ESAB ARC250i User manual

ARC250i
INVERTER MMA
Welding Power Source
Instruction manual

ARC250i
INVERTER MMA WELDING POWER SOURCE
Instruction manual
For
Installation, Operation & General maintenance

CONTENTS
Item
Page No.
SAFETY
1-2
RATING AND INSTALLATION
3
CAUTIONS FOR INSTALLATION
4
CONNECTIONS
5-6
WELDING OPERATIONS
7
WIRING DIAGRAM
8
TROUBLESHOOTING
9
PARTS LIST AND EXPLODED VIEW
10-11
ESAB INDIA LOCATIONS AND CONTACT DETAILS
12

SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety
precautions. Safety precautions must meet the requirements that apply to this type of
welding equipment. The following recommendations should be observed in addition to
the standard regulations that apply to the workplace.
Trained personnel well acquainted with the operation of the welding equipment must
carry out all the work. Incorrect operation of the equipment may lead to hazardous
situations, which can result in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding
2. The operator must ensure that:
• no unauthorized person is stationed within the working area of the equipment
when it is started up.
• no one is unprotected when the arc is struck
3. The workplace must:
• be suitable for the purpose
• be free from drafts
4. Personal safety equipment
• Always wear recommended personal safety equipment, such as safety glasses,
flameproof clothing, and safety gloves.
• Do not wear loose—fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns.
5. General precautions
• Make sure the return cable is connected securely.
• Only a qualified electrician may carry out work on high voltage equipment.
• Appropriate fire extinguishing equipment must be clearly marked and close at
hand.
• Lubrication and maintenance must not be carried out on the equipment during
operation.
1

Read and understand the instruction manual before installing or operating.
ESAB can provide you with all necessary welding protection and accessories.
WARNING
Arc welding and cutting can be injurious to yourself and others. Take
precautions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’
hazard data.
ELECTRIC SHOCK –Can kill
• Install and earth the welding unit in accordance with applicable
standards.
• Do not touch live electrical parts or electrodes with bare skin, wet
gloves or wet clothing.
• Insulate yourself from earth and the workpiece.
• Ensure your working stance is safe.
FUMES AND GASES –Can be dangerous to health
• Keep your head out of the fumes.
•Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS –Can injure eyes and burn skin.
• Protect your eyes and body. Use the correct welding screen and filter
lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE –Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk.
MALFUNCTION –Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding
Do not dispose of electrical equipment together with normal waste!
In accordance with national law, electrical equipment that has
reached the end of its life must be collected separately and returned
to an environmentally compatible recycling facility. As the owner of
the equipment, you should get information on approved collection
systems from the local representative. By applying this Directive you
will improve the environment and human health
2

RATING
RATING OF ARC250i INVERTER WELDING POWER SOURCE
CHARACTERISTICS
CONSTANT CURRENT TYPE
Input:
SUPPLY VOLTAGE, PHASE & FREQUENCY
230V± 15%, 1Phase, 50 Hz, AC
MAXIMUM INPUT CURRENT
48 A
MAXIMUM RATING
11.02 KVA
Output:
OUTPUT CURRENT RANGE
DC 30-250A
OPEN CIRCUIT VOLTAGE
80 V DC
TYPE OF WELDING CURRENT CONTROL
STEPLESS
CLASS OF INSULATION
‘H’
COOLING
FORCED AIR COOLED
APPROX DIMENSION (LxWxH) IN MM
435 x 170 x 330
WEIGHT (APPROX)
10.7 KG.
INSTALLATION
The complete installation should consist the following items:
Description
Type
Quantity
1.
Welding Power Source
ARC250i
1
2.
Welding Cable with Holder
1
3
Earth cable with Clamp
1
3

