ESAB Buddy Arc 145 User manual

Buddy™
Instruction manual
0463 276 001 GB 20150424 Valid for: serial no. 01107071701
Arc 145

TABLE OF CONTENTS
0463 276 001 © ESAB AB 2015
1 SAFETY ................................................................................................................ 4
2 INTRODUCTION................................................................................................... 7
2.1 Equipment............................................................................................................. 7
3 TECHNICAL DATA ............................................................................................... 8
4 INSTALLATION..................................................................................................... 9
4.1 Location ................................................................................................................ 9
4.2 Mains power supply.............................................................................................9
4.2.1 Recommended fuse sizes and minimum cable area ......................................... 9
5 OPERATION ....................................................................................................... 10
5.1 Connections ....................................................................................................... 10
5.2 Symbols .............................................................................................................. 10
5.3 Connection of welding and return cable..........................................................10
5.4 Overheating protection...................................................................................... 11
5.5 MMA welding ...................................................................................................... 11
5.5.1 Striking the arc ................................................................................................. 11
5.5.2 Manipulation of electrode ................................................................................. 11
5.5.3 Anti-electrode pick-up ...................................................................................... 12
5.5.4 Joint forms........................................................................................................ 12
5.5.5 Electrode selection........................................................................................... 13
6 MAINTENANCE.................................................................................................. 14
6.1 Power source...................................................................................................... 14
7 FAULT-TRACING................................................................................................ 15
8 ORDERING SPARE PARTS ............................................................................... 16
DIAGRAM ..................................................................................................................17
ORDERING NUMBERS.............................................................................................18
ACCESSORIES .........................................................................................................19
Rights reserved to alter specifications without notice.

1 SAFETY
0463 276 001 -4- © ESAB AB 2015
1 SAFETY
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. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting
2. 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
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,
flame-proof clothing, 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.
• Work on high voltage equipment may only be carried out by a qualified electrician.
• Appropriate fire extinquishing equipment must be clearly marked and close at hand.
• Lubrication and maintenance must not be carried out on the equipment during operation.
WARNING!
Do not use the power source for thawing frozen pipes.

1 SAFETY
0463 276 001 -5- © ESAB AB 2015
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the 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.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
CAUTION!
Read and understand the instruction manual before
installing or operating.
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.
CAUTION!
This product is solely intended for arc welding.

1 SAFETY
0463 276 001 -6- © ESAB AB 2015
ESAB can provide you with all necessary welding protection and accessories.


DISMANTLING AND SCRAPPING
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.
Welding equipment primarily consists of steel, plastic and non-ferrous metals, and must be
handled according to local environmental regulations.

2 INTRODUCTION
0463 276 001 -7- © ESAB AB 2015
2 INTRODUCTION
Arc 145 is a general MMA arc welding power source.
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The power source is supplied with:
• 3 meter welding cable with electrode holder
• 3 meter return cable with return clamp
• Instruction manual

3 TECHNICAL DATA
0463 276 001 -8- © ESAB AB 2015
3 TECHNICAL DATA
Arc 145
Mains voltage 230 V 1~ ±10 %, 50/60 Hz
Primary current I max 27.8 A
Setting range 10 A / 20.4 V - 145 A / 25.8 V
Permissible load at
15 % duty cycle 145 A / 25.8 V
60 % duty cycle 70 A / 22.8 V
100 % duty cycle 55 A / 22.2 V
Power factor at maximum current 0.76
Efficiency at maximum current 80 %
Open-circuit voltage U0max 66 V
Operating temperature -10 to +40 °C
Transportation temperature -20 to +55 °C
Sound pressure at no-load <70 db (A)
Dimensions l × w × h 280 x 120 x 220 mm
Weight 4.5 kg
Enclosure class IP 23S
Application class
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.
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.

4 INSTALLATION
0463 276 001 -9- © ESAB AB 2015
4 INSTALLATION
The installation must be carried out by a professional.
4.1 Location
Position the power source such that its cooling air inlets and outlets are not obstructed. Also
position the power source so that the air inlet does not get clogged with unwanted material.
4.2 Mains power supply
Make sure that the welding power source is
connected to the correct supply voltage and
that it is protected by the correct fuse rating.
The outlet shall have a protective earth
connection.
A. Rating plate with supply connection data
4.2.1 Recommended fuse sizes and minimum cable area
Arc 145
Mains voltage 230 V 1 - ± 10 %, 50/ 60 Hz
Mains cable area mm23 G 1.5
Phase current I1eff (TIG) 10.8 A
Phase current I1eff (MMA) 16 A
NOTE!
Use the power source in accordance with the relevant national regulations.

5 OPERATION
0463 276 001 - 10 - © ESAB AB 2015
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
5.1 Connections
1. Indicating lamp, green, power supply ON 5. Connection (+) for return cable or welding
cable
2. Indicating lamp, yellow, overheating 6. Connection for mains cable
3. Knob for setting the welding current 7. Mains power supply switch 1/O
4. Connection (-) for return cable or welding
cable
5.2 Symbols
Power supply ON Overheating
5.3 Connection of welding and return cable
The power source has two outputs, a negative [-] terminal (4) and a positive [+] terminal (5),
for connecting welding and return cables.
The output to which the welding cable is connected depends on the type of electrode, please
refer to electrode packaging for information relating to the correct electrode polarity.

