ESAB | ET 300i | Instruction manual | ESAB ET 300i User manual

ESAB ET 300i User manual
ET 300i, ET 300iP
Welding power source TIG 300 A
Instruction manual
0463 416 001 GB 20171016
Valid for: serial no. 721-, 742-xxx-xxxx
TABLE OF CONTENTS
SAFETY .........................................................................................................
5
1.1
Meaning of symbols .................................................................................
5
1.2
Safety precautions ...................................................................................
5
INTRODUCTION ............................................................................................
8
2.1
Overview ...................................................................................................
8
2.2
Equipment .................................................................................................
8
3
TECHNICAL DATA ........................................................................................
9
4
INSTALLATION..............................................................................................
11
4.1
Location ....................................................................................................
11
4.2
Lifting instructions ...................................................................................
11
4.3
Mains supply.............................................................................................
12
4.4
Recommended fuse sizes and minimum cable area ............................
15
OPERATION ..................................................................................................
17
5.1
Overview ...................................................................................................
17
5.2
Connections and control devices ...........................................................
17
5.3
TIG welding ...............................................................................................
18
5.4
MMA welding.............................................................................................
18
5.5
Connection of welding and return cables ..............................................
18
5.6
Turning the mains power on/off ..............................................................
18
5.7
Connect to cooler EC 1000 ......................................................................
19
5.8
Fan control ................................................................................................
19
5.9
Thermal protection ...................................................................................
20
5.10
Voltage reducing device (VRD) ...............................................................
20
5.11
Remote control .........................................................................................
20
5.12
USB connection........................................................................................
20
CONTROL PANEL.........................................................................................
21
6.1
ET 300i .......................................................................................................
21
6.1.1
Navigation ..............................................................................................
21
6.1.2
Weld program .........................................................................................
22
ET 300iP ....................................................................................................
23
Navigation ..............................................................................................
24
TIG settings...............................................................................................
25
6.3.1
Hidden TIG functions..............................................................................
26
6.3.2
Measured values ....................................................................................
26
TIG functions explanation .......................................................................
26
Foot pedal functions explanation............................................................
28
MMA settings ............................................................................................
30
6.5.1
Hidden MMA functions ...........................................................................
30
6.5.2
Measured values ....................................................................................
26
MMA functions explanation.....................................................................
31
1
2
5
6
6.2
6.2.1
6.3
6.4
6.4.1
6.5
6.6
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TABLE OF CONTENTS
MAINTENANCE .............................................................................................
32
7.1
Routine maintenance ...............................................................................
32
7.2
Cleaning instruction.................................................................................
32
8
TROUBLESHOOTING ...................................................................................
36
9
ERROR CODES.............................................................................................
37
9.1
Error code descriptions ..........................................................................
37
ORDERING SPARE PARTS ..........................................................................
39
DIAGRAM .............................................................................................................
40
ORDERING NUMBERS .......................................................................................
41
ACCESSORIES ....................................................................................................
42
7
10
Rights reserved to alter specifications without notice.
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1 SAFETY
1
SAFETY
1.1
Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2
Safety precautions
Users of ESAB 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 equipment. The following
recommendations 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
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.
2.
3.
Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
The workplace must:
○ be suitable for the purpose
○ be free from drafts
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1 SAFETY
4.
5.
Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ 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
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
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1 SAFETY
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
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 electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
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2 INTRODUCTION
2
INTRODUCTION
2.1
Overview
The ET 300i and ET 300iP are welding power sources intended for TIG welding and for
welding with covered electrodes (MMA).
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.2
Equipment
The power source is supplied with:
•
•
•
•
Instruction manual
3 m (9.8 ft) mains cable with plug
Gas hose for TIG welding, including hose clamps
Return cable
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3 TECHNICAL DATA
3
TECHNICAL DATA
ET 300i (0445 100 900), ET 300iP (0445 100 920)
Mains voltage
230–480 V ±10%,
3~ 50/60 Hz
230 V ±10%, 1~ 50/60 Hz
Mains supply Ssc min
4.1 MVA
No demand
Zmax
0.04 Ohm
No demand
Imax MMA
30.0 A
29.0 A
Imax TIG
22.0 A
20.0 A
Primary current
No-load power demand when in the energy-saving mode
Uin 230 V
63 W
Uin 400 V
68 W
Uin 480 V
72 W
74 W
Setting range
MMA
5 A / 20 V - 300 A / 32 V
5 A / 20 V - 200 A / 28 V
TIG
5 A / 10 V - 300 A / 22 V
5 A / 10 V - 200 A / 18 V
Permissible load at MMA
40% duty cycle
300 A / 32.0 V
60% duty cycle
250 A / 30.0 V
100% duty cycle
200 A / 28.0 V
200 A / 28.0 V
Permissible load at TIG
40% duty cycle
300 A / 22.0 V
60% duty cycle
250 A / 20.0 V
100% duty cycle
200 A / 18.0 V
200 A / 18.0 V
Power factor at maximum current
TIG
0.96
0.98
MMA
0.96
0.99
Apparent power I2 at
maximum current
11.6 kVA
6.6 kVA
Active power I2 at maximum 11.2 kW
current
6.6 kW
Efficiency at maximum current
TIG
83%
83%
MMA
86%
86%
Open-circuit voltage U0
max
48 V
48 V
Open-circuit voltage U0
34 V
max with VRD 35 V activated
34 V
UPK
12.4 kV
Operating temperature
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12.4 kV
-10 to +40 °C (+14 to +104 °F)
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3 TECHNICAL DATA
ET 300i (0445 100 900), ET 300iP (0445 100 920)
Transportation temperature
-20 to +55 °C (-4 to +131 °F)
Continual sound pressure
at no-load
Dimensions l × w × h
< 70 db (A)
460 × 200 × 320 mm (18.1 × 7.9 × 12.6 in.)