CAUTIONS FOR INSTALLATION
Provide a Switch Box for every Welding Power Source, and use designated
fuse
Tolerance of Power Voltage Variation is 10% of rated input voltage.
a) Installation place
Install in the place where less moisture and dust exist. Avoid direct sunlight and
rain, and maintain ambient temperature within –10o to +45o C as much as
possible.
Keep the welding power source at least 20 cm. away from the wall (if any).
In case of installation of more two units side by side, a distance of more than 20
cm is recommended between the two power sources.
Use a shield to protect the welding arc in case of excessive air draft.
b) Ventilation
Adequate ventilation is recommended at the place of installation. For
example the following guideline should be followed:
a) In case of the area being more than 300 square meters (per unit), no
ventilation is required, provided the room is not completely airtight.
b) In case of the area being less than 300 square meters and the welding
is continuously performed, adequate ventilation is recommended with
the help of vent fan or exhaust duct.
c) While performing the grounding work, it is recommended that a skilled
electrician does the work.
4

Connections
1. Welder’s Placement
Connection between Welder and Power Source
Notice: Input Power supply earth connection is not power supply neutral.
5
Air switch
Input power

Connection between Welder and Electrode Holder (Output Connection diagram)
Insert the OKC connector of the welding cable on the electrode holder into current
output “+” electrode adaptor on the lower half of the front panel and then rotate down
clockwise.
Insert the OKC connector of earth cable with earth clamp into current outp
The earth clamp is connected with work piece.
Notice: Do not use steel plate or the materials alike which are poor conductor,
to connect between welder and work piece.
2. EXTENSION CORD - We do not recommend an extension cord because of the
voltage drop they produce. This drop in voltage can affect the performance of the
welder. If you need to use an extension cord, we recommend you check with a
qualified electrician and your local electrical codes for your specific area. Do not use
an extension cord over 25 ft. in length.
3. INSTALLATION OF OPTIONAL TIG TORCH
3.1 Remove the ground cable and the electrode holder from the weld output
connections. Install the ground cable to the Positive (+) weld output connection.
3.2 Secure the ground clamp to the work piece
3.3 Connect a regulator to a cylinder of ARGON gas. Then connect the gas
connection from the TIG torch to the regulator.
3.4 Connect the TIG torch weld cable to the Negative (-) weld output connection.
3.5 Set desired amperage on the amperage control knob on the front panel of the
welder.
3.6 Turn on the input power switch on the welder.
Be aware that the TIG torch will be electrically energise when the Input Power Switch
on the welder is turned on.
3.7 Turn on the regulator on the cylinder of shielding gas and adjust the regulator to
approximately 20 CFH. Then open the shielding gas valve on the torch to start the
flow of shielding gas.
3.8 Touch the tungsten that is installed in the TIG torch, to the work piece and quickly
pull away approximately 1/4" to create an arc.
6

WELDING OPERATION
High voltage danger from power source! Consult a qualified electrician for
proper installation of receptacle at the power source. This welder must be
grounded while in use to protect the operator from electrical shock. If you are
not sure if your outlet is properly grounded, have it checked by a qualified
electrician. Do not cut off the grounding wire or alter the plug in any way and do
not use any adapter between the welder's power cord and the power source
receptacle. Make sure the POWER switch is OFF then connect your welder's
power cord to a properly grounded 230 VAC, 50 HZ, single phase, 50 amp power
source.
1 Current display
2MMA/Lifttig
switch
3 Current Output “-” Electrode
OKC Connector Socket
4 welder’s
handle
5 Alarm Indicator
6 ARC force
7Welding Current Adjustment
Knob
8 Current Output
“+”
Electrode OKC
Connector Socket
9 Power Input Wire
10. Air switch
Once the installation of the equipment is completed, connect the work Cable to
the negative output terminal and the cable end of the electrode holder to the
Positive output terminal. These cable connections should be tightened properly
to avoid electrical heating due to loose connections. Put the main Switch box in
‘ON’. Turn on “Power ON/OFF switch” on the rear panel. The Display on the
panel of the Power Source will glow and the fan will start rotating. Now the
equipment is ready. Connect an Electrode with the Electrode Holder. The
welding current can be controlled by the current control potentiometer mounted
on the front panel of the Power.
Welding Current Adjustment
Put the MMA/ TIG switch to ‘MMA’ mode. Now set the DC output current as
required with the help of the current control potentiometer and ignite an
experimental Arc. For the fine-tuning of the required current, set the parameters
using the Ammeter mounted on the front panel of the power source.
7

