ESAB Caddy Arc 151i VRD User manual

Valid for serial no. 828-xxx-xxxx0460 825 174 GB 20120814
Caddy
Arc 151i VRD
GB Instruction manual

- 2 -

- 3 -
TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 Equipment 6................................................................
3 TECHNICAL DATA 7.................................................
4 INSTALLATION 8....................................................
4.1 Location 8..................................................................
4.2 Mains power supply 8........................................................
4.2.1 Recommended fuse sizes and minimum cable area 9.......................
5 OPERATION 9.......................................................
5.1 PFC - Power factor correction 9...............................................
5.2 Connections and control devices 9............................................
5.3 Connection of welding and return cable 10.......................................
5.4 Overheating protection 10.....................................................
5.5 MMA welding 10.............................................................
5.6 TIG welding 11...............................................................
5.7 Remote control unit 11........................................................
6 MAINTENANCE 11....................................................
6.1 Inspection and cleaning 12....................................................
7 FAULT-TRACING 12..................................................
7.1 Fault codes 12...............................................................
8 ORDERING SPARE PARTS 13.........................................
9 DISMANTLING AND SCRAPPING 13...................................
DIAGRAM 14............................................................
ORDER NUMBER 16.....................................................
ACCESSORIES 17.......................................................

© ESAB AB 2012
- 4 -
bh38d1e
1 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 work
place.
All work must be carried out by trained personnel well-acquainted with the operation of the welding equipment. Incorrect oper
ation 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, 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.
CAUTION
This product is solely intended for arc welding.
WARNING
Do not use the power source for thawing frozen pipes.
GB

© ESAB AB 2012
- 5 -
bh38d1e
WARNING
Read and understand the instruction manual before installing or operating.
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.
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.
ESAB can provide you with all necessary welding protection and accessories.
GB

© ESAB AB 2012
- 6 -
bh38d1e
2 INTRODUCTION
Arc 151i is a welding current power source intended for use with coated electrodes
(MMA welding) and TIG welding.
ESAB's accessories for the product can be found on page 17.
2.1 Equipment
Arc 151i is supplied with a 3 m welding cable, return cable, 3 m mains cable and an
instruction manual for power source and control panel.
Control panel A33
Welding process parameters are controlled via the control panel.
NOTE! See the separate instruction manual for a detailed description of the control
panel.
GB

© ESAB AB 2012
- 7 -
bh38d1e
3 TECHNICAL DATA
Arc 151i
Mains voltage 230 V, 1 50/60 Hz
Primary current
Imax TIG
Imax MMA
14 A
22 A
Mains supply Zmax 0.35 ohm
No-load power 30 W
Setting range, MMA 4 A - 150 A
Setting range, TIG 3 - 150 A
Permissible load at MMA
25% duty cycle
60% duty cycle
100% duty cycle
150 A / 26.0 V
100 A / 24.0 V
90 A / 23.6 V
Permissible load at TIG
20% duty cycle
25% duty cycle
60% duty cycle
100% duty cycle
-
150 A / 16.0 V
120 A / 14.8 V
110 A / 14.4 V
Power factor at maximum current
MMA
TIG
0.99
0.98
Efficiency at maximum current
MMA
TIG
80%
77%
Open-circuit voltage MMA/TIG
with VRD
55 - 60 V
< 35 V
Operating temperature -10°C- +40°C
Transportation temperature -20°C- +55°C
Constant A-weighted sound pressure < 70 dB
Dimensions, l x b x h 418 x 188 x 208 mm
Weight 8.1 kg
Enclosure class IP 23
Application class
Mains supply, Zmax
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
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.
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 designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
GB

© ESAB AB 2012
- 8 -
bh38d1e
4 INSTALLATION
The installation must be carried out by a professional.
Note
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case 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 may be connected.
4.1 Location
Position the power source such that its cooling air inlets and outlets are not
obstructed.
4.2 Mains power supply
Check that the welding power source is connected to
the correct voltage and that the correct fuse size is used.
A protective earth connection must be made in accordance
with regulations
Location of rating plate
GB

© ESAB AB 2012
- 9 -
bh38d1e
4.2.1 Recommended fuse sizes and minimum cable area
Arc 151i
Mains voltage 230 V 10 %, 1-phase
Mains frequency 50-60 Hz
Mains cable, area 3G2.5 mm2
Phase current I1eff 11 A
Welding cable, area 16 mm2
Fuse
anti-surge
type C MCB
16 A
13 A
NOTE!
The cable area and fuse rating above comply with Swedish regulations. Use the
welding power source in accordance with the relevant national regulations.
5 OPERATION
5.1 PFC - Power factor correction
The Arc 151i is a 230 V single-phase power sources equipped with a PFC circuit
making it possible to use the full range of the machine on a 16 A fuse. The PFC also
protects the machines against fluctuating mains voltage and makes it safer to use
with a generator. The power source can operate with extra long mains cables, over
100 m, giving you a very larger working radius.
5.2 Connections and control devices
1Connection (+)
MMA: for return cable or welding cable
TIG: for return cable
4Connection (+)
MMA: for return cable or welding cable
TIG: for Tig torch l
2Connection for remote control unit 5Toggle switch for mains power supply 0 / 1
3Control panel 6Mains cable
GB

© ESAB AB 2012
cmha2p11
cmha2p10
- 10 -
bh38d1e
5.3 Connection of welding and return cable
The power source has two outputs, a positive terminal (+) and a negative terminal
(-), for connecting welding and return cables. The output to which the welding cable
is connected depends on the type of electrode used. The connecting polarity is
stated on the electrode packaging. Connect the welding cable to the terminal stated
on the electrode packaging.
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.
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.
5.5 MMA welding
Arc 151i gives direct current, and you can weld most metals to alloy and non-alloy
steel, stainless steel and cast iron.
The power source allows you to weld most coated electrodes from Ø1.6 to Ø3.25.
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 immedi
ately 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, then raise it so
as to give an appropriate arc length (approx. 2 mm). If the arc
is too long, it will crackle and spit before finally going out com
pletely.
If you are working on a welding bench, check before attempting
to strike the arc that residual waste metal, pieces of electrode
or other objects on the bench do not insulate the part to be
welded.
Once the arc has been struck, move the electrode from left to
right. The electrode must be at an angle of 60°to the metal in
relation to the direction of welding.
When you want to weld wide beads, or when you want the weld
to be so thick that you have to weld in a number of layers, how
ever, you have to use lateral movements.
GB