ESAB ARC 601i Welding Power Source Gouging Instruction Manual

ESAB ARC 601i Welding Power Source Gouging

Product Information

• Product Name: ARC 601i
• Type: Inverter MMA / GOUGING Welding Power Source
• Instruction Manual Version: 1.0 0421
• Manufacturer: ESAB
• Contact Details: ESAB INDIA CONTACT DETAIL

Product Usage Instructions

Safety Precautions:

• 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.
• Trained personnel well acquainted with the operation of the welding equipment must carry out all the work.
• Read and understand the instruction manual before installing or operating.
• Arc welding and cutting can be injurious to yourself and others.
• Take precautions when welding.
• Do not dispose of electrical equipment together with normal waste!
• Electrical equipment that has reached the end of its life must be collected separately and returned to an environmentally compatible recycling facility.

Rating of ARC 601i Inverter Welding Power Source:

Input Wiring:

• Ensure that the voltage, number of phases, frequency, and capacity of the input meet the recommended specifications.
• The recommended specifications for ground wire, fuse protector, or breaker are as follows:

Welding Machine Model| Duty Cycle| Input Voltage| Input Current| Most Effective Input Current| Cable Specification (Input)| Grounding Wire| Fuse Protector or Circuit Breaker
---|---|---|---|---|---|---|---
ARC601i| 60%| 415V| 45A| 34.8A| >4 mm2| >2.5 mm2| 63A

Output Connection: The positive and negative electrodes of the output terminal are located at the lower part of the front panel and marked with + and – symbols.

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.

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.

RATING

RATING OF ARC 601i INVERTER WELDING POWER SOURCE

INSTALLATION

Input wiring

• Ensure 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.
• Wiring shall be performed by a professional electrician.
• The input cable and air inlet are located on the back panel of the welding machine. Please refer to the structure diagram of the welding machine for a detailed location.
• Connect the input cable to the power to ensure a reliable connection.
• The 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.
• The recommended specifications of ground wire, fuse protector, or breaker are as follows:

Specifications for input cables, grounding wires, and input fuse protectors or circuit breakers at 3-phase /50Hz rated load duty cycle

Welding machine model

| Duty cycle| Input voltage| Input current| The most effective Input current| Cable specification| Fuse protector or

circuit breaker

Three-phase input cable| Grounding wire
ARC601i| 60%| 415V| 45A| 34.8A| >4 mm2| >2.5 mm2| 63A

Output connection

• The positive and negative electrodes of the output terminal are located at the lower part of the front panel and marked with “+” and “-” symbols.
• Connect one end of the negative output cable to the negative terminal, and the other end to the job.
• Connect one end of the positive output cable to the positive terminal, and the other end to the electrode holder.

CAUTIONS FOR INSTALLATION

• Provide a Switch Box for every Welding Power Source, and use the designated fuse
• The tolerance of Power Voltage Variation is 10% of the rated input voltage.

a) Installation place

• Install in a place where less moisture and dust exist. Avoid direct sunlight and rain and maintain the 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 than 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 guidelines 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 the area is less than 300 square meters and the welding is continuously performed, adequate ventilation is recommended with the help of a vent fan or exhaust duct.
  • c) While performing the grounding work, it is recommended that a skilled electrician does the work.

WELDING OPERATIONS

• The power switch of the welding machine is located on the upper part of the rear panel of the welding machine.
• Turn on the power switch of the welding machine and the welding machine will be on.
• The power indicator light of the welding machine on the front panel will be on (the green light will be on), the digital display will display value, the fan will start running, and the output voltage will be available.

Front Panel

• GOUGING / MMA
  • MMA or GOUGING mode of operation can be selected, selected LED will be on.
• LOCAL / REMOTE
  • LOCAL MODE: Output current control can be done from the panel.
  • REMOTE MODE: Output current control can be done from the remote controller.
• CURRENT
  • Welding / gouging current can be controlled in local mode.
• ARC FORCE
  • Arc force can be controlled by rotating this knob. Droplet transition performance can be improved.
• HOT START
  • Arc striking performance can be improved.
• VRD ON / VRD OFF
  • VRD function can be switched to ON or OFF condition.
  • The digital display will show the output current value in AMP and the output voltage value in Volt.

