ESAB ET 301i AC/DC Operating Manual
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ESAB ET 301i AC/DC Operating Manual

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ESAB ET 301i AC/DC
Operating
Manual
4010062
Révision : AE Issue Date: 14/2/2018
Manual No.: 0-5347
Art # A-12858_AB
CURRENT
AC
DC
HF START
PULSE
HF
esab.com

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  • Page 1 ESAB ET 301i AC/DC Operating Manual Art # A-12858_AB CURRENT 4010062 HF START PULSE Révision : AE Issue Date: 14/2/2018 Manual No.: 0-5347 esab.com...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on the web at www.esab.com...
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufac- turer assumes no liability for its use. Welding Power Supply Operating Manual Number 0-5347 for: ESAB ET 301i AC/DC Power Source Part Number W1009400 Published by: ESAB 2800 Airport Rd.
  • Page 4 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cut- ting, and Gouging,”...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY (ENGLISH) ................1-1 Safety Precautions ..................1-1 CHAPITRE 1 : SÉCURITÉ (French) ............... 1-1 Précautions de sécurité .................. 1-1 SECTION 2: INTRODUCTION ................2-1 2.01 How To Use This Manual ................2-1 2.02 Equipment Identification ................. 2-1 2.03 Receipt of Equipment ..................
  • Page 6 Routine Service and Calibration Requirements ..........5-4 5.04 Cleaning the Welding Power Source ............... 5-6 SECTION 6: KEY SPARE PARTS ................6-1 6.01 Key Spare Parts ....................6-1 APPENDIX A: CIRCUIT DIAGRAM OF ET 301i AC/DC ..........A-1 Revision History .................... A-2...

  • Page 7: Section 1: Safety (English)

    SECTION 1: SAFETY (ENGLISH) Safety Precautions Users of ESAB welding and plasma cutting 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 or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
  • Page 8 ET 301I AC/DC Arc welding and cutting can be injurious to yourself and others. Take WARNING precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill.

  • Page 9: Chapitre 1 : Sécurité (French)

    CHAPITRE 1 : SÉCURITÉ (FRENCH) Précautions de sécurité Les utilisateurs du matériel de soudage et de coupage plasma ESAB ont la responsabilité ultime d'assurer que toute personne qui utilise ou qui se trouve dans l'aire de travail observe l’ensemble des précautions de sécurité...
  • Page 10 ET 301I AC/DC LE SOUDAGE ET LE COUPAGE À L'ARC PEUVENT CAUSER AVERTISSEMENT DES BLESSURES À L'OPÉRATEUR OU AUX AUTRES PER- SONNES SE TROUVANT DANS L'AIRE DE TRAVAIL. ASSU- REZ-VOUS DE PRENDRE TOUTES LES PRÉCAUTIONS NÉ- CESSAIRES LORS DES OPÉRATIONS DE SOUDAGE OU DE COUPAGE.

  • Page 11: Section 2: Introduction

    ET 301I AC/DC SECTION 2: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification To ensure safe operation, read the entire manual, including the The unit’s identification number (specification or part number), chapter on safety instructions and warnings. model, and serial number usually appear on a nameplate at- Throughout this manual, the words WARNING, tached to the control panel.

  • Page 12: Description

    ESAB. Advice in this regard can be obtained by contacting an Accredited ESAB Distributor. This equipment or any of its parts should not be altered from standard specification without prior written approval of ESAB. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by ESAB.

  • Page 13: Specifications

    ET 301I AC/DC ET 301i AC/DC GTAW (TIG) SMAW (STICK) SAFE OPERATING REGION (TIG & STICK) Art # A-12859 Figure 2-1: ET 301i AC/DC Duty Cycle 2.09 Specifications Description ET 301i AC/DC Power Source Part Number W1009400 Power Source Mass 35.9lbs (16.3kg) without power cable...

  • Page 14: Optional Accessories

    Generator Requirements at the Maximum Output Duty Cycle. Due to large variations in performance and specifications of different brands and types of generators, ESAB cannot guarantee full welding output power or duty cycle on every brand or type of generator.

  • Page 15: Section 3: Installation, Operation And Setup

    ET 301I AC/DC SECTION 3: INSTALLATION, OPERATION AND SETUP 3.03 Ventilation 3.01 Environment These units are designed for use in environments with increased WARNING hazard of electric shock as outlined in IEC 60974-1. Since the inhalation of welding A. Examples of environments with increased hazard of electric...

  • Page 16: High Frequency Introduction

    ET 301I AC/DC Input Power NOTE! Each unit incorporates an INRUSH circuit and input voltage This unit is equipped with a three-conduc- sensing circuit. When the MAIN SWITCH is turned ON, the inrush tor with earth power cable that is con- circuit provides a pre-charging of the input capacitors.

  • Page 17: Electromagnetic Compatibility

    ET 301I AC/DC 3.07 Electromagnetic Compatibility WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation. A. Installation and Use - Users Responsibility The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If elec- tromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer.

  • Page 18: Power Source Controls, Indicators And Features

    ET 301I AC/DC 4. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time.
  • Page 19 Mains voltage potential. 6. Mains Supply Lead The ET 301i AC/DC is fitted with a heavy duty three phase mains supply lead, 10ft long cable, no plug. 7. Gas Inlet The Shielding Gas Inlet connection is used to supply the appropriate shielding gas to the unit. The gas inlet is located on the rear of the Power Source.
  • Page 20 ET 301I AC/DC A-12034 Figure 3-3: 14 Pin Remote Control Socket Socket Pin Part Number / Description Trigger Switch Input Trigger Switch Input Remote Control 5k ohm Potentiometers Maximum Remote Control 5k ohm Potentiometers Wiper Remote Control 5k ohm Potentiometers Minimum...
  • Page 21 ET 301I AC/DC Art # A-12842 Figure 3-4: Control Panel Weld Mode & Meter Displays 10. Welding Mode Button Press the MODE button to select the Welding Process mode. Available modes are GTAW 2T, GTAW 4T, GTAW Spot, GTAW Pulse 2T, GTAW Pulse 4T, TIPTRONIC, TT and SMAW.
  • Page 22 ET 301I AC/DC 17. Welding Type Button Press the TYPE button to select the Welding Type mode, i.e. current mode. Selects the welding current type DC, AC with/without HF ignition. In SMAW (Stick) mode, the available modes are Electrode DC-, Electrode DC+.
  • Page 23 ET 301I AC/DC 28. Digital Voltmeter / Parameter meter The digital volt meter is used to display the actual output voltage of the power source. It is also used to display Welding Parameters. Depending on the Programming Parameter selected, the status indictor adjacent to the volt meter will illuminate to show the units of the welding parameter.
  • Page 24 ET 301I AC/DC Art # A-12843 Figure 3-5: Control Panel 38. Pre Flow indicator light This light will illuminate when the Pre Flow Welding Parameter is selected. 39. Initial Current time (GTAW) and Hot Start time (SMAW) indicator light This light will illuminate when the Initial Current Time Welding Parameter is selected in GTAW mode, or when Hot Start Time Welding Parameter is selected in SMAW mode.

  • Page 25: Setup For Tig (Gtaw) Welding

    ET 301I AC/DC 48. Crater Current time indicator light This light will illuminate when the Crater Current Time Welding Parameter is selected. 49. Electrode Diameter Out-of-Range indicator light This light will illuminate when the set welding current is outside the normal operating range for the selected Electrode Diameter.
  • Page 26 ET 301I AC/DC Art # A-12861 Figure 3-6: Setup for TIG Welding INSTALLATION, OPERATION AND SETUP Manual 0-5347 3-12...
  • Page 27 ET 301I AC/DC • First, select a Welding Type by pressing the Weld Type (17) button. Welding Type Welding Type Selection DC HF TIG AC Liftarc TIG DC Liftarc TIG AC HF TIG • Then, select a Welding Mode by pressing the WELDING MODE (10) button.

