXWXH), mm
687X320X581
Weight, Kg
45
45
50
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.

6
INSTALLATION
The complete installation for MIG application should consists of the following items:
Sl. No
Description
Type
Quantity
1.
Welding Power Source
MIG 301i / 401i / 501i
1
2.
Wire feeder with Interconnections,
Wire spool
MIG 301i wire feeder /
MIG 401i wire feeder/
MIG 501i wire feeder
1
3.
MIG Torch
1
4.
Earth cable with clamp
1
5.
Heater - Optional
110V A.C for Co2
1
6.
GAS with regulator
1
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.

7
WELDING OPERATIONS
Front Panel
MIG 301i / 401i
MIG 501i

8
Rear Panel
To start the power source, switch on the main switch on the front panel. To stop the
power source, switch OFF the main switch.
Depending on the selection, put process switch on MIG/ MMA/ GOUGING mode.
MIG Mode
Welding current and voltage can be set by knobs on the wire feeder remote. INCHING
push switch is on the wire feeder remote for inching wire without voltage. Flow of Gas
can be checked by GAS switch on the front panel.
Selection of wire diameter, type of material and 2 stroke / 4 stroke mode can be
selected on the front panel of the machine.
Crater voltage and current can be set by knobs on the machine front panel.
Control on Wire Feeder
1.Welding Current 2. Wire Inch Push Button 3. Welding Voltage Setting

9
Main Supply
Make sure that the welding power source is connected to the correct supply voltage
and that it is protected by the correct fuse rating. A protective earth connection must
be made in accordance with regulations.
The power source will automatically adjust to the supplied input voltage.
Recommended specification of input cable, grounding wire and fuse
Power Source
MIG 301i
MIG 401i
MIG 501i
Mains Voltage
415V, 3Ph,50Hz
Input Protector
Fuse
30A
40A
50A
Cross-section
of cable
Welding cable
2.5 mm2
4 mm2
6 mm2
Grounding wire
> 6 mm2
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.
Connect the return cable to the negative terminal 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.
Recommended specifications of the output cable
Power Source
MIG 301i
MIG 401i
MIG 501i
Cross-section of
Cable (mm2 )
≥ 35
≥ 35
≥ 50

10
TROUBLESHOOTING
General Maintenance
All parts of the fan are sealed such that extra maintenance is not required
for the fan. When operated at dusty place, the air duct may get plugged to
cause the machine overheated, therefore, remove dust with dry
compressed air regularly.
Overload Protection
The thermostat inside the welding machine can effectively protect
important power devices with overload or insufficient cooling avoided by
the thermostat switch. When the machine is continuously overloaded or
the power device IGBT and fast recovery diodes are not cooled
adequately, the overheat indicator will be lighted, normal output of the
welder will be stopped When these components are sufficiently cooled,
the overheat indicator will be off, the digital indicator and the voltage
output of the machine returns to normal.
Out of Phase, Over Voltage, Under Voltage Protection
A power supply detection section inside machine may be active when the
input voltage phase, over voltage, under voltage to detect abnormal state.
This fault will close the main circuit output, warning lights lit up at the
same time.

11
BLOCK DIAGRAM
MIG 301i / 401i / 501i

12
PART LIST & EXPLODED VIEW
Table 1：
SL.NO.
Name of components
Material code
1
Air Socket
0012001002
2
Output Terminal
0040214018
3
Miniature circuit breaker
0011501062
4
Potentiometer knob
0010603056
5
Carbon film potentiometer
0010602038
6
Display panel
0030101564
7
Carbon film potentiometer
0010602038
8
Three-phase input conductor
0031001109

13
Table 2：
SL.NO.
Name of components
Material code
9
FAN
0011702012
10
Radiator（MIG 501i）
0060301221
Radiator（MIG 401i）
0060301313
Radiator（MIG 301ii）
0060301226
11
Thermostat
0011208018
12
Diode
0012102033
13
Diode absorption plate
0030101565
14
Control transformer
0060101177
15
control board（MIG 501i）
0030101938
control board（MIG 401i）
0030101939
control board（MIG 301i）
0030101652
16
Auxiliary inductance
0031001106
17
Horn pin seat （Half Gold Tin）[thread]
040204073-02
18
Horn pin seat （Half Gold Tin）[thread]
040204064-02
19
Feedback assembly
0030501892
20
Reactor (MIG-501i)
0030901137
Reactor（MIG 301i/401i）
0030901140

14
Table 3：
SL. NO.
Name of components
Material
code
21
Grounding screw
0040113002
22
Heater socket
0012301275
23
Fuse hold
0011402002
24
Fuse
0011401024
25
Fuse
0011401008
26
Three-phase arc cover
0061301171
27
Combined connection terminal
0060701065
28
Retaining ring（die opening）
0061301150
29
Protective ring thimble（mold opening）
0061301147

15
Table 4：
SL. NO.
Name of components
Material code
30
Shunt
0011305008
31
Main transformer（MIG 501i）
0030801558
Main transformer（MIG 301i/401i）
0030801559
32
absorption plate
0030101644
33
Primary inductance
0031001108
34
Current transformer
0030501565
35
IGBT radiator（MIG 501i）
0060301222
IGBT radiator（MIG 301i/401i）
0060301225
36
Thermostat
0011208025
37
Driver board
0030101591
38
IGBT（MIG 501i）
0012101028
IGBT（MIG 301i/401i）
0012101029
39
VDR
0030501532
40
Three-phase rectifier bridge（MIG
501i）
012103013-01
Three-phase rectifier bridge（MIG
301i/401i）
012103001-01
41
Capacitor
0010227001

16
Web: www.esabindia.com