INDICATOR

• LED1: GOUGING indicator
• LED2: MMA indicator
• LED3: VRD indicator
• LED4: Power indicator
• LED5: Overheating indicator
• VR1: Welding current adjust potentiometer
• VR2: Arc striking current adjust potentiomete
• VR3: Thrust current adjust potentiometer
• T.r1: Temperature relay
• T.r2: Temperature relay
• T.r3: Temperature relay
• L1: Former edge inductance
• L2: Auxiliary inductance
• K1: GOUGING/MMA
• К2: VRD
• C1/C2/C3: DC fitter capacitor
• R9: Discharge resistance
• M1BM2B: Tube IGBT
• M3: Mutual indicator
• D1: Diode
• D2: Diode
• C3/R1: RC absorber
• C4/R2: RC absorber
• T1: Main transformer
• N1: Magnet ring
• FS1: AC fan
• BR1: 3-phase rectifier bridge
• TF1: Control transformer
• SE: Hall sensor

Remark

• T.r1/T.r2 inttall to IGBT radiator
• T.r3 install to quick recovery diode radiator

General maintenance

• No additional maintenance for the fan is required as all parts of the fan are sealed.
• If the welding machine is used where there is a lot of dust, the dust may block the air duct of the welding machine and cause the welding machine to heat up.
• Therefore, it is necessary to use dry compressed air to remove the dust inside the welding machine at set intervals.

Overload protection

• The temperature sensing device in the welding machine can provide effective protection for the important power devices of the welding machine, which uses the temperature switch to prevent overload or insufficient cooling.
• When a continuous overload or power device IGBT and fast recovery diode cannot get adequate heat dissipation, the overheating indicator light will be ON, and the normal output of the welding machine will be stopped.
• When the power devices cool down, the overheating indicator light will go to OFF state and the output of the welding machine will automatically return to normal.
• The control circuit of the welding machine has under-voltage protection.
• The too-low input voltage of the welding machine will affect normal welding work seriously.
• When the input voltage of the welding machine is too low, the output of the welding machine will be stopped.
• When it is found that there is no voltage at the output end, the power indicator light is ON, but the overheating indicator light doesn’t work, please check the input power voltage.

Parts List

Parts List and Exploded view

8

| ****

0011501003

| ****

MINIAT.CIRCUIT BREAKER ARC601i

---|---|---

9

| ****

0050802003

| ****

CABLE CONNECTOR ARC 601i

10

| ****

0030501596

| ****

INPUT CABLE ARC 601i

21

| ****

0011301005

| ****

HALL SENSOR ARC 601i

---|---|---

22

| ****

0030101565

| ****

ABSORPTION BOARD ARC 601i

23

| ****

0030801644

| ****

MAIN TRANSFORMER ARC 601i

24

| ****

0010227001

| ****

CAPACITOR ARC 601i

25

| ****

0011303003

| ****

CURRENT TRANSFORMER ARC 601i

26

| ****

0031001122

| ****

PRIMARY SIDE INDUCTOR ARC 601i

27

| ****

0010110030

| ****

CEMENT RESISTOR ARC 601i

28

| ****

0012103002-01

| ****

3PH REC’ER BRIDGE MOD. ARC601i

29

| ****

0010114003

| ****

VOLT.DEPENDENT RESISTOR ARC 601i

30

| ****

0011304008

| ****

TEMPERATURE SENSOR ARC 601i

31

| ****

0060301222

| ****

IGBT RADIATOR ARC 601i

32

| ****

0012101070

| ****

IGBT MODULE ARC 601i

33

| ****

0030101618

| ****

PWR SUP.DETECTION BRD ARC 601i

34

| ****

0030101427

| ****

INVERTER BOARD ARC 601i

• 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: info@esab.co.in.
• Web: www.esabindia.com.

References

• ESAB | Home
• ESAB | Home

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