ESAB MTS 3500i User manual

P/N 0558007140 - 208-230/460 Vac 3-phase, 230 Vac 1-phase, 60 Hz

P/N 0558007140F - 208-230/460 Vac 3-phase, 230 Vac 1-phase, 60 Hz, Bilingual

P/N 0558007141 - 575 Vac 3-phase, 60 Hz, Bilingual

P/N 0558007142 - 400/440 Vac 3-phase 50/60 Hz

P/N 0558009280 - 400/440v BRAZIL

Power Source

Instruction Manual (EN, FR, ES)

0558008058 06/2010

MTS 3500i

2

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

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, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

3

SECTION TITLE PAGE

SAFETY ........................................................................................................................................................ 5

SECTION 1 DESCRIPTION ........................................................................................................................................................................7

1.1 General ......................................................................................................................................................................................7

1.2 Scope .........................................................................................................................................................................................7

1.3 MTS 3500i Multi-Process .....................................................................................................................................................8

1.4 Package Ordering Information .........................................................................................................................................9

1.5 Optional Accessories ......................................................................................................................................................... 10

1.6 Duty Cycle ............................................................................................................................................................................. 11

1.7 Volt-Ampere Curves ........................................................................................................................................................... 11

SECTION 2 INSTALLATION ................................................................................................................................................................... 13

2.1 General ................................................................................................................................................................................... 13

2.2 Required Tools ..................................................................................................................................................................... 13

2.3 Unpacking and Placement .............................................................................................................................................. 13

2.4 Primary Input Connections ............................................................................................................................................. 14

2.4.1 Input Voltage Selection ....................................................................................................................................... 16

2.4.2 Fuse Replacement.................................................................................................................................................. 16

2.5 Secondary Output Connections ................................................................................................................................... 17

SECTION 3 OPERATION ......................................................................................................................................................................... 21

3.1 General ................................................................................................................................................................................... 21

3.2 Welding Controls / Indicators ........................................................................................................................................ 21

3.3 Typical Slope Settings ....................................................................................................................................................... 24

3.4 MIG / GMAW (CV) Operation .......................................................................................................................................... 24

3.5 TIG / GTAW (CC) Operation .............................................................................................................................................. 25

3.6 Stick / SMAW (CC) Operation .......................................................................................................................................... 26

SECTION 4 MAINTENANCE .................................................................................................................................................................. 79

4.1 General ................................................................................................................................................................................... 79

4.2 Inspection and Cleaning .................................................................................................................................................. 79

4.3 IGBT Handling ...................................................................................................................................................................... 79

4.4 Module Replacement ........................................................................................................................................................ 80

SECTION 5 TROUBLESHOOTING ........................................................................................................................ 81

5.1 Troubleshooting ................................................................................................................................................................. 81

5.2 List of help Codes ............................................................................................................................................................... 81

5.3 Functionality Check ........................................................................................................................................................... 82

SECTION 6 REPLACEMENT PARTS ...................................................................................................................... 83

6.1 General ................................................................................................................................................................................... 83

6.2 Ordering ................................................................................................................................................................................. 83

6.3 Torque Recommendations .............................................................................................................................................. 84

6.4 Control Board Assembly .................................................................................................................................................. 85

6.5 Parts List ................................................................................................................................................................................. 86

Diagrams .....................................................................................................................................................attached packet

TABLE OF CONTENTS

4

TABLE OF CONTENTS

5

SAFETY PRECAUTIONS

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.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma

cutting 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. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person 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, ame proof

clothing, safety gloves.

- Do not wear loose tting 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.

- Work on high voltage equipment may only be carried out by a qualied electrician.

- Appropriate re extinquishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or

water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and

against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not in-

tended to be used outside during precipitation unless sheltered.

Enclosure Class

Maximum

Tilt Allowed

15°

CAUTION

If equipment is placed on a surface that

slopes more than 15°, toppling over may oc-

cur. Personal injury and / or signicant dam-

age to equipment is possible.

6

SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON

MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting 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 / plasma cutting screen and lter lens and wear

protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING

This product is solely intended for plasma cutting. Any other

use may result in personal injury and / or equipment damage.

CAUTION

To avoid personal injury and/or equipment

damage, lift using method and attachment

points shown here.

7

1.1 General

The MTS 3500i X-Series® power source is a multi-process, fourth generation inverter power source that puts reliability and

ease of use into a powerful, versatile package. Refer to the following pages for descriptions of the available power sources

as well as performance specications.

1.2 Scope

The purpose of this manual is to provide the operator with all the information required to install and operate the MTS 3500i

Power Source. Technical reference material is also provided to assist in troubleshooting the welding package.

SECTION 1 DESCRIPTION

Designed for use with the following ESAB 42/115 VAC wire feeders:

Mig-4HD

Mig-4HD Dual

Mig-28A / ST-23A

Mig-35

Duradrive 4-30

Duradrive 4-48HD

Mobilefeed 200AVS

Mobilefeed 300AVS

Mobilemaster IV

8

1.3 MTS 3500i Power Source

• The MTS 3500i is a high performance constant voltage (CV) and constant current (CC) inverter power source designed

to provide multi-process welding capabilities with dependability and ease of use. The MTS 3500i is a self-contained

unit which will produce power for Gas Metal Arc (MIG), Gas Tungsten Arc (TIG) and Shielded Metal Arc (Stick) welding

without the use of optional apparatus.

• For MIG (CV) welding, the MTS 3500i supports welding a wide selection of ferrous and non-ferrous alloys by utilizing

Fixed Slope and inductance controls.

• A special "Touch Tig" circuit eliminates the need for high frequency or "scratch" starting when using the TIG (CC) weld-

ing process. This feature provides smooth starts without contaminating the electrode or the work.

• The Stick (CC) welding mode provides adequate open circuit voltage (70 V dc) for easy starts and re-starts as well as an

adjustable arc force which controls arc penetration and wetting action.

• The "Auto Fan" feature operates the cooling fan only when the contactor is energized or when the internal tempera-

ture exceeds the safe operating level. During normal operation, the fan shuts down about 5 minutes after the contac-

tor disengages.

1 phase Input ................................................ 230 vac, 60 Hz, 44A

1 phase Output ..............225 amps @ 29v - 100% duty cycle

3 phase Input ................................230/460 vac, 60 Hz, 39/24 A

................................................400/440 vac, 50/60 Hz, 24/27 A

...................................................................... 575 vac, 60 Hz, 17 A

3 phase Output .................350 amps @ 34v - 60% duty cycle

Voltage requirements ..................................... 208V, -5%, +15%

Specications: MTS 3500i

Duty Cycle: The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a certain load

without overloading. The duty cycle is valid for 40 degrees C.

......................................................230, 400, 460, 575V, +/- 15%

........................................................................440V, - 15%, + 10%

Open Circuit Voltage (max) ................................................73 vdc

Dimensions ...................................................W = 11.5” (292 mm)

........................................................................H = 16.4” (417 mm)

........................................................................D = 29.8” (757 mm)

Weight .....................................................................101 lbs. (39 kg)

Note: The MTS 3500i may also operate from a 208 V pri-

mary input when 230 V input voltage is selected. However,

output is derated 10%.

SECTION 1 DESCRIPTION

9

1.4 Package Ordering Information

MTS 3500i Migmaster Packages

The following packages include an ESAB MTS 3500i 230/460 vac power source, wire feeder, control cable, gas hose,

.035/.045 in. (0.9/1.2mm) feed rolls, GunMaster gas-cooled gun, 15 ft. (4.5m) work cable with clamp, 15 ft. (4.5m)

wire feeder weld cable and R-33 regulator with adjustable owmeter unless otherwise noted.

Packages for Argon & Argon Mixed Shield Gases (R-33-FM-580)

MTS 3500i, Mig 4HD, GM-250cc-10ft. (3.0m) .........................................................................................................0558008345

MTS 3500i, Mig 4HD, GM-400cc-15ft. (4.5m) .........................................................................................................0558001472

MTS 3500i, Mig 4HD Dual, GM-400cc-15ft. (4.5m) ..............................................................................................0558007805

(Supplied with 2 each, Gunmaster 400, R-33FM580, and feeder weld cable)

MTS 3500i, Mig 35, GM-400cc-15ft. (4.5m) .............................................................................................................0558001473

Packages for CO2 Shield Gas (R-33-FM-320)

MTS 3500i, Mig-4HD, GM-400cc .................................................................................................................................0558001474

MTS 3500i, Mig-35, GM-400cc ....................................................................................................................................0558001475

Notes:

MIG-4HD kits have 8 ft. (2.4m) control cable and 9.5 ft. (3.7m) gas hose.

MIG-35 kits have 6 ft. (1.8m) control cable and 12.5 ft. (4.9m) gas hose.

MTS 3500i Migmaster DuraDrive Pulse Package

MTS 3500i, DuraDrive 4-30 Pulse, 60 ft. (18.3m) Control cable .......................................................................0558005373

(Gun, owmeter-regulator, gas hose, feeder welding cable and work cable must be ordered separately)

The components that are included in the MTS 3500i packages may be purchased separately by using the appropri-

ate P/N when placing orders.

Consoles:

MTS 3500i 230/460v ..........................................................................................................................................0558007140

MTS 3500i 230/460v Bilingual ......................................................................................................................0558007140F

MTS 3500i 575v Bilingual .................................................................................................................................0558007541

MTS 3500i 400/440v ..........................................................................................................................................0558007142

SECTION 1 DESCRIPTION

10

1.5 Optional Accessories:

HC-5 Hand Pendant Control 30 ft. (9.1 m) cable .........................................................................................................................P/N 34838

Provides remote control of Weld Process Selection (cv-Mig/cc-Tig/cc-Stick), Output Control (cc-amps/cv-volts), and Arc

Control (arc force-Stick/Inductance-Mig)

Ultra-Pulse 350 Mig Pulse Pendant Control ...............................................................................................................................P/N 36988

Easy-to-use synergic pulse Mig control. Simply select the desired wire type and diameter, set the wire feed speed and begin

welding. Twenty preset combinations include steel, stainless steel, aluminum and silicon bronze.

Note: MIG-4HD is required.

EAS-IV Electronic Tig Arc Starter and Plumbing Box .............................................................................................................P/N 34839

This high voltage arc starter is designed for DCSP (electrode negative) Tig applications where arc starting without the tungsten

electrode touching the work is required. The EAS-IV is also eective at eliminating problems associated with RF generating

arc starters or high frequency arc starters. The EAS-IV is rated 400 amps at 40% duty cycle and includes selection switch (Arc

Start/Touch Tig), gas solenoid, gas pre ow timer and gas postow timer, direct Tig torch connections, water inlet/outlet t-

tings, quick connector output connections, 4 ft. (1.2m) welding power input cables with male quick connectors, 8 ft. (2.4m)

control cable, carrying handle and remote control plug (14 pin).

Note: Remote contactor control (such as TC-2B, HC-3B or FC-5B/C) is required.

Tig Torches - 2-piece cable and hose assembly with Twist Lock Cable Connector for direct connection to the power

source.

HW-17V-2-TL, 12.5 ft ................................................................................................................................................................P/N 35857

HW-17V-2-TL, 25 ft ...................................................................................................................................................................P/N 35856

HW-26V-2-TL, 12.5 ft ...............................................................................................................................................................P/N 35858

FC-5B EHD Foot Control - 30 ft. (9.1 m) cable. ........................................................................................................................... P/N *33841

FC-5C Foot Control - 30 ft. (9.1 m) cable ....................................................................................................... ................. P/N *0558004234

TC-2B Torch Control - 25 ft. (7.5 m) cable. ................................................................................................................................... P/N *33839

TC-3A Torch Control - 30 ft. (9.1 m) cable, use with HW-9, 17, 20, 20A & 24. .................................................................. P/N *35783

TC-3A Torch Control - 30 ft. (9.1 m) cable, use with HW-18 & HW-26R .. .......................................................................... P/N *36680

*Note: FC-5 & TC-2 provide contactor and current control. TC-3 provides contactor control only.

Tig Accessory Kit - for HW-17, 18 or 26 ......................................................................................................... .............................. P/N 999126

Power Source to Feeder Cable, Lug w/ quick-connect 15 ft. (4.5m) ..................................................................................P/N 36254

Work Cable Assembly, Clamp w/ quick-connect 15 ft. (4.5m) ...............................................................................................P/N 36253

Stick Electrode Holder Assembly - 300A, 15 ft. (4.5m) ............................................................................................................P/N 21226

Inverter Cart (2 cylinder) for use with SVI 450i & 350 mpi ........................................................................................................P/N 31700

SECTION 1 DESCRIPTION

11

Figure 1-2. Volt-Ampere Characteristics and Duty Cycles

NOTE:

These measurements are made at the output terminals of the power source. Additional voltage "drops" will occur in the

welding cable, torch cable, and in the workpiece. The use of proper size welding cable and secure electrical connections

for the electrode and ground circuits will minimize these eects which adversely aect welding conditions and waste

electrical energy.

cv - MIG mode Volt-Amp Curve

F

M

S

DC Volts

AMPS

DC Volts

AMPS

Minimum

Maximum

Lift Arc Start

DC Volts

AMPS

Minimum

Maximum

Arc Force Range

Three Phase

Single Phase

Duty Cycle Chart

% Duty Cycle

Amps - rated output @ NEMA load line

1.6 Duty Cycle

The MTS 3500i power source will operate on a 60% duty cycle with a load of 350 amperes at 34 V dc (with 3-phase input).

Duty cycle is dened as the ratio of operating time to total time. Ratings are based on a 10-minute cycle. The 60% duty

cycle rating means that the 350 ampere, 34 volt rated load can be applied for a total of 6 minutes and shut o for a total of

4 minutes in a 10-minute period. If the welding current (or voltage) is reduced, the duty cycle increases. Conversely, if the

welding current (or voltage) is increased, the duty cycle will decrease. Refer to Figure 1-2.

1.7 Volt-Ampere Curves

Figure 1-2 illustrates the static volt-ampere characteristics for the power source in the MIG (CV), TIG (CC), and Stick (CC) modes.

The slant of these curves is referred to as the slope and is generally dened as the voltage drop per 100 amperes of current

rise. These curves show the output voltage available at any given output current between the minimum and maximum

settings of the output control. Values for other settings fall between the minimum and maximum curves.

SECTION 1 DESCRIPTION

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13

Figure 2-1. Correct and Incorrect Lifting Techniques

INCORRECT! INCORRECT!

CORRECT!

A. Immediately upon receipt of the MTS 3500i, inspect for damage which may have occurred in transit. Notify the

carrier of any defects or damage at once.

B. After removing the components from the shipping container(s), check the container for any loose parts. Remove

all packing materials.

C. Check air passages of power source for any packing materials that may obstruct air ow through the power source.

D. If the equipment is not to be installed immediately, store it in a clean, dry, well-ventilated area.

E. The location of the power source should be carefully selected to ensure satisfactory and dependable service. Choose

a location relatively close to a properly fused source of electrical power.

F. The machine components are maintained at proper operating temperatures by forced air which is drawn through

the cabinet by the fan unit. For this reason, it is important that the machine be located in an open area where air

can circulate freely at front and rear openings. If space is at a premium, leave at least 1 foot (300 mm) of clearance

between the rear of the power source and wall or other obstruction. The area around the unit should be relatively

free of dust, fumes, and excessive heat. It is also desirable to locate the unit so the cover can be removed easily for

cleaning and maintenance.

2.1 General

This section provides detailed instructions for the proper installation of the MTS 3500i power source from initial receipt of

the equipment to output welding connections. It is recommended that these instructions be followed carefully to allow for

the best possible operating environment.

2.2 Required Tools

Some procedures require use of the following tools:

3/8" wrench, Phillips or Robertson, and a screwdriver. The use of socket wrenches or nutdrivers are recommended over

straight wrenches due to the location of attaching hardware.

When lifting the MTS 3500i, apply direct upward pressure to both of

the carrying handles. Do not transport the MTS 3500i with only one

handle or apply outward pressure to the handles. Do not lift the unit

by the handles with the cover removed. See Figure 2-1.

2.3 Unpacking and Placement

CAUTION

SECTION 2 INSTALLATION

CORRECT!

14

ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD

BE TAKEN TO PROVIDE MAXIMUM PROTECTION AGAINST ELECTRI

CAL SHOCK. BE SURE THAT ALL POWER IS OFF BY OPENING THE LINE

WALL DISCONNECT SWITCH AND BY UNPLUGGING THE POWER

CORD TO THE UNIT WHEN CONNECTIONS ARE MADE INSIDE OF THE

POWER SOURCE.

2.4 Primary Input Connections

The MTS 3500i consoles are equipped with approximately 10 ft. (3.0 m) of 4-conductor input power cable for 3

phase connection. If single-phase connection is desired, cap the unused wire on the input power cable per chart

below.

CUSTOMER FUSED LINE DISCONNECT SWITCH

(See Table 2-1)

PRIMARY INPUT

POWER CABLE

Figure 2-2. Input Connections

WARNING

STANDARD UNITS

(NON-CE)

CE UNITS

(EUROPE)

PHASE 3 1 PHASE 3 1

L1 White White L1 Brown Brown

L2 Black Black L2 Black -

L3 Red - L3 Gray Gray

GND Green Green GND Green/Yel Green/Yel

INSULATE UNUSED POWER CORD

CONDUCTOR WHEN CONNECTING

FOR SINGLE PHASE.

WARNING

SECTION 2 INSTALLATION

15

Before connecting to input power, make sure there is a line (wall) disconnect switch with fuses or circuit breakers

at the main power panel. You may either use the factory-installed input power cable [4/c, type SO (90 °C), 10 ft

(3.0 m) length] or provide your own input power leads. If you choose to provide your own, make sure they are

insulated copper conductors. You must have two (single-phase) or three (3 phase) power leads and one ground

wire. The wires may be heavy rubber covered cable or may be run in a solid or exible conduit. Ensure the

ground lead is suciently long inside the machine. In an event where the power cord is pulled from the machine,

the ground lead must not break from the ground connection before the power leads have broken from their

connection. Refer to Table 2-1 for recommended input conductors and line fuse sizes.

BEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUT

PUT TERMINALS, MAKE SURE THAT ALL PRIMARY INPUT POWER TO

THE POWER SOURCE IS DEENERGIZED OFF AT THE MAIN DISCON

NECT SWITCH AND THAT THE INPUT POWER CABLE IS UNPLUGGED.

THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL

GROUND. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK, SE

VERE BURNS OR DEATH.

WARNING

Table 2-1. (MTS 3500i)

Recommended Sizes For Input Conductors and Line Fuses

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CON

NECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PRO

CEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS ARE TO BE

MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH IN THE

OFF POSITION AND PADLOCK IT TO PREVENT INADVERTENT TRIPPING.

IF THE CONNECTION IS MADE FROM A FUSEBOX, REMOVE THE CORRE

SPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS NOT POSSI

BLE TO USE PADLOCKS, ATTACH A RED TAG TO THE LINE DISCONNECT

SWITCH OR FUSE BOX WARNING OTHERS THAT THE CIRCUIT IS BEING

WORKED ON.

MTS 3500i

Input Requirements Input & Gnd

Conductors

Line

Fuse

Volts Phase Amps Cu / Awg Amps

230 1 44 6 60

230 3 39 8 50

400 3 24 10 30

440 3 27 10 35

460 3 24 10 30

575 3 17 10 25

SECTION 2 INSTALLATION

16

Line Voltage Fluctuations

The MTS 3500i is designed to compensate for line voltage variations of plus or minus 10 percent from the rated level while

maintaining rated output, without damage to internal components. If line voltage uctuations exceed this range, serious

damage could occur. Therefore, prior to installation, it is recommended that the line voltage of the supply circuit be mea-

sured at several times during the day. If uctuations beyond the +/-10% level are detected, another supply circuit should

be selected, or the local power company should be asked to adjust the supply. In addition, certain types of factory equip-

ment can cause rapid voltage swings (transients) which can cause the MTS 3500i safety circuits to “trip”. Examples of such

equipment are resistance welders, punch presses, and starting of large electric motors.

2.4.1 Input Voltage Selection

As shipped from the factory, the 230/460 V model is set for 460 volts input and the 400/440 V model is set for 440 volts input.

If you will be operating the machine from a 230 V or 440 V source, open the switch access panel on the rear panel of the

machine and ip the Voltage Selector Switch to the 230 V or 440 V position. See Figures 2-3a or 2-3b.

Figure 2-3a.

Input Voltage Select Access Panel (Opened)

230/460 V model

Figure 2-3b.

Input Voltage Select Access Panel (Opened)

400/440 V model

2.4.2 Fuse Replacement

The 230/460 V model requires a 4 Amp, 500 V Slo-Blo fuse. The 575 V and 400/440 V models require a 2 Amp, 600 V Slo-Blo

fuse. Replace fuse with the same type and rating only.

575 V and 400/440 V models

Replace fuse with Slo-Blo, 2 Amp, 600 V only

MAKE SURE THE POWER

SOURCE IS SWITCHED OFF

BEFORE REMOVING FUSE.

WARNING

230/460 V model

Replace fuse with Slo-Blo, 4 Amp, 500 V only

SECTION 2 INSTALLATION

17

Two male plug connectors are supplied with the MTS 3500i (see Figure 2-4). To assemble the connectors onto each of your

welding cables, refer to the following instructions:

1. Slip the insulating boot over the end of the cable.

2. Strip the wire approximately 1-1/2" (37 mm) from the end.

3. Place the ferrule over the stripped wire end.

4. Place the male connector over the ferrule and tighten the two Allen screws until they are ush with the connec-

tor.

5. Slide the insulating boot over the assembly.

Refer to Tables 2-2 and 2-3 and Figures 2-4, 2-5, 2-6, and 2-7 when attaching welding cables and optional equipment to the

MTS 3500i.

Particular attention should be paid to the electrical resistance in the welding circuit; especially, the work and work cable and

when using a water-cooled torch. High resistance in the welding circuit can cause performance deterioration (loss of "heat"

input, popping of weld puddle, bushy arcs, etc.). It is recommended that the power source/wire feeder and workpiece be

placed as close together as possible to limit this resistance. Make sure that the work cable (ground) is large enough, kept

as short as possible, properly insulated, securely connected to the workpiece, and that all connections are clean and tightly

secured. If the work circuit includes mechanical xtures, ship structure, robot xtures, etc., make sure that the circuit is secure

and presents a low resistance path to the ow of weld current. Also, the power cable on a water-cooled torch is normally

subject to gradual deterioration and increasing resistance due to corrosion which leads to the poor performance described

above. To assure good torch performance, the water-cooled power cable should be replaced periodically.

ELECTRIC SHOCK CAN KILL! Before making any connections to the power source

output terminals, make sure that all primary power input power is deenergized (OFF)

at the line (wall) disconnect switch or circuit breaker.

2.5 Secondary Output Connections

MIG Welding

(DCRP)

TIG Welding

(DCSP)

Stick Welding

(DCSP or DCRP)

Electrode positive (+) negative (-)

positive (+) DCRP

negative (-) DCSP

Work negative (-) positive (+)

negative (-) DCRP

positive (+) DCSP

Table 2-2. Typical Output Connections

* Total cable length includes work and electrode cables. Cable size is based on direct current, insulated copper conductors, 100% duty cycle, and a

voltage drop of 4 or less volts. The welding cable insulation must have a voltage rating that is high enough to withstand the open circuit voltage of the

machine.

** The supplied male output connectors will not accept anything smaller than #2 gauge (35 mm) cable.

Table 2-3. Recommended Welding Cable Sizes - AWG (mm

2

)

Welding

Current

Total Length (Feet) of Cable in Welding Circuit*

50

(13 m)

100

(25 m)

150

(38 m)

200

(51 m)

250

(64 m)

100

150

200

250

300

6 (16)**

4 (25)**

3 (30)**

2 (35)

1 (50)

4 (25)**

3 (30)**

1 (50)

1/0 (50)

2/0 (70)

3 (30)**

1 (50)

1/0 (50)

2/0 (70)

3/0 (95)

2 (35)

1/0 (50)

2/0 (70)

3/0 (95)

4/0 (120)

1 (50)

2/0 (70)

3/0 (95)

4/0 (120)

SECTION 2 INSTALLATION

WARNING

18

Figure 2-4. Male Output Cable Connectors

Figure 2-5. MIG (GMAW) Interconnection Diagram

GMAW

DCEP

OPTIONAL PENDANT

OR HAND CONTROL

WORKPIECE ( - )

TORCH W/ SWITCH

WIRE FEEDER

SECTION 2 INSTALLATION

19

Figure 2-7. Stick (SMAW) Interconnection Diagram

Figure 2-6. TIG (GTAW) Interconnection Diagram

STRAIGHT POLARITY

Electrode Negative

REVERSE POLARITY

Electrode Positive

GTAW

DCEN

SMAW

DCEP / DCEN

OPTIONAL PENDANT

OR HAND CONTROL

OPTIONAL FOOT

CONTROL

WORKPIECE ( - )

WORKPIECE ( + )

OPTIONAL PENDANT

OR HAND CONTROL

OPTIONAL FOOT

CONTROL

WORKPIECE ( + )

OPTIONAL TORCH

CONTROL

GAS SUPPLY

TIG TORCH ADAPTOR

TIG TORCH W/ GAS VALVE

(air or water cooled)

SECTION 2 INSTALLATION

20

SECTION 2 INSTALLATION

21

Never, under any circumstances, operate the power source with the cover removed.

In addition to the safety hazard, improper cooling may cause damage to internal

components.

To prevent serious injury, never touch any torch parts forward of the handle unless

the power switch is in the o position.

Wear proper protective gloves, clothing, safety glasses, and helmet. A helmet with

lter lens shade No. 11-14 should provide adequate protection for your eyes. Refer

to the Safety Precautions in the beginning of this manual for additional operating

precautions.

Positive Output

Connection

Negative Output

Connection

E

F

D

O

P

N

M

Figure 3-1. Controls / Indicators

C

B

A

WARNING

3.1 General

3.2 Welding Controls/Indicators (Figure 3-1)

A. SLOPE CONTOL - This 3-position switch sets the slope

of the volt-ampere curve characteristic in the MIG

(CV) mode. This control is bypassed in the TIG and

Stick modes. In MIG (GMAW) welding, slope is particu-

larly useful in short circuiting transfer (“short-arc”, “dip

transfer”) and for welding of aluminum. Slope adjust-

ments control the short-circuit current and reduce

spatter during short-circuiting welding of steel, and

reduce the current uctuations which can cause insta-

bility when welding aluminum.

Typical slope settings are shown on Table 3-1 for several

dierent electrode types, shielding gases, and arc modes.

For more complete explanation of the function of slope,

refer to the “Mig Welding Handbook”, Part No. 791F18,

or The Welding Handbook, published by the American

Welding Society.

G

H

J

I

K

L

SECTION 3 OPERATION

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