ESAB TIG 401iW User manual

TIG 401iW
INVERTER TIG
Welding Power Source
Instruction manual

1
TIG 401iW
INVERTER TIG WELDING POWER SOURCE
Instruction manual
For
Installation, Operation & General Maintenance

2
CONTENTS
Item
Page No.
SAFETY
3-4
RATING AND INSTALLATION
5-6
CAUTIONS FOR INSTALLATION
6
WELDING OPERATIONS
7-8
WIRING DIAGRAM
9
TROUBLESHOOTING
10
PARTS LIST AND EXPLODED VIEW
11-15

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.
ESAB can provide you with all necessary welding protection and accessories.

4
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
RATING
TIG 401i W INVERTER WELDING POWER SOURCE
Item
Unit
TIG 401iW
Input power
V
3～415
Frequency
Hz
50/60
Rated input capacity
KVA
18.7
Rated input current
A
26
OCV
V
65
Rated welding voltage
V
26
Welding current
A
20～400
Base current
A
20～400
Tig welding current
A
20～400
MMA welding current
A
25～350
Current up, down time
S
0～10
Pulse frequency
Hz
0.5～250
Duty ratio
%
0～100
Gas pre-flow
S
0.3～10
Gas post-flow
S
0.5～25
Rated output
%
60
TIG arc
HF
Efficiency
η
≥ 85%
Power factor
Cosφ
0.93
Insulation grade
Level
H
IP
IP
IP21S
Dimension L×W×H
mm
670*307*610
Weight
kg
38

6
INSTALLATION
The complete installation for TIG application should consist the following items:
Description
Type
Quantity
1.
Welding Power Source
TIG 401i w
1
2.
TIG Torch for TIG Welding
1
3.
Earth cable with Clamp
1
4.
GAS connection with regulator
1
The complete installation for MMA application should consist the following items:
Description
Type
Quantity
1.
Welding Power Source
TIG 401i w
1
2.
Welding Cable with
Electrode Holder.
1
3.
Earth cable with Clamp
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
FRONT PANEL
1. Power Indicator.
2. Protection
Indicator.
3. Working
Indicator.
4. Voltage Display.
5. Welding Data Display.
6. TIG Welding
Trigger Mode
Selection.
7. Remote
Control Indicator.
8. Down Slope / Idle
Time adjusting knob.
9. Post Gas Flow
adjusting Knob.
10. Arc Force / Base
Current adjusting
Knob.
11. Crater
Current Adjusting
Knob.
12. Pulse Frequency
adjusting Knob.
13. Pulse Ratio
adjustment Knob.
14. Ignition Current
Adjustment Knob.
15. Pre Gas flow
adjusting Knob.
16. MMA Current /
Peak Current
adjusting Knob.
17. Hot Start / UP
Slope/Spot Time
adjusting knob.
18. Remote Control
Socket.
19. Pulse ON /
OFF Selection.

8
FRONT PANEL LOWER
1. “+” output power
Socket.
2. Remote Socket.
3.Torch Switch
Control Socket.
4. “-”Output
Power Socket
(TIG Torch).
5. TorchGAS connection.
6. Water connection
for TIG Torch.
7. Water connection
for TIG Torch.
REAR PANEL
1. Power ON/ OFF
Switch.
2. Air / Water Torch
Selection.
3.FlowSensor
connection.
4. InputPowerConnection.
5. InputGasconnection.
6. Power Output
to cooling unit.

9
WIRING DIAGRAM

10
TROUBLESHOOTING
Fault
Cause
Solutions
Cooling fan
is not
working
Fan is faulty
Replace or repair
Wire is cut /falling off
Find the disconnection and connect it
reliably
No HF arc-
pilot
Torch switch is faulty
Replace
Main PCB is faulty
Replace
Wire is cut /falling off
Find the disconnection and connect it
reliably
No output
Gas
No Gas input
Check the regulator & gas pipe and
resume supplying gas to welder
Main PCB is faulty
Replace
Gas valve is faulty
Replace
Gas path jammed
Remove foreign matter & clear path
Problem in
water flow /
trip
Water pump is not working
Check supply, Motor and Flow switch.
Water path is Jammed
Remove foreign matter & clear path
Overheating
protection
indicator
light on
Inside case overheating.
Recover after the inner temperature cool
down
Temperature sensor faulty
Replace
Power over or under
voltage +-15%.
Until the voltage is normal.
Panel
current
knob
malfunction
The relevant
potentiometer is faulty.
Replace
Main PCB is faulty.
Replace
Wire is cut /falling off.
Find the disconnection and connect it
properly.
Current
meter no
display
Wire is cut /falling off
Find the disconnection and connect it
properly.
PCB is faulty.
Replace
Wire is cut /falling off.
Find the disconnection and connect it
reliably
Arc not
smooth
Loose connection
between torch and welder
Check & correct according to manual
Argon not pure
Change 99.99% Argon
Tungsten electrode not
good or pin head broken
Change to correct electrode
Power trip
Power switch first time
turn on after long
time(over two days)cut off
Filter capacitor’s charge in the main circuit
lead to trip, return on the switch is OK.
Others
Please contact ESAB service

