ESAB Origo Mig 3001i User manual

GB
Valid for serial no. 835--xxx--xxxx0460 739 001 GB 090127
OrigotAristot
Mig 3001i
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
3.2 Control panel A24 5.........................................................
4 TECHNICAL DATA 6.................................................
5 INSTALLATION 7....................................................
5.1 Lifting instructions 7.........................................................
5.2 Location 8..................................................................
5.3 Mains supply 8..............................................................
6 OPERATION 9.......................................................
6.1 Connections and control devices 9............................................
6.2 Connection of welding and return cable 9.......................................
6.3 Fan control 10...............................................................
6.4 Overheating protection 10.....................................................
6.5 MIG/MAG and FCAW--S welding 10............................................
6.6 TIG welding 10...............................................................
6.7 MMA welding 11.............................................................
7 MAINTENANCE 11....................................................
7.1 Power source 11.............................................................
7.2 Welding torch 11.............................................................
8 FAULT--TRACING 12..................................................
9 ORDERING SPARE PARTS 12..........................................
DIAGRAM 14............................................................
ORDERING NUMBER 16.................................................
ACCESSORIES 17.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-
ing power source Mig 3001i from serial number 835 are constructed and tested in compliance with the
standard EN 60974--1 and EN 60974--10 (Class A) in accordance with the requirements of directive
(2006/95/EC) and (2004/108/EEC).
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Kent Eimbrodt
Global Director
Equipment and Automation
Laxå 2008--08--14
2SAFETY
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 recommen-
dations 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:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sno--one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
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!
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 electromagnic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Read and understand the instruction manual before
installing or operating.
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Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation 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 our local representative.
By applying this European Directive you will improve the environment and human
health!
ESAB can provide you with all necessary welding protection and accessories.
3 INTRODUCTION
Mig 3001i is a welding power source intended for MIG/MAG welding, as well as for
welding with powder filled cored wire (FCAW--S), TIG welding and for welding with
coated electrodes (MMA).
ESAB’s accessories for the product can be found on page 17.
3.1 Equipment
Mig 3001i can be supplied with or without cooling unit. The cooling unit can be retro
fitted. Installation kit for the cooling unit is available as an accessory, see page 17 .
The power source is supplied with:
S4.5 m return cable with contact clamp
S5 m mains cable with 32 ampere connector
Sinstruction manual for the welding power source
Sinstruction manual in English for the control panel (if applicable)
Sinstruction manual for the cooling unit (if applicable)
Instruction manuals in other languages can be downloaded from the website,
http://www.esab.com.
3.2 Control panel A24
Welding process parameters are controlled via the control panel. See the separate
instruction manual for a detailed description of the panels.
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4 TECHNICAL DATA
Mig 3001i
Mains voltage 400 V ±10%, 3 ∼50/60 Hz
Mains supply Ssc min 1.4 MVA
Primary current
Imax MIG/MAG
Imax TIG
Imax MMA
16 A
13 A
19 A
No--load power demand when in the
energy--saving mode, 6.5 min. after welding
30 W
Setting range
MIG/MAG
TIG
MMA
16 A / 8 V -- 300 A / 48 V
4 -- 300 A
16 -- 300 A
Permissible load at MIG/MAG
35 % duty cycle
60 % duty cycle
100% duty cycle
300 A / 29 V
240 A / 26 V
200 A / 24 V
Permissible load at TIG
35 % duty cycle
60 % duty cycle
100% duty cycle
300 A / 22 V
240 A / 19.6 V
200 A / 18 V
Permissible load at MMA
30 % duty cycle
60 % duty cycle
100% duty cycle
300 A / 32 V
230 A / 29,2 V
190 A / 27.6 V
Power factor at maximum current
MIG/MAG
TIG
MMA
0.90
0.89
0.90
Efficiency at maximum current
MIG/MAG
TIG
MMA
85 %
82%
84 %
Open--circuit voltage 67 V
Operating temperature -- 1 0 t o + 4 0 ˚C
Transportation temperature -- 2 0 t o + 5 5 ˚C
Continual sound pressure at no--load <70db(A)
Dimensions lxwxh
with cooling unit
652 x 249 x 423 mm
714 x 249 x 693 mm
Weight
with cooling unit
33 kg
53.5 kg
Insulation class transformer H
Enclosure class IP23
Application class
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000--3--12
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Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading. The duty cycle is valid for 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 IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
5 INSTALLATION
The installation must be executed by a professional.
5.1 Lifting instructions
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5.2 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
5.3 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
distrubution network operator if necessary, that the equipment may be connected.
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.
Rating plate with supply connection data
NOTE! The welding power source is designed for connection to a 400 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 3001i
Mains voltage 400 V 3μ50 Hz
Mains cable area mm24G2.5 mm2
Phase current Ieff 10 A
Fuse
anti--surge
type C MCB
16 A
16 A
NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish
regulations. Use the welding power source in accordance with the relevant national regulations.
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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
6.1 Connections and control devices
1Connection for wire feed unit or remote
control unit
4Mains voltage switch 1 / 0
2Connection (--) MIG/MAG: Return cable
TIG: Welding torch
MMA: Return cable or welding cable
5Fuse for supply voltage for feeder unit,
42 V
3Connection (+) MIG/MAG: Welding cable
TIG: Return cable
MMA: Welding cable or return cable
6.2 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.
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 be-
tween the work piece and the output for the return cable on the power source.
For MMA welding, the welding cable can be connected to the positive terminal (+) or
negative terminal (--) depending on the type of electrode used. The connecting polar-
ity is stated on the electrode packaging.
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6.3 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.
6.4 Overheating protection
The welding power source has overheating protection that operates 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.
6.5 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 supplemented with:
Swire feed unit
Swelding torch
Sconnection cable between power source and wire feed unit
Sgas bottle
To ensure problem--free operation, the installation height from the cooling unit to the
welding gun must be max. 7 m. Heights in excess of this can cause problems, such
as long starting times, air bubbles, vacuums, etc.
If an installation height in excess of 7 m is required, we recommend an installation kit
comprising a non--return valve and a solenoid valve, refer to accessories on page
17. Once these valves have been installed, the hose package must be horizontal
during the initial startup so that everything fills with water. Then raise the wire feed
unit and hose package to the high height. Continued safe operation at installation
heights of up to 12 m can now commence.
6.6 TIG welding
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten
electrode, which does not itself melt. The weld pool and the electrode are protected
by shielding gas.
For TIG welding, the welding power source is supplemented with:
Sa TIG torch with gas valve
San argon gas cylinder
San argon gas regulator
Stungsten electrode
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