ESAB Heliarc 283i AC/DC User manual

Instruction manual
0463 369 001 GB 20131114 Valid for: 283i=S2733450468 353i=S2733450508
Coolingunit=S2733450427
Heliarc283iAC/DC
Heliarc353iAC/DC
Heliarccoolingunit

TABLE OF CONTENTS
0463 369 001 © ESAB AB 2013
1 SAFETY ................................................................................................................ 5
2 INTRODUCTION................................................................................................... 8
2.1 Overview ............................................................................................................... 8
2.2 Equipment............................................................................................................. 8
3 TECHNICAL DATA ............................................................................................... 9
4 INSTALLATION................................................................................................... 11
4.1 General................................................................................................................ 11
4.2 Lifting instructions............................................................................................. 11
4.3 Location .............................................................................................................. 11
4.4 Mains supply ...................................................................................................... 12
5 OPERATION ....................................................................................................... 14
5.1 Overview ............................................................................................................. 14
5.2 Connections and control devices power source ............................................14
5.3 Quick set up........................................................................................................ 17
5.3.1 Operation mode selection ................................................................................17
5.3.2 Stick (SMAW) mode ......................................................................................... 17
5.3.3 TIG (GTAW) two stroke mode with remote switch ...........................................18
5.3.4 TIG (GTAW) two stroke mode with foot control................................................ 18
5.3.5 TIG (GTAW) four stroke mode .........................................................................18
5.3.6 TIG (GTAW) spot mode.................................................................................... 19
5.3.7 AC mode .......................................................................................................... 19
5.3.8 Pulse mode - Peak/Background.......................................................................20
5.3.9 Pulse mode - Frequency/Duty cycle ................................................................ 20
5.3.10 Store and recall programs................................................................................21
5.3.11 General functions ............................................................................................. 22
5.3.12 Remote control - On/Off/Minimum ................................................................... 22
5.4 Sub menu power source ...................................................................................22
5.5 Main functions power source ...........................................................................23
5.6 TIG welding information ....................................................................................25
5.7 Power source overheated .................................................................................26
5.8 Connections and control devices cooling unit ...............................................26
5.9 Starting up the cooling unit ..............................................................................27
6 MAINTENANCE.................................................................................................. 29
6.1 Overview ............................................................................................................. 29
6.2 Power source...................................................................................................... 29
6.3 Welding torch ..................................................................................................... 29
6.4 Cooling unit ........................................................................................................ 29
6.5 Fill up the cooling unit with coolant.................................................................30
7 FAULT TRACING................................................................................................ 31

TABLE OF CONTENTS
0463 369 001 © ESAB AB 2013
8 ORDERING SPARE PARTS ............................................................................... 33
DIAGRAM ..................................................................................................................34
WELDING TABLES ...................................................................................................36
ORDERING NUMBERS.............................................................................................38
ACCESSORIES .........................................................................................................39
Rights reserved to alter specifications without notice.

1 SAFETY
0463 369 001 -5- © ESAB AB 2013
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 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 equpment
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
○ Lubrication and maintenance must not be carried out on the equipment during
operation

1 SAFETY
0463 369 001 -6- © ESAB AB 2013
WARNING!
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. Protect your
ears. Use earmuffs or other hearing protection
• Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
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.

1 SAFETY
0463 369 001 -7- © ESAB AB 2013
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.

2 INTRODUCTION
0463 369 001 -8- © ESAB AB 2013
2 INTRODUCTION
2.1 Overview
The Heliarc 283i and 353i AC/DC are welding power sources intended for MMA and TIG
welding. The Heliarc 283i is rated up to 280 A and the Heliarc 353i up to 350 A.
A 230 V AC auxiliary supply is available, accessed through the rear panel, when using the
Heliarc cooling unit.
The Heliarc cooling unit is used with the Heliarc 283i and 353i AC/DC. It distributes 2
litres/min, with the torch connected, with a power of 60 W.
A trolley is an option available for the power sources.
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.2 Equipment
The power sources comes with:
• 5 m return cable with clamp
• 5 m mains cable
• gas hose
• instruction manual
The cooling unit comes with:
• instruction manual

