Esab Caddyarc 150 User manual

Valid for serial no. 316--xxx--xxxx, 328--xxx--xxxx,

341--xxx--xxxx

0459 263 001 GB 041101

CaddyArc 150

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 4...................................................

3.1 Equipment 4................................................................

4 TECHNICAL DATA 5.................................................

5 INSTALLATION 5....................................................

5.1 Placing 5...................................................................

5.2 Rating plate 5...............................................................

5.3 Mains power supply 6........................................................

6 OPERATION 6.......................................................

6.1 Connections and control devices 6............................................

6.2 Control panel 7.............................................................

6.3 Settings 8..................................................................

6.4 Overheating protection 8.....................................................

6.5 MMA welding 8.............................................................

6.6 TIG welding 9...............................................................

6.7 Remote control unit 9........................................................

7 MAINTENANCE 10....................................................

7.1 Cleaning the dust filter 10.....................................................

8 FAULT TRACING 10...................................................

8.1 Fault codes 11...............................................................

9 ORDERING SPARE PARTS 11..........................................

DIAGRAM 12............................................................

ORDERING NUMBER 14.................................................

SPARE PARTS LIST 15...................................................

ACCESSORIES 16.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding

power source CaddyArc 150 from serial number 316 complies with standard IEC/EN 60974--1, in ac-

cordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with stan-

dard EN 50199 in accordance with the requirements of directive (89/336/EEC) and addendum

(93/68/EEC).

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Henry Selenius

Vice President

ESAB AB Arc Equipment

SE--695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2003--04--10

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.

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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.

WARNING!

Read and understand the instruction manual before installing

or operating.

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

3 INTRODUCTION

The CaddyArc 150 is a welding current power source intended for use with coated

electrodes (MMA welding) and TIG welding.

3.1 Equipment

The CaddyArc 150 is supplied with 3 m of mains cable and an instruction manual.

ESAB’s accessories for the product can be found on page 16.

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4 TECHNICAL DATA

CaddyArc 150

Mains voltage 230 V, 1 µ50/60 Hz

Fuse (delayed--action) 16 A

Primary current Imax 36 A

Primary current Ieff 21 A

Voltage/current range (DC) 4 A /20 V -- 150 A /26 V

Maximum permissible load at

25% duty cycle

35% duty cycle

60% duty cycle

100% duty cycle

150 A / 26 V

140 A / 26 V

110A/25V

90 A / 24 V

Power factor at maximum current 0,62

Efficiency at maximum current 77%

Open--circuit voltage 71--78 V

Operating temperature -- 1 0 ˚C-- +40˚C

Constant A--weighed sound pressure <70db

Dimensions, l x b x h 394 x 267 x 274 mm

Weight 9kg

Enclosure class IP 23C

Application class

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.

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.

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 power source so that its cooling air inlets and outlets are not obstructed.

5.2 Rating plate

The rating plate is located on the underside of the power source.

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5.3 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. The standards for the country in

question must be complied with as regards the mains cable area. A protective earth

connection must be made in accordance with regulations.

5.3.1 Recommended fuse sizes and minimum cable areas

CaddyArc 150

Mains voltage 230 V ¦10 %, 1--phase

Mains frequency 50--60 Hz

Fuse (delayed--action)

100A 20% duty cycle

120A 35% duty cycle

150A 35% duty cycle

10 A

16 A

20 A*)

Mains cable, area 3x2.5mm

Welding cable, area 16 mm2

*) Note! The installed plug is approved for max. 16A.

North American version: The mains cable is approved for maximun 18 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.

6OPERATION

6.1 Connections and control devices

1Main power supply switch, 0 / 1 4Connection for remote control

2Mains cable 5Welding cable connector (+)

3Connection for return cable (--) 6Control panel (see 6.2)

3and 5are used for welding current supply and return cable connection during MMA

welding

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6.2 Control panel

Welding process parameters are controlled via the control panel.

6.2.1 Functional description

Pos Symbol/Function Set values

1Knob for setting data --

2Arc Force 0 -- 99%

3Hot Start 0 -- 99%

4TIG welding “Live TIG--start” --

5MMA welding with coated electrodes --

6Pushbutton indicating welding current (A) and/or arc voltage (V) --

7Connection of remote control unit --

8Indicating lamp (green), mains power supply --

9Indicating lamp (yellow) for overheating --

6.2.2 Panel function symbols

MMA Amp/Volt Fjärrdon

TIG Hot Start Arc Force

6.2.3 Hidden functions

A number of setting options for welding data, such as drop welding and ArcPlust,

are obtained by pressing Arc Force and Hot Start simultaneously

for at least 1 second. The function is selected using the setting knob, and the

welding method is selected by pressing the ArcForce or HotStart button.

Return by pressing ArcForce and HotStart simultaneously for 1

second.

cmha2p11

cmha2p10

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6.3 Settings

Settings Setting range In steps of: Default value

Arc Force 0 -- 99% 1% 5%

Drop welding I/0 -- 0

Regulator ArcPlustI/0 -- 1

Hot Start 0 -- 99% 1% 0%

6.4 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.

6.5 MMA welding

The CaddyArc 150 gives direct current, and you can weld most metals to alloy and

non--alloy steel, stainless steel and cast iron.The CaddyArc 150 allows you to weld

most coated electrodes from ∅1.6 to ∅3.25.

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 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 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.

Setting regulator -- ArcPlust

The CaddyArc 150 is supplied with ArcPlust, a new type of control that, during MMA

welding, produces a more intensive, more concentrated and calmer arc. It recovers more

quickly after a drop short--circuit, which reduces the risk of the electrode becoming stuck.

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Drop welding (MMA)

Drop welding can be used when welding with stainless electrodes.

This technique involves alternately striking and extinguishing the arc in order to achieve

better control of the supply of heat. The electrode needs only to be raised slightly to

extinguish the arc.

Hot Start

Hot start increases the weld current for an adjustable time at the start of welding,

thus reducing the risk of poor fusion at the beginning of the joint.

Arc Force

The arc force is important in determining how the current changes in response to a

change in the arc length. A lower value gives a calmer arc with less spatter.

Current

A higher current produces a wider weld pool, with better penetration into the

workpiece.

The current set value can be changed irrespective of which menu is displayed. This

value is displayed in the main menu only.

6.6 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 when high quality standards are required and when

welding thin sheet. Caddy also has very good TIG welding characteristics.

Before using the Caddy for TIG welding it must be equipped with a TIG torch and

gas valve, a cylinder of argon, an argon regulator, tungsten electrodes and, if

necessary, suitable filter metal.

“Live Tig--start“

The Live Tig--start“ function strikes the arc when the electrode is brought into contact

with the workpiece and then lifted away from it.

6.7 Remote control unit

The remote control unit has to be connected to the remote control unit socket on the

power source.

If the remote control unit is not to be used, this function is removed from the panel.

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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.

7.1 Cleaning the dust filter

SRemove the fan grille: see sketch.

SRelease the dust filter

SBlow the filter clean with compressed air (reduced pressure).

SEnsure that the filter with the finest mesh is placed towards the grille.

SReplace the fan grille with the dust filter.

8 FAULT TRACING

Try these recommended checks and inspections before sending for an authorised

service technician.

Type of fault Action

No arc. SCheck that the mains power supply switch is turned on.

SCheck that the welding current supply and return cables are

correctly connected.

SCheck that the correct current value is set.

SCheck to see whether the MCB has tripped.

The thermal overload trips ope-

rate frequently.

SCheck whether the thermal overload trips have operated

(indicated by the orange lamp on the front panel).

SCheck the main power supply fuses.

The thermal overload trip opera-

tes frequently.

SCheck to see whether the dust filter is clogged.

SMake 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. SCheck that the welding current supply and return cables are

correctly connected.

SCheck that the correct current value is set.

SCheck that the correct electrodes are being used.

SCheck the main power supply fuses.

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8.1 Fault codes

The CaddyArc 150 comes with built--in fault monitoring. If a fault occurs, a code is

shown in the display.

If any of these fault codes is displayed permanently or recurs often, the machine

should be sent to an authorised ESAB service workshop for repair.

Fau

lt Description Resetting Action

E1 Internal RAM fault Restart the machine.