  • Page 28: Tig (Gtaw) Programming Mode

    ET 301I AC/DC 3.10 TIG (GTAW) Programming Mode Art # A-12845 Figure 3-7: TIG Programming Mode • Press the WELDING MODE (10) button to select the appropriate GTAW mode. Several GTAW operating modes are available. 2T (normal mode). The 2T LED (16) will illuminate.
  • Page 29 ET 301I AC/DC • Press the BACK button (22) or FORWARD button (23) so the Electrode Diameter LED (41) and Inches LED (29) are illuminated. Use the Multi Function Control (24) to adjust the Electrode size being used. • Press the BACK button (22) or FORWARD button (23) until the Peak Current LED (43) is illuminated.
  • Page 30 ET 301I AC/DC Parameter Range LED Code Parameter Value Factory (Left Display) (Right Display) Setting Up Slope Time This parameter operates in 0 - 99% GTAW modes only and is used to set the time for the weld current to ramp up from Initial current to welding current.
  • Page 31 ET 301I AC/DC Parameter Range LED Code Parameter Value Factory (Left Display) (Right Display) Setting Shielding Gas Post-Flow time This parameter operates in GTAW 20 – 500% modes only and is used to adjust the post gas flow time once the arc has extinguished.
  • Page 32 ET 301I AC/DC Parameter Range LED Code Parameter Value Factory (Left Display) (Right Display) Setting Pulse Frequency This parameter sets the Pulse 0.2 – 2000Hz Frequency when in GTAW Pulse operating mode. Pulse Balance This parameter sets 1 – 99% of Welding percentage “on”...

  • Page 33: Tig (Gtaw) Welding Secondary Parameters

    ET 301I AC/DC 3.11 TIG (GTAW) Welding Secondary Parameters Secondary parameters are available. These are required to be set separately. • Press and hold the WELDING MODE (10) button then press the SAVE (54) button. • Press the BACK button (22) or FORWARD button (23) to select the Parameter.

  • Page 34: Gtaw Spot Welding Mode With Dwell Time (Stitch Mode)

    ET 301I AC/DC 3.12 GTAW Spot Welding Mode with DWELL Time (Stitch Mode) Art # A-12846 Figure 3-8: GTAW Spot Welding Mode with DWELL Time To enable Spot Welding with Dwell Time (Stitch welding) the parameter “PSP” needs to be set to ON (refer secondary parameters) it is possible to have automated spot welds with this Stitch function.

  • Page 35: Tip Tronic Operation

    ET 301I AC/DC 3.13 Tip Tronic Operation In GTAW modes, up to 100 jobs can be saved. These are arranged as 10 jobs numbers, in 10 job sets. These are shown on the meter displays. The first number on the display is the job set, the second is the job number. In the example, the job set is 2 and the job number is 9.
  • Page 36 ET 301I AC/DC Load a TipTronic Job • Using the Welding Mode button (10) select TipTronic mode (14). Either 2T or the 4T may be lighted as well as the TT symbol for Tip Tronic setting depending on the last saved job.

  • Page 37: Setup For Stick (Smaw) Welding

    ET 301I AC/DC 3.14 Setup for Stick (SMAW) Welding A. Connect the Electrode Holder lead to the Electrode welding terminal (top). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via 50mm Dinse type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

  • Page 38: Stick (Smaw) Programming Mode

    ET 301I AC/DC • First, select Stick Mode by pressing the Welding Mode (10) button. Welding Type Welding Mode Selection Stick Mode • Then, select Welding Type by pressing the welding Type (17) button. Welding Type Welding Type Selection DC Negative Stick DC Positive Stick 3.15 Stick (SMAW) Programming Mode...
  • Page 39 SMAW mode is current. limited to 200A for e.g. HOT START current = 125 the ET 301i AC/DC. amps when welding current = 100 amps & HOT START = 125% Hot Start Time tS...
  • Page 40 ET 301I AC/DC Secondary parameters are available. These are required to be set separately. Art # A-12850 Figure 3-12: Stick Programming Mode Press and hold the WELDING MODE (10) button then press the SAVE (53) button. The Arc Dynamic Parameter is selected. In the left hand AMPS display dAr is displayed. In the right hand VOLTS display, the value of the parameter is displayed.

  • Page 41: User Specific Menus

    ET 301I AC/DC 3.16 User Specific Menus Art # A-12851 Figure 3-13: User Specific Menus • Switch off the power to the unit. Press and hold the BACK Welding Parameter Button (22) . Switch on the power to the unit.

  • Page 42: Special Function

    ET 301I AC/DC 3.17 Special Function Soft Reset • Press and hold the BACK button (22). • Press the SAVE button (53). • All control panel LED’s will light up briefly to confirm the Soft Reset has been completed. NOTE! The only difference between soft &...
  • Page 43 ET 301I AC/DC Control Panel Test • Press and hold the BACK button (22). • Press the FORWARD button (23). • All control panel LED’s and meter displays will light up for approximately 4 seconds. Art # A-12854 Figure 3-16: Control Panel Test Fan Test •...

  • Page 44: Shielding Gas Regulator Operating Instructions

    ET 301I AC/DC If there is an error, or no pump is connected, the error message Will be displayed after approximately 5 seconds. Art # A-12856 Figure 3-18: Water Pump Test 3.18 Shielding Gas Regulator Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only.
  • Page 45 ET 301I AC/DC CAUTION Match regulator/ flowmeter to cylinder. NEVER CONNECT a regulator/ flowmeter designed for a particular gas or gases to a cylinder containing any other gas. INLET CONNECTION OUTLET HIGH PRESSURE CONNECTION GAUGE (SUPPLY) FLOW GAUGE (DELIVERY) PRESSURE...

  • Page 46: Foot Control, Part No. W4013200 (Optional Accessory)

    ET 301I AC/DC Adjusting Flow Rate Figure 3-20: Adjust Flow Rate With the regulator/ flowmeter ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.
  • Page 47 ET 301I AC/DC Description Not Used Trigger Switch Trigger Switch Not Used Potentiometer Maximum Potentiometer Minimum Potentiometer Wiper Not Used Table 3-11: 8 Pin Socket Description The Tweco Foot Control is a foot operated switch and potentiometer which starts and stops the welding process and controls welding current through operation of the foot pedal.
  • Page 48 ET 301I AC/DC This Page Intentionally Blank INSTALLATION, OPERATION AND SETUP Manual 0-5347 3-34...

  • Page 49: Section 4: Basic Welding Guide

    ET 301I AC/DC SECTION 4: BASIC WELDING GUIDE 4.01 Stick (SMAW) Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available.
  • Page 50 ET 301I AC/DC Art # A-07688 Figure 4-2: Flat Position, Gravity Fillet Weld Art # A-07689 Figure 4-3: Horizontal Position, Butt Weld Art # A-07690 Figure 4-4: Horizontal-Vertical (HV) Position Art A-07691 Figure 4-5: Vertical Position, Butt Weld Art # A-07692...
  • Page 51 ET 301I AC/DC Art # A-07694 Figure 4-8: Overhead Position, Fillet Weld Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
  • Page 52 ET 301I AC/DC Arc Welding Technique - A Word to Beginners Arc Length For those who have not yet done any welding, the simplest way The securing of an arc length necessary to produce a neat weld to commence is to run beads on a piece of scrap plate. Use mild soon becomes almost automatic.
  • Page 53 ET 301I AC/DC Art # A-07700_AB Art # A-07698 Figure 4-12: Weld Build up Sequence Heavy plate will require several runs to complete the joint. Figure 4-14: Multi-runs in HV Fillet Weld After completing the first run, chip the slag out and clean the weld with a wire brush.
  • Page 54 ET 301I AC/DC Art # A-07702 Art # A-07704 Figure 4-18: Overhead Fillet Weld Figure 4-16: Multi Run Vertical Fillet Weld Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur.
  • Page 55 ET 301I AC/DC stresses (distortion), or the weld may crack, in any case, there will remain "locked-up" stresses in the job. Figures 4-19 and 4- 20 illustrate how distortion is created. Upsetting Weld Art # A-07705_AB Art # A-07707 Expansion with...

  • Page 56: Stick (Smaw) Welding Troubleshooting

    ET 301I AC/DC Art # A-07428_AB Figure 4-26: Chain Intermittent Welding Art # A-07713_AB Figure 4-27: Staggered Intermittent Welding 4.02 Stick (SMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE parameter is Reduce the ARC FORCE parameter until welding current...
  • Page 57 ET 301I AC/DC FAULT CAUSE REMEDY Art: A-04971 Figure 1: Example of insufficient gap or incorrect sequence 4 A groove has been A Welding current is too A Reduce welding current. formed in the base high. metal adjacent to B Welding arc is too long.
  • Page 58 ET 301I AC/DC FAULT CAUSE REMEDY 6 Gas pockets or A High levels of sulphur in A Use an electrode that is designed for high sulphur steels. voids in weld metal steel. (porosity) B Electrodes are damp. B Dry electrodes before use.