5 OPERATION
0463 276 001 - 11 - © ESAB AB 2015
Connect the return cable to the remaining welding terminal on the power source. Secure the
return cable's contact clamp to the work piece and ensure that there is good contact.
5.4 Overheating protection
The welding power source has a thermal overload trip which operates if the temperature
becomes too high, interrupting the welding current and lighting a yellow indicating lamp on
the front of the power source. The thermal overload trip resets automatically when the
temperature has fallen.
NOTE!
If the utilization of the power source is to high it might get
overheated. See permissable load in the TECHNICAL
DATA chapter in this manual.
If the air inlet or outlet is blocked or get clogged with
unwanted material the power source might get
overheated. Make sure that the airflow through the power
source is not blocked.
5.5 MMA welding
5.5.1 Striking the arc
MMA welding may also be referred to as welding with coated electrodes. Striking the arc
melts the electrode, and its coating forms protective slag.
If, when striking the arc, the tip of the electrode is pressed against the metal, it immediately
melts and sticks to the metal, rendering continued welding impossible. Therefore, the arc has
to be struck in the same way that you would light a match. Quickly strike the electrode
against the metal and then raise it to give an appropriate arc length (approx. 2 mm). If the arc
is too long, it will crackle and split before finally going out completely. Once the arc has been
struck, move the electrode from left to right. The electrode should be at an angle of 60° to the
metal.
5.5.2 Manipulation of electrode
In MMA welding, there are three motions to being matched in the end of electrode: the
electrode moving to the molten pool along axes [1]; a small oscillation maybe neccessary to
achieve the desired width of the melt pool [2]; the electrode moving along welding way [3].
The operator can choose the manipulation of electrode based on welding joint sharp, welding
position, electrode spec, welding current and operation skill, etc.

5 OPERATION
0463 276 001 - 12 - © ESAB AB 2015
1. electrode moving 4. workpiece
2. the electrode oscilliation (right and left) 5. weld
3. the electrode move along weld 6. electrode
5.5.3 Anti-electrode pick-up
If, during the welding, the electrode would get in direct contact (touching) with the workpiece
to form short circuit, the welding current will drop to a miminum to prolong the life of the
electrode.
5.5.4 Joint forms
Butt joint Corner joint Lap joint T joint

5 OPERATION
0463 276 001 - 13 - © ESAB AB 2015
5.5.5 Electrode selection
The electrode diameter selection is based on
the workpiece thickness, welding position,
joint form, welding layer, etc. Please refer to
the recommendations on the electrode
package for further details.
• To ensure good quality weld, the
electrode should always be dried or dry
stored. This to avoid hydrogen inclusion,
blowholes and cold cracks.
• In the welding process, the arc must not
be too long; otherwise, it will cause
unstable arc burning, large spatter, light
penetration, undercut, blowhole, etc. If the
arc is too short, it will cause electrode
stick.

6 MAINTENANCE
0463 276 001 - 14 - © ESAB AB 2015
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe, reliable operation.
CAUTION!
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1 Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on:
• welding process
• arc time
• positioning of power source
• surrounding environment
It is normally sufficient to blow the power source with dry compressed air (reduced pressure)
once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.

7 FAULT-TRACING
0463 276 001 - 15 - © ESAB AB 2015
7 FAULT-TRACING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault Corrective action
No arc. • Check that the mains power supply switch is turned on.
• Check That the mains input Voltage is not too low or too
high. The yellow LED will illuminate if the input is below or
above the recommended levels and the equipment is at
normal working temperature.
• Check that the welding current supply and return cables
are correctly connected.
• Check that the correct current value is set.
• Check to see whether the MCB has tripped.
The welding current is
interrupted during welding.
• Check whether the thermal cut-outs have tripped
(indicated by the yellow lamp on the front panel).
• Check the mains power supply fuses.
The thermal cut-out trips
frequently.
• Check to see whether the dust filter is clogged.
• Make sure that you are not exceeding the rated data for
the power source (i.e. that the unit is not being
overloaded). See permissable load in the TECHNICAL
DATA chapter in this manual.
• Make sure that the positioning of the power source is such
that its cooling air inlets and outlets are not obstructed.
Poor welding performance. • Check that the welding current supply and return cables
are correctly connected.
• Check that the correct current value is set.
• Check that the correct electrodes are being used.

8 ORDERING SPARE PARTS
0463 276 001 - 16 - © ESAB AB 2015
8 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.
Arc 145 is designed and tested in accordance with the international and European
standards EN 60974-1 and EN 60974-10. It is the obligation of the service unit which
has carried out the service or repair work to make sure that the product still conforms
to the said standard.
Spare parts may 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.

DIAGRAM
0463 276 001 - 17 - © ESAB AB 2015
DIAGRAM

ORDERING NUMBERS
0463 276 001 - 18 - © ESAB AB 2015
ORDERING NUMBERS
Ordering no. Denomination Type
0700 300 884 Welding power source Buddy™ Arc 145
0459 839 065 Spare parts list Buddy™ Arc 145
Technical documentation is available on the Internet at: www.esab.com

ACCESSORIES
0463 276 001 - 19 - © ESAB AB 2015
ACCESSORIES
0700 006 883 Return cable with clamp
200A, OKC 25, 5 m
0700 006 882 Welding cable
200A, OKC 25, 5 m

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