Weight with cooler
without cooler
26.6 kg (58.6 lb)
16.8 kg (37.0 lb)
Isolation class transformer
F
Enclosure class
IP23
Application class
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40 °C / 104 °F, or below.
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 intended for indoor and outdoor use.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
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4 INSTALLATION
4
INSTALLATION
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.
4.1
Location
Position the power source so that its cooling air inlets and outlets are not obstructed.
A. Minimum 200 mm (8 in.)
B. Minimum 200 mm (8 in.)
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.
4.2
Lifting instructions
Mechanical lifting must be done with both outer handles.
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4 INSTALLATION
4.3
Mains supply
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit
power is greater than or equal to Sscmin at the interface point between the user's
supply and the public system. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply with a short-circuit
power greater than or equal to Sscmin. Refer to the technical data in the
TECHNICAL DATA chapter.
The power source will automatically adjust to the supplied input voltage; make sure it is
protected by the correct fuse rating. A protective earth connection must be made, in
accordance with regulations.
1.
Rating plate with supply connection data
Installation of mains cable
NOTE!
The power source is delivered with a 4×2.5 mm2 mains cable and a 16 A mains
plug which in combination can handle the rated data given for 3-phase
380–415 V mains supply. If other mains voltage is required, the mains cable may
be changed according to relevant national regulations. For recommendations,
see section Recommended fuse sizes and minimum cable area.
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4 INSTALLATION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Remove the side panel.
If tightened, release the stopping block (A).
If a cable is connected, disconnect all wires, cut the cable tie (D), and remove the
cable.
Optional: The fan with foam can at this point be removed to simplify the installation.
Note the direction of the fan (the sticker towards the inside).
Strip the new wire according to specification (B).
Insert the cable with about 1 cm (0.4 in.) of isolation inside the stopping block. Tighten
the stopping block by using 1.5–2 Nm (13.3–17.7 in. lb) (A).
Use two cable ties to fasten the cables (D).
Optional: If the fan with foam has been removed it shall now be re-installed. A symbol
on the side of the fan (G) shows the air flow direction.
Install the ferrites and connect the earth wire (C). A toothed washer should be located
closest to the heat sink. Tighten the screw to a torque of 6.0 ±0.6 Nm (53.1 ±5.3 in. lb).
Connect all wires in accordance with illustrations for 1-phase and 3-phase. Tighten the
screw to a torque of 1.0 ±0.2 Nm (8.9 ±1.8 in. lb).
Ensure that the IP shield is correctly mounted on the inside of the side panel (E).
Reassemble the side panel (F).
Tighten the screws on the side panel with 3 ±0.3 Nm (26.6 ±2.7 in. lb).
3-phase
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4 INSTALLATION
1-phase
WARNING!
In 1-phase operation the terminal L3 is powered, even though not connected.
Make sure to keep terminal L3 disconnected.
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4 INSTALLATION
4.4
Recommended fuse sizes and minimum cable area
Recommended fuse sizes and minimum cable area
ET 300i, ET 300iPET 300i, ET 300iP
3~ 50/60 Hz
Mains voltage
1~ 50/60
Hz
230 V
380 V
400 V
415 V
480 V
230 V
4×4 mm²
4×2.5
mm²
4×2.5
mm²
4×2.5
mm²
4×2.5
mm²
3×6 mm²
Maximal current rating
Imax
MMA
30 A
18 A
17 A
16 A
14 A
29 A
I1eff
MMA
19 A
11 A
11 A
10 A
9A
29 A
Maximal current rating
Imax
TIG
22 A
13 A
12 A
12 A
10 A
20 A
I1eff
TIG
14 A
8A
8A
7A
7A
16 A
Fuse
anti-surge
20 A
16 A
16 A
16 A
10 A
35 A
type C MCB
25 A
16 A
16 A
16 A
16 A
32 A
Maximum
recommended
extension cord length
100 m/
330 ft.
100 m/
330 ft.
100 m/
330 ft.
100 m/
330 ft.
100 m/
330 ft.
100 m/
330 ft.
Minimum
recommended
extension cord size
4×4 mm² 4×4 mm² 4×4 mm² 4×4 mm² 4×4 mm² 3×6 mm²
Mains cable area
NOTE!
Different variants of ET 300i and ET 300iP are certified for different mains
voltage. Always refer to the rating plate for the specification of the power source
in use.
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. Use the power source in accordance with the relevant
national regulations.
1-phase 230 V mains voltage with 16 A mains fuse
See table below for informative data for use at 1-phase 230 V mains voltage with 16 A mains
fuse. A 16 A mains fuse may enable the use of a 16 A mains plug in combination with a
3×2,5 mm2 mains cable.
MMA 1~ 230 V 16 A
25%
60%
100%
I2
200 A*
150 A
120 A
U2
28.0 V
26.0 V
24.8 V
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© ESAB AB 2017
4 INSTALLATION
Imax
28.2 A
20.2 A
15.3 A
Ieff
14.1 A
15.6 A
15.3 A
TIG 1~ 230 V 16 A
60%
100%
I2
200 A*
170 A
U2
18.0 V
16.8 V
Imax
19.1 A
15.3 A
Ieff
14.8 A
15.3 A
*) Porcelain fuses are recommended to achieve 200 A in MMA and TIG mode. MCB fuses
break the circuit faster than porcelain fuses.
Supply from power generators
The power source can be supplied from different types of generators. However, some
generators may not provide sufficient power for the welding power source to operate
correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better
type of regulation, with rated power 20 kW, are recommended.
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5 OPERATION
5
OPERATION
5.1
Overview
General safety regulations for handling the equipment can be found in the chapter
"Safety". Read it through before you start the equipment.
NOTE!
When moving the equipment use intended handle. Never pull the cables.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
5.2
Connections and control devices
1. User interface, see chapter CONTROL
PANEL.
2. Connection (+): TIG: Return cable MMA:
Welding cable or return cable
3. Gas supply output
4. TIG torch trigger
5. Connection (-): TIG: torch MMA: Return
cable or welding cable
6. Connection for remote control unit
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7. Gas supply input
8. Mains power supply switch, O/I
9. USB connection
10. Connection for cooling unit
11. Mains cable
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5 OPERATION
NOTE!
When connecting a gas hose to the gas supply input, it must be secured using a
hose clamp.
NOTE!
Always use the cover when the USB connection is not in use.
5.3
TIG welding
TIG welding melts the metal of the workpiece, using an arc initiated from a
non-consuming tungsten electrode. The weld pool and electrode are protected
by a shielding gas that usually consists of an inert gas.
For TIG welding, the welding power source shall be supplemented with:
•
•
•
•
•
•
5.4
a TIG torch
a gas hose connected to the gas supply input (using a hose clamp)
an argon gas cylinder
an argon gas regulator
a tungsten electrode
a return cable (with clamp)
MMA welding
MMA welding may also be referred to as welding with covered electrodes. The
arc melts the electrode as well as a local part of the workpiece. The coverage,
when melting, forms a protective slag and creates a shielding gas to protect the
weld pool from atmospheric contamination.
For MMA welding the power source shall be supplemented with:
• welding cable with electrode holder
• return cable with clamp
5.5
Connection of welding and return cables
The power source has two outputs, a positive welding terminal (+) and a negative welding
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 between the work
piece and the output for the return cable on the power source.
•
•
For TIG welding, the negative welding terminal (-) is used for the welding torch and the
positive welding terminal (+) is used for the return cable.
For MMA welding, the welding cable can be connected to the positive welding terminal
(+) or negative welding terminal (-) depending on the type of electrode used. The
connecting polarity is stated on the electrode packaging.
5.6
Turning the mains power on/off
Turn on the mains power by turning switch to the ”I” position.
Turn the unit off by turning the switch to the ”O” position.
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5 OPERATION
Whether the mains power supply is interrupted or the power source is switched off in the
normal manner, weld programs will be stored so that it is available next time the unit is
started.
CAUTION!
Do not turn off the power source during welding (with load).
5.7
Connect to cooler EC 1000
NOTE!
Take care so that the interface cable does not get squeezed between the power
source and the cooling unit!
NOTE!
Power supply of the cooling unit is done from the welding power source via the
connection cable (for more information, see the cooling unit instruction manual).
5.8
Fan control
The power source has an automatic thermal control. The fan continues to run during a few
minutes after welding has stopped while the power source switches to energy-saving mode.
The fan starts again when welding restarts.
During energy-saving mode the fan will start occasionally and run for a few minutes.
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5 OPERATION
5.9
Thermal protection
The power source includes thermal protection against overheating. When
overheating occurs the welding is stopped and overheating indicator on the
panel will be lit and an error message shows in the display. The protection is
automatically reset when the temperature has been sufficiently reduced.
5.10
Voltage reducing device (VRD)
The VRD function ensures that the open-circuit voltage does not exceed 35 V
when welding is not being carried out. This is indicated by a lit VRD indicator on
the panel. Contact an authorised ESAB service technician to activate this
function.
5.11
Remote control
Connect the remote control on the rear side of the power source and activate the
remote control by pressing the remote control button on the panel (remote
control indicator being lit when activated). When the remote control is activated
the control panel is locked for interaction but displays welding data.
5.12
USB connection
Always use the USB cover when the USB connection is not in use.
Do not use for charging units such as mobile phones.
The welding process is blocked when a USB flash drive is connected. The USB
connection can be used to retrieve welding statistics. The statistics contains of
total number of welds performed, total welding time and average current.
Retrieving welding statistics
Always make sure that the power source is not used for welding when retrieving
welding statistics.
1.
2.
3.
4.
5.
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Insert an empty USB flash drive into the power source USB connector.
To confirm that the power source has read the USB flash drive, the text
"USB" flashes in the display for a moment, after which the text "USB" is
shown with fixed light.
When the text "USB" is shown with fixed light: Remove the USB flash drive
from the USB connector.
The USB flash will contain a text file (.txt) with the welding statistics.
Recommended program for opening the text file is Microsoft WordPad or
Microsoft Word.
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© ESAB AB 2017
6 CONTROL PANEL
6
CONTROL PANEL
6.1
ET 300i
1. Memory 1, 2 and 3.
2.
3.
4.
5.
6.
7.
8. Current set and measure value / Voltage
measure value
Display, shows set or measured value.
9. Slope down indicator.
Button to select welding method: TIG HF, 10. Gas post flow indicator.
LiftArc™ or MMA.
Set indicator.
11. Parameter selection button, selection
indicated by (8) to (10). Also used for
access to hidden fuctions.
Button to select 2-stroke or 4-stroke (TIG 12. Overheating indicator.
only).
Button to activate and deactivate remote 13. VRD function (reduced open-circuit
control unit.
voltage) indicator.
Knob for setting data.
6.1.1
Navigation
Parameter selection
By pressing the button (11) different values can be shown. Use the knob (7) to change the
values. The sequence is:
1.
2.
3.
4.
5.
Set current value.
Measured current value.
Measured voltage value.
Slope down (TIG only)
Gas post flow (TIG only)
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6 CONTROL PANEL
Set parameter
The set indicator (4) will be lit when the displayed value can be changed. It cannot be
changed from the panel when a remote control is activated. Trying to change a value while in
measured value mode will result in automatically move to set current value mode.
The set indicator is off when measured values are shown.
6.1.2
Weld program
For each welding process (MMA/TIG) three different weld programs can be stored in the
setting panel memory (1). Press selection button 1, 2 or 3 for 3 seconds to store a weld
program in the memory. The memory indicator will be lit when finished.
To switch between the different weld programs press button 1, 2 or 3.
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6 CONTROL PANEL
6.2
ET 300iP
1. Button to change between direct current
and pulse current.
2. Display, shows set or measured value.
3. Button to select welding method: TIG HF,
LiftArc™ or MMA.
4. Set indicator.
5. Button to select 2-stroke or 4-stroke (TIG
only).
6. Button to activate and deactivate remote
control unit.
7. Knob for setting data.
8. Gas pre flow indicator.
9. Slope up indicator.
10. Direct current or pulse current indicator.
12. Background current indicator.
13. Pulse frequency indicator.
14. Slope down indicator.
15. Gas post flow indicator.
16. Button to change between the parameters
in the graph.
17. Indicates which is shown in the display:
s (seconds for gas pre flow, gas post flow,
slope up and slope down), % (pulse
balance), Hz (pulse frequency).
18. Current set and measure value / Voltage
measure value.
19. Parameter selection button, selection
indicated by (18). Also used for access to
hidden functions.
20. Overheating indicator.
21. VRD function (reduced open-circuit
voltage) indicator.
11. Pulse balance.
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6 CONTROL PANEL
6.2.1
Navigation
Parameter selection
By pressing the button (19) different values can be shown and changed. Use the knob (7) to
change the values. The sequence is:
1.
2.
3.
Set current value.
Measured current value.
Measured voltage value.
Set parameter
The set indicator (4) will be lit when a displayed value can be changed. It cannot be changed
from the panel when a remote control is activated. Trying to change a value while in
measured value mode will result in automatically move to set current value mode.
The set indicator (4) is off when measured values are shown.
Weld parameters
The weld parameters are stored for pulse and no pulse respectively. The values are changed
when changing between pulse and no pulse.
