ESAB Caddy Professional 250 User manual

GB
Valid for serial no. 632--xxx--xxxx0457 552 301 GB 060814
Professional 250
Caddyt
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 5...................................................
4 TECHNICAL DATA 5.................................................
4.1 Equipment 5................................................................
4.2 Field of application 6.........................................................
5 INSTALLATION 6....................................................
5.1 Placing 6...................................................................
5.2 Connection 6...............................................................
6 OPERATION 7.......................................................
6.1 Overload protection 7........................................................
7 MAINTENANCE 7....................................................
7.1 Cleaning 7.................................................................
8 FAULT TRACING 8...................................................
9 ORDERING OF SPARE PARTS 8......................................
DIAGRAM 10............................................................
ORDERING NUMBER 11.................................................
SPARE PARTS LIST 12...................................................
ACCESSORIES 13.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-
ing power source Professional 250 from serial number 632 complies with standard IEC/EN 60974--1,
in accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with
standard IEC/EN 60974--10 in accordance with the requirements of directive (89/336/EEC) and add-
endum (93/68/EEC).
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Kent Eimbrodt
Global Director Equipment and Automation
ESAB AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2006--08--11
2SAFETY
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 recommen-
dations 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
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 welding equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
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 PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
SInstall and earth the welding 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!
ESAB can provide you with all necessary welding protection and accessories.
This product is solely intended for arc welding.
WARNING!
Read and understand the instruction manual before installing
or operating.
Do not use the power source for thawing frozen pipes.
WARNING!
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation 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 our local representative.
By applying this European Directive you will improve the environment and human health!
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3 INTRODUCTION
The Professional 250 are one transistor controlled welding power source designed
for welding with coated electrodes and for TIG welding (touch start).
The advanced electronics provide rapid control response, low power demand and
excellent welding characteristics. Inverter technology contributes to low weight and
compact dimensions of the units.
The rounded slimline shape of the unit makes it comfortable to carry. The strap can
be folded to serve as a carrying handle, or fully extended to serve as a shoulder
strap.
ESAB’s accessories for the product can be found on page 13.
4 TECHNICAL DATA
Performance:
at 35% duty cycle
at 60% duty cycle
at 100% duty cycle
250 A/30 V
180 A/27 V
140 A/26 V
Setting range continuously variable 4--250 A
Open circuit voltage 50--80 V
Mains supply:
voltage
frequency
fuse
mains cable, area
400 V AC
50/60 Hz
16 A*
4x1,5 mm2**
Enclosure class IP 23
Application class
Dimensions L x W x H 472x142x256
Weight 11 kg
*When welding below 100 A a 10 A slow fuse is adequate..
**Power cable ratings complies with Swedish regulations..
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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.
4.1 Equipment
Professional 250 is equipped with a remote control socket which activates
automatically when a remote control device is connected. NOTE! The contact pins L
and M must be strapped in the remote device’s connection cable for automatic
activationtofunction.Theinverterissuppliedwitha3meterlongmainscable.
Professional 250 is delivered with 5 meter long welding and return cables. These are
attached to cable connectors allowing quick change of polarity.
The manufacturer’s serial number is stamped on the rating plate.
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4.2 Field of application
Professional 250 supply direct current, which allows you to weld most alloyed and
non--alloyed steels, stainless steels and cast iron. .
With the Professional 250 you can use coated electrodes from ∅1.6 to ∅5mm
Tig--welding
TIG welding is particularly useful when high quality standards are required and when
welding thin sheet.
Before using the Caddy Professional 250 for TIG welding it must be equipped with:
Sa TIG torch and gas valve
Sa cylinder of argon
San argon regulator
Stungsten electrodes
Ssuitable filler metal, if necessary.
The best method to use is the touch start, where you gently stroke the tungsten
electrode against the workpiece to establish the arc.
5 INSTALLATION
The installation must be executed by a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.
5.1 Placing
Place the machine so that there is nothing to prevent the cooling air from passing
through it.
5.2 Connection
To get maximum performance from the Professional 250 it must be fitted with a 16A
slow fuse.
The Professional 250 have mains voltage compensation, which means that ¦10%
fluctuation in the supply voltage produces only ¦0.2% variation in the welding
voltage.
The Professional 250 is intended for 400V, 3 phase supplies. It can be used with 50
Hz or 60 Hz supplies.
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6OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
The power switch is at the rear of the Professional 250. The white
lamp on the front will glow when the power is on.
1. Yellow lamp
2. Welding current control 4--250 A
3. White lamp
4. Remote control socket
The current is adjusted using the knob on the front.
Important!
Only use the accompanying welding cable and return cable,
with a cross--sectional area of 35 mm@.(See list of spare parts
for order number).
6.1 Overload protection
To save you worrying about overloading the Caddy Professional 250 it has a thermal
cut--out that will trip before the temperature becomes too high. You can tell when the
rectifier has been overloaded because the yellow light comes on and it will no longer
be possible to weld.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Note!
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.
Maintenance must be executed by a professional.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
7.1 Cleaning
Normally it is sufficient to blow the welding power source clean regularly using dry
compressed air (reduced pressure), and to clean the filter in the front regularly.
In dusty and dirty environment the welding power source should be cleaned at
shorter intervals.
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8 FAULT TRACING
Type of fault Measure
No arc is generated by
the welding power
source.
SMake sure the mains switch is on.
SCheck that the welding and return cables are properly connected.
SMake sure the welding current set is correct.
The welding current is
interrupted in the
course of welding.
SCheck if the thermal cut--out has tripped (the orange indicating lamp
on the front panel is on).
SCheck the mains fuse.
The thermal cut--out
trips frequently.
SCheck that the filter is not packed with dust.
SCheck that the ratings of the welding power source have not been
exceeded (overload of the power source).
Poor welding result. SCheck that the welding and return cables are properly connected.
SMake sure the welding current set is correct.
SCheck that there is nothing wrong with the electrodes.
9 ORDERING OF SPARE PARTS
Professional 250 is designed and tested in accordance with the international an Euro-
pean standards IEC/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 last page of
this publication.
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Edition 060814
Diagram
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Professional 250
Edition 060814
Ordering number
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Ordering no. Denomination Type
0457 516 880 Welding power source Professional 250
0457 552 990 Spare parts list Professional 250

