ESAB TIG 400i User manual

TIG 400i
INVERTER TIG
Welding Power Source
Instruction manual
Ver:3.0 3220

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TIG 400i
INVERTER WELDING POWER SOURCE
Instruction manual
For
Installation, Operation & General maintenance

2
CONTENTS
Item Page No.
SAFETY 3-4
RATING AND INSTALLATION 5-7
CAUTIONS FOR INSTALLATION 7-8
WELDING OPERATIONS 9-11
WIRING DIAGRAM 12
GENERAL MAINTENANCE 13
PARTS LIST AND EXPLODED VIEW 14-17
ESAB INDIA CONTACT DETAIL 18

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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.

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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

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RATING
RATING OF TIG 400i INVERTER WELDING POWER SOURCE
Contents of parameters Unit TIG 400i
Output
No-load voltage V 76
The working voltage of
manual welding
V 20.4-36.0
The working voltage of
argon arc welding
V 10.4-26.0
Rated welding current A TIG: 400
MMA: 400
Current adjustment
range
A TIG:10-400
MMA
:10
-
400
Rated load duty cycle
(Argon arc welding) 400A @ 60% 310A @100%
Rated load duty cycle
(Manual welding) 305A @ 60% 240A @ 100%
Input
Number of phases Phase 3
Frequency HZ 50/60
Supply voltage V 415V ±15%
Rated input current
(Ar
gon arc welding)
A 18
Maximum effective
input current
(Argon arc welding) A 14
Rated input current
(Manual welding)
A 24
Maximum effective
input current
(Manual welding) A 14
Rated input capacity KVA 17
Static external characteristic Down slope
characteristic
Lifting device Handle
Efficiency η ≥85%
Power Factor 0.9
Insulation grade H
Enclosure protection grade IP21S
Weight Kg 35
Boundary dimensions (L* W* H) mm 510×275×420

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INSTALLATION
Input wiring
oEnsure that the voltage, number of phases, frequency and capacity of the input
power are consistent with the calibration values on the nameplate of the welding
machine.
oWiring shall be performed by professional electrician.
oThe input cable and air inlet are located on the back panel of the welding machine.
Please refer to the structure diagram of welding machine for detailed location.
oConnect the input cable to the power to ensure the reliable connection.
oThe casing must be grounded, and the grounding bolt is located at the lower right
corner of the back panel of the welding machine and marked with a grounding
mark.
oConfirm the air inlet is connected smoothly with the argon cylinder during the weld
of argon arc welding.
oThe recommended specifications of ground wire, fuse protector or breaker are as
follows:
Specifications for input cables, ground wires and input fuse protectors or breakers at three-phase /50Hz
rated load duty cycle
Welding
machine
model
Load duty
cycle Input voltage Input current
Maximum
effective
input
current
60
℃
cable specification Fuse
protector
or
breaker
Three-phase
input cable Ground wire
TIG 400i 60% 415V 24A 14A ≥4 mm2≥4 mm260 A
Output connection
oThe positive pole of the output end, the negative pole of the output end and the
control connector (welding torch switch) are all located on the lower side of the
front panel, please refer to the structure diagram of welding machine for details.
(1) Manual arc welding connection method
oConnect one end of the negative output cable to the negative quick coupling,
and the other end to the job.
oConnect the negative quick coupling to the negative pole of the output end and

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tighten it clockwise.
oConnect one end of the positive output cable to the positive quick coupling, and
the other end to the electrode holder.
oConnect the positive quick coupling to the positive pole of the output end and
tighten it clockwise.
(2) Argon arc welding connection method
oConnect one end of the positive output cable to the positive quick coupling, and
the other end to the job.
oConnect the positive quick coupling to the positive pole of the output end and
tighten it clockwise.
oConnect the two-core control plug in the argon arc welding torch cable to the
control connector (welding torch switch) and tighten it, and connect the cable
connector in the argon arc welding torch cable to the negative quick coupling.
oConnect the negative quick coupling to the negative pole of the output end and
tighten it clockwise.
oConnect the air pipe of the argon cylinder to the input of the gas inlet. Please
refer to the structure diagram of back panel for the location of the input gas
connection.
oConnect the air pipe of argon arc welding torch to air outlet nozzle of the air
outlet. Please refer to the front panel structure diagram for the position of the air
outlet nozzle.
oNote: confirm that the air inlet is reliably connected with the argon cylinder.
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.

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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.

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WELDING OPERATIONS
Front Panel
oSelect the parameters to be adjusted by adjusting the LEFT or RIGHT shift keys
on the front panel, and preset the parameters to be welded through the panel
ADJUSTMENT knob.
oEach welding parameter on the front panel can be independently adjusted, and
the ranges are as follows:
Pre flow Gas Initial current Up slope time Welding current
0.1-10s 10-welding current 0-15s 10-400A
Down slope
tim
e
Crater current Post Flow Gas Arc Force
0-25s 10-welding current 0.5-30s 0-100%
TIG welding has three modes of operation, which are 2-step, 4-step and repeat mode.
The schematic diagram of the operational modes are as follows: