ESAB Caddy Series User manual

Caddy®
Instruction manual
0460 446 301 GB 20190619 Valid for: serial no. 840-xxx-xxxx
Arc 151i, Arc 201i

TABLE OF CONTENTS
0460 446 301 © ESAB AB 2019
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 7
2.1 Equipment ............................................................................................... 7
2.2 Control panel .......................................................................................... 7
3TECHNICAL DATA ...................................................................................... 8
4INSTALLATION............................................................................................ 10
4.1 Location................................................................................................... 10
4.2 Mains power supply ............................................................................... 10
4.2.1 Recommended fuse sizes and minimum cable area............................ 10
5OPERATION ................................................................................................ 11
5.1 PFC - Power factor correction............................................................... 11
5.2 Connections and control devices ......................................................... 11
5.3 Connection of welding and return cable .............................................. 12
5.4 Overheating protection .......................................................................... 12
5.5 MMA welding........................................................................................... 12
5.6 TIG welding ............................................................................................. 13
5.7 Remote control unit................................................................................ 14
6MAINTENANCE........................................................................................... 15
6.1 Inspection and cleaning......................................................................... 15
7TROUBLESHOOTING ................................................................................. 16
7.1 Fault codes.............................................................................................. 16
8ORDERING SPARE PARTS ........................................................................ 17
DIAGRAM ............................................................................................................ 18
ORDERING NUMBERS....................................................................................... 22
ACCESSORIES ................................................................................................... 23
Rights reserved to alter specifications without notice.

1 SAFETY
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1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2 Safety precautions
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 or other applicable operation of the equipment
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 or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
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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 extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
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MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
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.
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.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
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2 INTRODUCTION
Arc 151i, Arc 201i is a welding current power source intended for use with coated electrodes
(MMA welding) and TIG welding.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this
manual.
2.1 Equipment
Arc 151i, Arc 201i is supplied with a 3 m welding cable, return cable, 3 m mains cable and an
instruction manual for power source and control panel.
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
2.2 Control panel
Control panel A31
• Knob for setting the current
• Mains voltage LED (green)
• Thermal overload trip indicator (yellow)
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.

3 TECHNICAL DATA
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3 TECHNICAL DATA
Arc 151i Arc 201i
Mains voltage 230 V, 1 ~ 50/60 Hz 230 V, 1 ~ 50/60 Hz
Primary current:
Imax TIG 13.8 A 24.1 A
Imax MMA 21.3 A 24.9 A
No-load power 30 W 32 W
Voltage/current range, MMA:
A31 8A/20V-150A/26V -
A33 4A/20V-150A/26V 4A/20V-170A/26.8V
Voltage/current range TIG 3A / 10V - 150 A / 16V 3A / 10V - 220A / 18V
Permissible load at MMA:
25% duty cycle 150 A / 26.0 V 170 A / 26.8 V
60% duty cycle 100 A / 24.0 V 130 A / 25.2 V
100% duty cycle 90 A / 23.6 V 110 A / 24.4 V
Permissible load at TIG:
20% duty cycle - 220 A / 18.8 V
25% duty cycle 150 A / 16.0 V -
60% duty cycle 120 A / 14.8 V 150 A / 16.0 V
100% duty cycle 110 A / 14.4 V 110 A / 14.4 V
Power factor at maximum current 0.99 0.99
Efficiency at maximum current 80% 81%
Open-circuit voltage:
A31 without VRD function 1) 58 - 72 V -
A33 VRD function deactivated 2) 56 V 56 V
VRD function activated 2) 23 V 22 V
Operating temperature -10 °C - +40 °C -10 °C - +40 °C
Transportation temperature -20 °C - +55 °C -20 °C - +55 °C
Constant A-weighted sound
pressure
< 70 dB < 70 dB
Dimensions (l × b × h) 418 × 188 × 208 mm 418 × 188 × 208 mm
Weight:
with A31 7.9 kg -
with A33 8.1 kg 8.3 kg
Enclosure class IP 23 IP 23
Application class
1) Valid for power sources without VRD specification on the rating plate.
2) Valid for power sources with VRD specification on the rating plate. The VRD function is
explained in the instruction manual for the control panel.