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6 CONTROL PANEL
6.3
Symbol
TIG settings
Function
Setting range
Setting steps
Default
value
ET 300i ET 300iP
TIG HF*
ON/OFF
ON
X
X
LiftArc*
ON/OFF
OFF
X
X
Current
1ph: 5–200 A
1
100 A
X
X
0.1
1.5 s
H
X
3ph: 5–300 A
Slope up time H: 0.0–9.9 s
0.0–25.0 s
Slope down
time
0.0–25.0 s
0.1
3.0 s
X
X
Gas pre flow
time
H: 0.0–9.9 s
0.1
1.0 s
H
X
0.1
7.0 s
X
X
0.0–25.0 s
Gas post flow 0.0–25.0 s
time
2-stroke*
ON/OFF
ON
X
X
4-stroke*
ON/OFF
OFF
X
X
Remote
control unit*
ON/OFF
OFF
X
X
Pulse*
ON/OFF
OFF
X
120 A
X
80 A
X
50%
X
Pulse current 1ph: 5–200 A
3ph: 5–300 A
Background
current
1ph: 5–200 A
3ph: 5–300 A
Pulse balance 10–90%
5
Pulse
frequency
0.10–0.99: 0.01 100 Hz
0.01–999 Hz
X
1.0–9.9: 0.1
10–100: 1
100–300: 10
300–999: 100
Remote min
current
0–99%
1
*) Parameter cannot be changed while welding
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20%
H
H
H = Hidden
function
© ESAB AB 2017
6 CONTROL PANEL
6.3.1
Hidden TIG functions
There are hidden functions in the control panel. To access the functions, press parameter
selection button for 3 seconds (see section SETTING PANEL for button placement). The
display shows a letter and a value. Select function by pressing the same button. The knob is
used to change the value of the selected function. To exit hidden functions, press the button
for 3 seconds again.
Letter
Function
Settings
A
Gas pre flow
0.0–9.9 s
b
Slope up
0.0–9.9 s
I
Remote min current
0–99%
6.3.2
Measured values
Measured current
Measured value in the display for welding current A is arithmetic average value.
Measured voltage
Measured value in the display for arc voltage V is arithmetic average value.
6.4
TIG functions explanation
HF start
The HF start function initiates the arc by using a high frequency voltage pilot arc.
This will reduce the risk of tungsten contamination in the starts. The high
frequency voltage might disturb other electrical equipment in the surrounding
area.
LiftArc™
The LiftArc™ function initiates the arc when the tungsten electrode is brought
into contact with the workpiece, the trigger switch is pressed, and the tungsten
electrode is lifted away from the workpiece. In order to minimize the risk of
tungsten contaminations the start current is very low and will slope up to the set
current (controlled by the slope up function).
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6 CONTROL PANEL
2-stroke
In 2-stroke mode, press the TIG torch trigger switch (1) to start the shielding gas
flow and iniate the arc. The current slopes up to the set current value. Release
the trigger switch (2) to start to slope down the current and terminate the arc.
The shielding gas will continue to flow in order to protect the weld and the
tungsten electrode.
A = Gas pre flow
B = Slope up
C = Slope down
D = Gas post flow
4-stroke
In 4-stroke mode, press the TIG torch trigger switch (1) to start shielding gas
flow and initiate the arc at a pilot level. Release the trigger switch (2) to slope up
the current to the set current value. To stop the welding, press the trigger switch
again (3). The current will slope down to the pilot level again. Release the trigger
switch (4) to terminate the arc. The shielding gas will continue to flow in order to
protect the weld and the tungsten electrode.
A = Gas pre flow
B = Slope up
C = Slope down
D = Gas post flow
Gas pre flow
The gas pre flow function controls the time during which shielding gas flows
before the arc is initiated.
Gas post flow
The gas post flow function controls the time during which shielding gas flows
after the arc is terminated.
Slope up
The slope up function is used to control the time of the current increase in the
weld initiation process to avoid any possible damage to the tungsten electrode.
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6 CONTROL PANEL
Slope down
The slope down function is used to control the time of the current decrease in
the weld termination process to avoid any pipes and/or cracks.
Pulse settings
In order to set a pulsed current, four parameters are required: pulse current,
background current, pulse balance and pulse frequency.
Pulse current
The higher of the two current values when using a pulsed current.
Pulse background current
The lower of the two current values when using a pulsed current.
Pulse balance
Pulse balance is the ratio between pulse current and background current in a
pulse cycle. In order to control the energy of the arc and the size of the weld
pool, pulse balance is adjustable by setting the percentage of the pulse current
in a pulse cycle.
For example: If the pulse balance is set to 50%, the time of the pulse current and
the background current will be distributed equally in the pulse cycle. If the pulse
balance is set to 90%, the time of the pulse current will be 90% of the pulse
cycle and the background current will only be 10%.
Pulse frequency
The amount of pulse cycles in a time period. The higher the frequency, the more
pulse cycles per time period. When the pulse frequency is set low, the weld pool
will have time to partially solidify between each pulse. If the frequency is set
high, a more focused arc can be obtained.