  • Page 59: Tig (Gtaw) Basic Welding Technique

    ET 301I AC/DC 4.03 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based.
  • Page 60 ET 301I AC/DC Tungsten Electrode Types Electrode Type Welding Application Features Colour Code (Ground Finish) DC welding of mild steel, Excellent arc starting, Long life, High current Thoriated 2% stainless steel and copper carrying capacity High quality AC welding of...

  • Page 61: Tig (Gtaw) Welding Problems

    TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operat- ing Manual. For further information please refer to www.esab.com or contact ESAB. 4.04 TIG (GTAW) Welding Problems...
  • Page 62 Electrode Selection Chart. B The wrong electrode B Select the right tungsten electrode is being used for the type. Refer to Table 4-5 ESAB Tungsten welding job. Electrode Selection Chart. C Gas flow rate is too C Select the right rate for the welding job.

  • Page 63: Section 5: Power Source Problems And Routine Service Requirements

    If major complex subassemblies are faulty, then the Welding Power Source must be returned to an accredited ESAB Service Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
  • Page 64 ET 301I AC/DC Error Messages If a message has been displayed, have an Accredited ESAB Service Provider check the power source. Message Code Error Cause Possible Remedy Thermal Overload of Duty Cycle has been exceeded Leave the power source Output Diodes switched ON and allow it to cool.

  • Page 65: Power Source Problems

    Replace primary control fuse. light is not lit and welding arc cannot blown. be established. Broken connection in Have an Accredited ESAB Service primary circuit. Provider check primary circuit. 3 Error Code E01 is displayed and unit Duty cycle of power source...

  • Page 66: Routine Service And Calibration Requirements

    B. Insulation Resistance Minimum insulation resistance for in-service ESAB Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5-2 below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.
  • Page 67 2. The Earth Ground terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying ESAB welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.

  • Page 68: Cleaning The Welding Power Source

    ET 301I AC/DC 5.04 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

  • Page 69: Section 6: Key Spare Parts

    ET 301I AC/DC SECTION 6: KEY SPARE PARTS 6.01 Key Spare Parts A-12885_AB Figure 6-1: Spare Parts Manual 0-5347 KEY SPARE PARTS...
  • Page 70 ET 301I AC/DC ET 301i AC/DC Spare Parts Item Part Number Description 982.0943.0 Clear Control Panel Cover 676.0350.8 Knob, Control W7006307 PCB, Display 655.9079.0 HF Filter 981.1419.0 Thermal Sensor 665.3076.0 Solenoid 24VDC W7006426 Rectifier 1600V 80A W7006427 PCB, Relay W7006428 Transformer 460V/230V - 0.24A 56VA...

  • Page 71: Appendix A: Circuit Diagram Of Et 301I Ac/Dc

    ET 301I AC/DC APPENDIX A: CIRCUIT DIAGRAM OF ET 301i AC/DC X1/1 +VCC X1/2 CAN_L X1/3 X1/4 CAN_H X1/5 X18/1 X1/6 X18/2 X1/7 X18/3 X11/1 X1/8 X18/4 REL02 X4/1 X10/1 X4/2 X10/2 X11/2 X4/3 X10/3 X13/1 X13/2 X3/1 X15/1 braun...

  • Page 72: Revision History

    ET 301I AC/DC REVISION HISTORY Cover Date Rev. Change(s) 05/07/15 Manual release 7/16/15 Updated per VCN-00931: 1. Updated Spare Parts Diagram and Spare Parts List; 2. Updated Wir- ing Diagram. 01/15/16 Updated 'Liftarc TIG' wording, error messages, Section 6 art, spart parts list and Appendix art.
  • Page 74 SOUTH AFRICA Bucharest Vamberk Tel: +40 316 900 600 ESAB Mexico S.A. ESAB Africa Welding & Cutting Ltd Tel: +420 2 819 40 885 Fax: +40 316 900 601 Monterrey Durbanvill 7570 - Cape Town Fax: +420 2 819 40 120...

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