3 TECHNICAL DATA
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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/104°F, or below.
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
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4 INSTALLATION
The installation must be carried out by a professional.
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit power
is greater than or equal to Sscmin at the interface point between the user's supply
and the public system. 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 is connected only to a supply with a short-circuit power greater than
or equal to Sscmin. Refer to the technical data in the TECHNICAL DATA chapter.
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
4.2.1 Recommended fuse sizes and minimum cable area
Arc 151i Arc 201i
Mains voltage 230 V ±10 %, 1-phase 230 V ±10 %, 1-phase
Mains frequency 50-60 Hz 50-60 Hz
Mains cable, area 3G2.5 mm23G2.5 mm2
Phase current I1eff 11 A 14 A
Welding cable, area 16 mm216 mm2
Fuse:
anti-surge 16 A 16 A
type C MCB 16 A 16 A
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. For other regions, supply cables must be suitable for the
application and meet local and national regulations.

5 OPERATION
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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 PFC - Power factor correction
The Caddy Arc 151i/201i are 230 V single-phase power sources equipped with a PFC circuit
making it possible to use the full range of the power source on a 16 A fuse.
The PFC also protects the power sources against fluctuating mains voltage and makes it
safer to use with a generator. Caddy Arc 151i/201i can operate with extra long mains cables,
over 100 m, giving you a very larger working radius.
5.2 Connections and control devices
1 Connection (+) 4 Connection (+)
MMA: for return cable or welding cable MMA: for return cable or welding cable
TIG: for return cable TIG: for Tig torch l
2 Connection for remote control unit 5 Toggle switch for mains power supply 0 / 1
3 Control panel 6 Mains cable

5 OPERATION
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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 / 201i gives direct current, and you can weld most metals to alloy and non- alloy
steel, stainless steel and cast iron.
Arc 151i / 201i allows you to weld most coated electrodes from Ø 1.6 mm to Ø 3.25 mm.
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 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.

5 OPERATION
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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 completely.
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, however,
you have to use lateral movements.
5.6 TIG welding
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten electrode,
which does not itself melt. The weld pool and the electrode are protected by shielding gas.
TIG welding is particularly useful where high quality is demanded and for welding thin plate.
Arc 151i / 201i also has good characteristics for TIG welding.
In order to TIG weld Arc 151i / 201i must be equipped with:
• a TIG torch with gas valve
• a welding gas cylinder (a suitable welding gas)
• a welding gas regulator (suitable gas regulator)
• tungsten electrode
• suitable auxiliary material, if necessary.
TIG scrape start (only A31)
To scrape start lightly scrape the tungsten electrode
against the workpiece to create an arc.
”Live TIG-start” (only A33)
With “Live TIG start” the arc strikes when the tungsten electrode is brought into contact with
the workpiece and then lifted away from it.

5 OPERATION
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5.7 Remote control unit
The remote control unit is connected to the remote control socket on the power source.

6 MAINTENANCE
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6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
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 Inspection and cleaning
Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on: the welding process, arc times,
positioning of power source, and the surrounding environment. It is normally sufficient to blow
down the power source with dry compressed air (reduced pressure) once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.
TIG torch
The TIG torch's wear parts should be cleaned and replaced at regular intervals in order to
achieve trouble-free welding.

7 TROUBLESHOOTING
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7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault Corrective actions
No arc. • Check that the mains power supply switch is turned on.
• 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 protections have tripped
(indicated by the orange lamp on the front panel).
• Check the mains power supply fuses.
The thermal protection 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).
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.
• Check the gas flow.
7.1 Fault codes
Arc 151i, 201i comes with built-in fault monitoring. If a fault occurs, a code is shown in the
display. See instruction manual for the control panel.

8 ORDERING SPARE PARTS
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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 151i and Arc 201i are designed and tested in accordance with the international and
European standards IEC-/EN 60974-1 and IEC-/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 mentioned standard.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. 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
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DIAGRAM
Arc 151i

DIAGRAM
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DIAGRAM
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Arc 201i