Remote min current
This is used to set the minimum current for the foot pedal. Is set in % of the set
current in the range from 0–99% in steps of 1%.
For example: If the current is set to 100 A and the remote min current function is
set to 20, the remote min current will be 20 A. If the current is set to 80 A and the
remote min current function is set to 50, the remote min current will be 40 A.
6.4.1
Foot pedal functions explanation
Foot pedal with 2-stroke using TIG torch trigger
In 2-stroke mode, with the foot pedal activated, press the TIG torch trigger switch (1) to start
the shielding gas flow and initiate the arc. The current slopes up to the set remote min
current. Use the foot pedal to adjust the current between the remote min current and the set
current value. Release the TIG torch trigger switch (2) to start to slope down the current and
terminate the arc. The shielding gas will continue to flow in order to protect the weld and the
tungsten electrode.
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© ESAB AB 2017
6 CONTROL PANEL
A = Gas pre flow
E = Set current
B = Slope up
F = Remote min current
C = Slope down
G = Current range adjustable by the foot
pedal
D = Gas post flow
Foot pedal with 4-stroke using TIG torch trigger
In 4-stroke mode, with the foot pedal activated, press the TIG torch trigger switch (1) to start
the shielding gas flow and initiate the arc at a pilot level. Release the trigger switch (2) to
slope up the current to the remote min current. Use the foot pedal to adjust the current
between the remote min current and the set current value. To stop the welding, press the
trigger switch again (3). The current will slope down to the pilot level again. Release the
trigger switch (4) to terminate the arc. The shielding gas will continue to flow in order to
protect the weld and the tungsten electrode.
A = Gas pre flow
E = Set current
B = Slope up
F = Remote min current
C = Slope down
G = Current range adjustable by the foot
pedal
D = Gas post flow
Foot pedal
Press down the foot pedal (1) to start the shielding gas flow and initiate the arc. The current
slopes up to the set remote min current. Use the foot pedal to adjust the current between the
remote min current and the set current value. Release the foot pedal to start to slope down
the current and to terminate the arc. The shielding gas will continue to flow in order to protect
the weld and the tungsten electrode.
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© ESAB AB 2017
6 CONTROL PANEL
A = Gas pre flow
E = Set current
B = Slope up
F = Remote min current
C = Slope down
G = Current range adjustable by the foot
pedal
D = Gas post flow
6.5
MMA settings
Symbol
Function
Setting range
MMA*
ON/OFF
Current
1ph: 5–200 A
Setting steps
Default
value
ON
1
100 A
ET 300i ET 300iP
X
X
3ph: 5–300 A
Arc force
0–99
1
50
H
H
Hot start
0–99%
1
20%
H
H
Remote
control unit*
ON/OFF
OFF
X
X
*) Parameter cannot be changed while welding
6.5.1
H = Hidden
function
Hidden MMA functions
There are hidden functions in the control panel. To access the functions, press parameter
selection button for 3 seconds (see section SETTING PANEL for button placement). The
display shows a letter and a value. Select function by pressing the same button. The knob is
used to change the value of the selected function. To exit hidden functions, press the button
for 3 seconds again.
Letter
Function
Settings
C
Arc force
0–99
H
Hot start
0–99%
6.5.2
Measured values
Measured current
Measured value in the display for welding current A is arithmetic average value.
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6 CONTROL PANEL
Measured voltage
Measured value in the display for arc voltage V is arithmetic average value.
6.6
MMA functions explanation
Arc force
The arc force function determines how the current changes in response to
variations in arc length during welding. Use a low value of arc force to get a calm
arc with little spatter and use a high value to get a hot and digging arc.
Arc force only applies to MMA welding.
Hot start
The hot start function temporarily increases the current in the beginning of the
weld, thus reducing the risk of lack of fusion in the starting point.
Hot start only applies to MMA welding.
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© ESAB AB 2017
7 MAINTENANCE
7
MAINTENANCE
WARNING!
Disconnect power before performing maintenance.
CAUTION!
Only persons with the appropriate electrical knowledge (authorised personnel)
may remove safety plates.
CAUTION!
The product is covered by manufacturer's warranty. Any attempt to carry out
repair work by non-authorised service centers will invalidate the warranty.
NOTE!
Regular maintenance is important for safe and reliable operation.
NOTE!
Perform maintenance more often during severe dusty conditions.
Before each use - make sure that:
•
•
Product and cables are not damaged,
The torch is clean and not damaged.
7.1
Routine maintenance
Maintenance schedule during normal conditions. Check equipment prior to every use.
Interval
Area to maintain
Every 3 month
Clean or replace
unreadable labels.
Clean weld terminals. Check or replace weld
cables.
Every 6 month
Clean inside
equipment. Use dry
compressed air with
reduced pressure.
