ESAB Caddy Arc 251i User manual

GB
Valid for serial no. 810-xxx-xxxx0460 324 001 GB 20110627
Caddy
Arc 251i
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Control panel A32, A34 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TECHNICAL DATA 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Mains supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Mains power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Recommended fuse sizes and minimum cable area 8. . . . . . . . . . . . . . . . . . . . . . .
5 OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Connections and control devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Connection of welding and return cable 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 TIG welding 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Overheating protection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 MAINTENANCE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Power source 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Welding torch 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 FAULT-TRACING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING SPARE PARTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sno-one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING
Do not use the power source for thawing frozen pipes.
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for arc welding.
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.
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Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/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 can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
Arc 25li 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 15.
2.1 Equipment
The power source is supplied with:
SInstruction manual for the welding power source
SInstruction manual for the control panel
S3 m return cable
S3 m welding cable
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
2.2 Control panel A32, A34
Welding process parameters are controlled via the control panel.
See the separate instruction manual for a detailed description of the control panels.
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3 TECHNICAL DATA
Arc 251i
Mains voltage 400 V $15%, 3∼50/60 Hz
Mains supply Ssc min 3.3 MVA
Primary current
Imax MMA
Imax TIG
14 A
10 A
No-load power demand when in the
energy-saving mode, 6.5 min. after welding 30 W
Setting range
MMA
TIG
4 - 250 A
3 - 250 A
Permissible load at MMA
30 % duty cycle
60 % duty cycle
100% duty cycle
250 A / 30 V
190 A / 27.6 V
150 A / 26 V
Permissible load at TIG
30 % duty cycle
60 % duty cycle
100% duty cycle
250 A / 20 V
190 A / 17.6 V
150 A / 16 V
Power factor at maximum current
MMA
TIG
0.94
0.93
Efficiency at maximum current
MMA
TIG
83 %
79 %
Open-circuit voltage
without VRD
with VRD
65 V
< 35 V
Operating temperature -10 to +40°C
Transportation temperature -20 to +55°C
Continual sound pressure at no-load <70 db (A)
Dimensions lxwxh 418 x 188 x 208 mm
Weight 10.5 kg
Insulation class transformer H
Enclosure class IP 23
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.
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.
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4 INSTALLATION
The installation must be executed by a professional.
4.1 Location
Place the power source so that its cooling air inlets and outlets are not obstructed.
4.2 Mains supply
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
distrubution network operator if necessary, that the equipment may be connected.
4.3 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. A protective earth connection must
be made in accordance with regulations.
Rating plate with supply connection data
4.3.1 Recommended fuse sizes and minimum cable area
Arc 251i
Mains voltage 400V
Mains cable area mm24 G 1.5
Phase current I1eff 8 A
Fuse
anti-surge
type C MCB
10 A
10 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.
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5 OPERATION
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
5.1 Connections and control devices
1Mains voltage switch 4Connection for remote control unit
2Connection (+)
TIG: return cable
MMA: welding cable or return cable
5Control panel,
see separate instruction manual
3Connection (-)
TIG: torch
MMA: return cable or welding cable
5.2 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 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.
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5.3 TIG welding
At TIG-welding complete the power source with:
Sa TIG torch with gas valve
San argon gas tube
San argon gas regulator
Stungsten electrode
5.4 Overheating protection
The welding power source has overheating protection that operates if the
temperature becomes too high. When this occurs the welding current is interrupted
and a fault code is displayed on the control panel.
The overheating protection resets automatically when the temperature has fallen.
6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
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:
Sthe welding process
Sarc times
Splacement
Sthe surrounding environment.
It is normally sufficient to blow the power source clean with dry compressed air
(reduced pressure) once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.
6.2 Welding torch
The wear parts should be cleaned and replaced at regular intervals in order to
achieve trouble-free welding.
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