11
Parts List and Exploded view
NO.
ESAB CODE
DESCRIPTION
1
020050080052
PLASTIC HANDLE TIG 401W
2
011010012207
METAL COVER TIG 401W
3
020070250166
CONTRAL TRANSFORMER TIG 401W
4
020070370028
THREE PHASE RECTIFIER TIG 401W
5
011120270006
MUTUAL INDUCTANCE TIG 401W
6
020070330015
IGBT MODULE TIG 401W
7
020030304727
COMMON CHOKE TIG 401W
8
011010031481
BACK PANEL TIG 401W
9
020040300009
POWER CABLE HOLDER TIG 401W
10
012070024209
POWER INPUT CABLE TIG 401W
11
020070520004
FUSE HOLDER TIG 401W
12
020050170019
BRACKET(PWR I/P CABLE)TIG 401W
13
020070800051
MAIN SWITCH TIG 401W
14
020070550033
GAS VALVE TIG 401W
16
020070120127
FILTERING CAPACITOR TIG 401W
17
020070890166
FAN TIG 401W
18
020050050293
INSULATING FRAME TIG 401W
19
020070430166
HEAT SINK TIG 401W
20
020070430165
HEAT SINK TIG 401W
21
011020013350
INSULATING FRAME TIG 401W
22
011020013348
SUPPORTING PANEL TIG 401W
23
011020013349
SUP.BRACKET(FRD H.SINK)TIG401W
24
012010100373
OUTPUT RECTIFIER PCB TIG 401W
25
011010060796
COVERING PANEL TIG 401W
26
011010041748
BOTTOM PANEL TIG 401W

12
27
020070660003
GAS CONNECTOR TIG 401W
28
020030300632
TRIGGER SWITCH TIG 401W
29
020070540025
TRIGGER SWITCH CONNECTOR TIG
401W
30
020070570185
EURO QUICK CONNECTOR TIG 401W
31
011050110246
OUTPUT PCB TIG 401W
32
011040030254
OUTPUT INDUCTANCE TIG 401W
33
011040050025
COUPLING TRANSFORMER TIG
401W
34
020050050289
PLASTIC FRONT PANEL TIG 401W
35
020070110022
POTENTIOMETER KNOB TIG 401W
36
011020010996
SUP.PANEL(FRT.CONT.PCB)TIG401W
37
011050070511
FRONT CONTROL PCB TIG 401W
38
011020013932
OUTPUT BUSBAR TIG 401W
39
011050110459
TORCH TRIGGER PCB TIG 401W
40
020070390071
HALL SENSOR TIG 401W
41
020070250130
MAIN TRANSFORMER TIG 401W
42
020070040090
FILTERING INDUCTANCE TIG 401W
44
011010050058
ASSEMBLING PANEL TIG 401W
45
011050020658
MAIN CONTROL PCB TIG 401W
46
011050100064
ARC STRIKING PCB TIG 401W
47
011020010997
SUP.PANEL(ARC STRIKING
PCB)TIG401W
48
011050030064
DRIVING PCB TIG 401W
49
011050110283
PULSE WIDTH MODUL.PCB TIG 401W
50
011030040012
IGBT BUSBAR TIG 401W

13

14
TIG 401W WATER COOLER
NO.
ESAB CODE
1
011020014456
CONN'TING FRAME TIG401W COOLER
2
011010012208
METAL COVER TIG401W COOLER
3
012010020001
BACK PANEL TIG401W COOLER
4
012070024209
POWER I/P CABLE TIG401W COOLER
5
020040300007
CABLE HOLDER TIG401W COOLER
6
020070570404
H2O CONN'OR RED TIG401W COOLER
7
020070570403
H2O CONN'R BLUE TIG401W COOLER
8
020070580007
HEAT SINK TIG401W COOLER
9
020050050456
WATER TANK TIG401W COOLER
10
012070024210
PUMP TIG401W COOLER
11
011020014221
BRACKET ( PUMP) TIG401W COOLER
12
011020014473
BRACKET(H2O TANK)TIG401W COOLER
13
020050070062
UNIVERSAL WHEEL TIG401W COOLER
14
011010031980
CONN.PLATE(FT.WHEEL)TIG401W
COOLER
15
011010040957
BOTTOM PANEL TIG401W COOLER
16
020050070061
RUBBER BACK WHEEL TIG401W
COOLER
17
020050050291
PLASTIC FRAME TIG401W COOLER
18
012010030004
FRONT PANEL TIG401W COOLER
19
020070520022
FUSE HOLDER TIG401W COOLER
20
020070800354
POWER SWITCH TIG401W COOLER
21
011020014222
H2O TANK PROT.FRAME TIG401W
COOLER
22
011020014458
SUP.FRAME FOR DRAWER TIG401W
COOLER

15

16
ESAB INDIA LIMITED
Registered and Head Office
13, Industrial Estate, III Main Road
Ambattur, Chennai - 600058
Telephone: + 91 44 42281100
Fax: + 91 44 4228 1107
Email: [email protected]
Web: www.esabindia.com