7.2
Cleaning instruction
To maintain the performance and increase the lifetime of the power source it is mandatory to
clean it regularly. How often depends on:
•
•
•
the welding process
the arc time
the working environment
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© ESAB AB 2017
7 MAINTENANCE
CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared workspace.
CAUTION!
During cleaning, always wear recommended personal safety equipment, such as
ear plugs, safety glasses, masks, gloves and safety shoes.
1.
Disconnect the power source from the mains supply.
WARNING!
Wait at least 30 seconds for the capacitors to discharge before continuing.
2.
Remove the four screws holding the right side panel (R) and remove the panel.
3.
Clean the right side of the power source, using dry compressed air with reduced
pressure.
NOTE!
Since the power source contains one "dirty side" (the right side) and one
"clean side" (the left side), it is important that you do not remove the left
side panel before cleaning the right side of the power source.
0463 416 001
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© ESAB AB 2017
7 MAINTENANCE
4.
Remove the four screws holding the left side panel (L) and remove the panel.
5.
Clean the left side of the power source, using dry compressed air with reduced
pressure.
Make sure that there is no dust left on any part of the power source.
After having finished cleaning the power source, reattach the power source panels in
the reverse order.
6.
7.
NOTE!
When reattaching the right side panel, make sure the IP shield on the
inside of the panel is in the correct position. The IP shield should be angled
approximately 90° into the power source, so that it is positioned between
the welding outlet connector and the transformer outlets.
0463 416 001
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© ESAB AB 2017
7 MAINTENANCE
8.
Tighten the screws on the side panels with 3 Nm ± 0.3 Nm (26.6 in lb. ± 2.6).
0463 416 001
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© ESAB AB 2017
8 TROUBLESHOOTING
8
TROUBLESHOOTING
Perform these checks and inspections before sending for an authorised service technician.
Type of fault
Corrective action
MMA welding problems
• Check that the welding and return cables are not damaged
and that they are correctly connected to the power source.
• Make sure the return clamp has proper contact with the
work piece.
• Check that the correct electrodes and polarity are being
used. For polarity, check electrode packaging.
• Check that the correct current value is set.
• Adjust Arc Force and Hot start.
TIG welding problems
• Check that the welding and return cables are not damaged
and that they are correctly connected to the power source.
• Make sure the return clamp has proper contact with the
work piece.
• Make sure the TIG torch lead is connected to negative
welding terminal.
• Make sure the correct shielding gas, gas flow, welding
current, filler rod placement, electrode diameter and
welding mode on power source is used.
• Make sure the gas valve on the TIG torch is on.
No arc
• Check that display is on to verify that the power source has
power.
• Check setting panel display correct values.
• Check that the mains power supply switch is turned on.
• Check that the mains, welding and return cables are
correctly connected.
• Check the mains power supply fuses.
Welding current is
interrupted during welding
• Check whether the overheating light (thermal protection) at
setting panel is on.
• Continue with fault type "No Arc".
The thermal protection
trips frequently
• Make sure the recommended duty cycle for the weld
current has not been exceeded.
See section "Duty cycle" in the TECHNICHAL DATA
chapter.
• Make sure the air inlets or outlets are not clogged.
• Clean inside machine according to routine mainteance.
• Check and clean the cooler.
The maximum current
setting is limited to 200 A
• Check that the power source is connected to 3-phase
mains power supply.
• Check the mains power supply fuses.
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© ESAB AB 2017
9 ERROR CODES
9
ERROR CODES
The error code is used to indicate that a fault has occurred in the equipment. Errors are
indicated by the text "Err" followed by the error code number shown in the display.
If several errors have been detected only the code for the last occurring error is displayed.
9.1
Error code descriptions
Error codes that the user can handle are listed below. If any other error code appears,
contact an authorised ESAB service technician.
Error code Description
Err 1
Temperature fault
The temperature of the power source is too high. A LED indicating
temperature fault is also lit on the panel. A temperature fault is indicated by
the overheating indicator on the control panel.
Action: The error code will automatically disappear and the LED indicating
temperature fault will be turned off when the power source has cooled down
and is ready for use again. If the error persists, contact a service technician.
Err 2
Coolant fault
The temperature of the coolant fluid is too high.
Action: Make sure that there is sufficient coolant fluid in the cooler. The error
code will automatically disappear when the coolant has cooled down and is
ready for use again. If the error persists, contact a service technician.
Err 3
Power supply fault
The power supply to the power source is too low or too high.
One phase is lost during 3-phase operation. Third phase voltage detected
during 1-phase operation.
Action: Make sure the power supply is stable, all leads are connected, that
the mains voltage (all 3 phases) are OK and restart the system. If the error
persists, contact a service technician.
Err 4
Communication fault
The communication between units has been disrupted.
Action: Check cables and connections, restart the power source. If the error
persists, contact a service technician.
Err 5
Memory fault
The program memory is damaged. This fault can disable preset functions or
other functions where values are stored.
Action: Remove the error indication from the display by pressing a button on
the panel. Restart the power source. If the error persists, contact a service
technician.
Err 6
Timing fault
The power source electronics are not able to execute all functions in a timely
fashion.
Action: Restart the power source. If the error persists, contact a service
technician.
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© ESAB AB 2017
9 ERROR CODES
Error code Description
Err 7
OCV fault
The OCV is too high or the electronic control of the OCV has been disrupted.
Action: Restart the power source. If the error persists, contact a service
technician.
Err 8
Water cooling disabled
The hose from the torch is not connected to the cooling unit.
Action: If a water cooled torch is used make sure it is connected to the
cooling unit. If a water cooled torch is not used, press a button on the control
panel to cancel the error. If the error persists, contact a service technician.
0463 416 001
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© ESAB AB 2017
10 ORDERING SPARE PARTS
10
ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The ET 300i and ET 300iP are designed and tested in accordance with international and
european standards IEC/EN 60974-1, IEC/EN 60974-3 and IEC/EN 60974-10, Canadian
standards CAN/CSA-E60974-1 and US standards ANSI/IEC 60974-1. On completion of
service or repair work, it is the responsibility of the person(s) performing the work to ensure
that the product still complies with the requirements of the above standard.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.
0463 416 001
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© ESAB AB 2017
DIAGRAM
DIAGRAM
0463 416 001
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© ESAB AB 2017
ORDERING NUMBERS
ORDERING NUMBERS
Ordering number
Denomination
Type
Notes
0445 100 900
Welding power source
ET 300i
EU
0445 100 920
Welding power source
ET 300iP
EU
0463 423 001
Spare parts list
0463 424 001
Service manual
Technical documentation is available on the Internet at www.esab.com
0463 416 001
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© ESAB AB 2017
ACCESSORIES
ACCESSORIES
0700 300 538
TIG torch TXH™ 151, 4 m (13 ft)
0700 300 544
TIG torch TXH™ 151, 8 m (26 ft)
0700 300 552
TIG torch TXH™ 201, 4 m (13 ft)
0700 300 555
TIG torch TXH™ 201, 8 m (26 ft)
0700 300 855
TIG torch TXH™ 252w, 4 m (13 ft)
0700 300 856
TIG torch TXH™ 252w, 8 m (26 ft)
0700 300 565
TIG torch TXH™ 401w, 4 m (13 ft)
0700 300 567
TIG torch TXH™ 401w, 8 m (26 ft)
0445 045 880
EC 1000 Cooler
0460 330 881
Trolley
0445 197 880
Shoulder strap kit
0700 006 902
Welding cable kit 3 meter, incl. electrode
holder and OKC 50 connector
0700 006 888
Welding cable kit 5 meter, incl. electrode
holder and OKC 50 connector
0700 006 903
Return cable kit 3 meter, incl. clamp and
OKC 50 connector
0700 006 889
Return cable kit 5 meter, incl. clamp and
OKC 50 connector
0160 360 881
OKC 50 male contact, pack 4 pcs
0463 416 001
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© ESAB AB 2017
ACCESSORIES
0445 536 881
ER 1 Remote control. 5 m (16.4 ft)
interconnection cable, 6 pin, included.
0445 536 882
ER 1 Remote control. 10 m (32.8 ft)
interconnection cable, 6 pin, included.
0445 536 883
ER 1 Remote control. 25 m (82 ft)
interconnection cable, 6 pin, included.
0445 280 880
Interconnection cable, 6 pin, 5 m (16.4 ft)
0445 280 881
Interconnection cable, 6 pin, 10 m (32.8 ft)
0445 280 882
Interconnection cable, 6 pin, 25 m (82 ft)
0445 550 881
ER 1 F Foot pedal. 5 m (16.4 ft)
interconnection cable, 6 pin, included.
0445 550 882
ER 1 F Foot pedal. 10 m (32.8 ft)
interconnection cable, 6 pin, included.
0445 254 880
Interconnection cable, 6 pin, 5 m (16.4 ft)
0445 254 881
Interconnection cable, 6 pin, 10 m (32.8 ft)
0445 139 880
1 to 3 phase adapter
Note! Only for use with Renegade ES 300i
(0445 100 880), ET 300i (0445 100 900)
and ET 300iP (0445 100 920)
0463 416 001
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© ESAB AB 2017
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 15 25 79 30
Fax: +32 15 25 79 44
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: +359 2 974 42 88
Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting
Products
Florence, SC
Tel: +1 843 669 4411
Fax: +1 843 664 5748
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
GERMANY
ESAB Welding & Cutting GmbH
Langenfeld
Tel: +49 2173 3945-0
Fax: +49 2173 3945-218
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
SWITZERLAND
ESAB Europe GmbH
Baar
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
www.esab.com
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 0220
Fax: +1 905 670 4879
SPAIN
ESAB Ibérica S.A.
San Fernando de Henares
(MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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