WIRING DIAGRAM OF ARC250I
8

TROUBLESHOOTING
No.
Breakdown
Analysis
Solutions
1
Yellow Indicator
is on
Bad power ventilation
lead to over-heat
protection
Improve the ventilation condition.
Circumstance
temperature is too high
It will automatically recover when
the temperature low down.
Using over the rated duty-
cycle
It will automatically recover when
the temperature low down.
2
The adjustment
knob on the front
panel didn’t work
Potentiometer defective
(current regulation)
Replace the potentiometer.
3
Cooling Fan not
working or turning
very slowly
Scarcity of phase
Recover the phase
Switch defective
Replace the switch
Fan defective
Replace or repair the fan
Wire broken or falling off
Check the connection
4
No no-load
voltage
Over temperature Trip
See No. 1
Switch defective
Replace the switch
5
Electrode Holder
and Cable getting
hot;“+” “-” polar
sockets becoming
hot
Electrode Holder’s
capacity is too small;
Replace it with a bigger capacity
one
Cable is of small size
Replace it with another one in
conformity with the requirement
Replace it with another
one in conformity with the
requirement
Remove the oxide skin and tighten
it
Bigger resistance
between the electrode
holder and the cable
6
Power source
tripping
Resume power over a
long period of time ( more
than two days )
Not failure. Trip caused by the main
power filter’s capacity charging.
Switch on the main power source.
In the process of welding
Contact us
7
Others
Contact us
9

Parts List and Exploded view
No.
Part No
Description
QTY
1
0800550001
handle
1
2
0800550002
cover
1
3
0800550003
filter capacitor
1
4
0800550004
capacitor busbar
2
5
0800550005
inverter PCB board
1
6
0800550006
pressure plate
2
7
0800550007
Heat sink
2
8
0800550008
right upper fixed board
2
9
0800550009
block switch
1
10
0800550010
switch support
2
11
0800550011
power cord
1
12
0800550012
cable fixed head
1
13
0800550013
right bottom fixed board
2
14
0800550014
fan
1
15
0800550015
back bottom panel
1
16
0800550016
rectifier PCB board
1
17
0800550017
positive busbar
1
18
0800550018
protection ear
1
19
0800550019
rectifier board fixed plate
1
20
0800550020
foot
4
21
0800550021
Front plate
1
22
0800550022
Front plastic panel
1
23
0800550023
Euro type quick connector
2
24
0800550024
welding mode select switch
1
25
0800550025
potentiometer knob
2
26
0800550026
overheat indicate light
1
27
0800550027
digital display
1
28
0800550028
potentiometer
1
29
0800550029
reactor
1
30
0800550030
power PCB board
1
31
0800550031
radiator connection plate
1
32
0800550032
mounting panel
1
33
0800550033
left bottom fixed board
2
34
0800550034
main control PCB board
1

35
0800550035
Insulation plate
1
36
0800550036
left upper fixed plate
2
11

ESAB INDIA LIMITED
Registered and Head Office
13, Industrial Estate, III Main Road
Ambattur, Chennai - 600058
Telephone: + 91 44 42281100
Fax: + 91 44 4228 1107
Email: [e-mail]
Eastern Regional Office
P41 Taratala Road
Kolkata 700088
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Western Regional Office
501/502, 5th Floor, Sagar Tech-B
Andheri Kurla Road, Saki Naka
Andheri East, Mumbai 400072
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Northern Regional Office
239 –240, DLF Tower
Shivaji Marg
Near Karampura Crossing
New Delhi 110 015
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Southern Regional Office
13, Industrial Estate,
III Main Road Ambattur
Chennai 600 058
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Central Regional Office
No. 218, Ashirvad
South Ambazari Road
Bajaj Nagar, Nagpur 440010
Telephone: [phone] / 48
Fax: [phone]
Email: [e-mail]
Web: www.esabindia.com
12
ESAB INDIA LIMITED
Registered and Head Office
13, Industrial Estate, III Main Road
Ambattur, Chennai - 600058
Telephone: + 91 44 42281100
Fax: + 91 44 4228 1107
Email: [email protected]