Professional 250
Edition 060814
Spare parts list
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Item Qty Ordering no. Denomination
1 1 0468 462 001 Filter
2 2 0467 796 001 Grille

Professional 250
Edition 060814
Accessories
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Remote control MMA 1 (10mcable) .........
MMA and TIG: current 0349 501 024
Remote control unit AT1 ...................
MMA and TIG: current
0459 491 896
Remote control unit AT1 CF ...............
MMA and TIG: rough and fine setting of current.
0459 491 897
Remote cable 12 pole -- 8 pole
5m.......................................
10m......................................
15m......................................
25m......................................
0459 552 880
0459 552 881
0459 552 882
0459 552 883
TIG--torch
HW--20ARV,3,8m.Formax140A ........... 0588 000 714

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ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]
www.esab.com
051118
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel:[phone]
Fax:[phone]
FINLAND
ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]
GERMANY
ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]
ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]
HUNGARY
ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]
NORWAY
AS ESAB
Larvik
Tel:[phone]
Fax:[phone]
POLAND
ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]
PORTUGAL
ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]
ESAB international AB
Gothenburg
Tel:[phone]
Fax:[phone]
SWITZERLAND
ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]
BRAZIL
ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]
INDIA
ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]
JAPAN
ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax: [phone]
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel:[phone]
Fax: [phone]
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: [phone]
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: [phone]
RUSSIA
LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]
LLC ESAB
St Petersburg
Tel: [phone]
Fax: [phone]
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com