3 TECHNICAL DATA
0463 369 001 -9- © ESAB AB 2013
3 TECHNICAL DATA
283i AC/DC 353i AC/DC
Mains voltage 400 V ±10%,
3~ 50/60 Hz
400 V ±10%,
3~ 50/60 Hz
Setting range GTAW/TIG AC/DC 4 - 280 A 350 A
Maximum output
GTAW/TIG, AC/DC 280 A at 100% 350 A at 45%
Gas pre-flow 0.5 - 30 sec 0.5 - 30 sec
Slope up/slope down 0.1 - 10 sec 0.1 - 10 sec
Gas post-flow 0.5 - 30 sec 0.5 - 30 sec
Frequency AC 20 -200 Hz 20 - 200 Hz
AC balance 10 - 90% 10 - 90%
DC Pulse mode frequency 0.4 - 300 Hz 0.4 - 300 Hz
AC Pulse mode frequency 0.4 - 2 Hz 0.4 - 2 Hz
Pulse duty (pulse
time/background time) 30 - 65% 30 - 65%
Background current 10 - 90 A 10 - 90 A
Slope down time 0.1 -10 s 0.1 - 10 s
Start/crater current (4-stroke) 10 - 90 % 10 - 90 %
Post purge time 0.5 - 30 s 0.5 - 30 s
Remote start point current 4 - 100 A 4 - 100 A
Open circuit voltage max 68 V 68 V
Power factor at 100 % TIG mode 0.75 0.8
Setting range SMAW/MMA 4 - 280 A 4 - 350 A
Maximum output SMAW/MMA, AC/DC
20% duty cycle - 350 A
40% duty cycle 280 A -
KVA GTAW/TIG 11 14.5
KVA SMAW/MMA 14.2 19
Enclosure class IP 21S IP 21S
Dimensions l × w × h 600 × 300 × 620 mm 600 × 300 × 620 mm
Weight without cooling unit 50 kg 50 kg
Weight trolley 35 kg 35 kg
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP21 is intended for indoor use.
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Heliarc cooling unit
Mains voltage 400 V ±10%, 1~, 50/60 Hz
Maximum power supply current 0.75 A

3 TECHNICAL DATA
0463 369 001 - 10 - © ESAB AB 2013
Heliarc cooling unit
P1l/min 0.5 kW
Cooling power 60 W
Coolant "ESAB's ready mixed coolant, see the
"ACCESSORIES" chapter.
Coolant quantity 5 l (delivered with approx. 2.5 l)
Pressure max 0.35 MPa
Maximum water flow 2.0 l/min
Operating temperature -10° to +40°C
Transportation temperature -20° to +55°C
Dimensions (l × w × h) 475 × 310 × 250 mm
Weight empty 14 kg
Enclosure class IP21
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP21 is intended for indoor use.

4 INSTALLATION
0463 369 001 - 11 - © ESAB AB 2013
4 INSTALLATION
4.1 General
The installation must be carried out by a professional.
4.2 Lifting instructions
Lifting the power source by hand.
WARNING!
The power source weighs 50 kg (110 lbs).
WARNING!
Be two persons and lift the power
source by using the two handles.
Lifting the power source using hoist and strap.
WARNING!
Lift the power source by using the
eyebolt. Keep the power supply
as horizontal as possible.
WARNING!
Secure the equipment -
particularly if the ground is
uneven or sloping.
4.3 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed. Make sure that no deposits or dust goes into the power source. Prevent impacts,
rubbing and exposure to dripping water, excessive heat sources or any unusual situations.

4 INSTALLATION
0463 369 001 - 12 - © ESAB AB 2013
4.4 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 distribution network operator if necessary, that the equipment may be
connected.
CAUTION!
Make sure that the ON/OFF switch is set to OFF (0) before making any electrical
connections between the power source and the 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 mains distribution panel must comply with the
regulations in force in the country of use. The mains supply system must be of the industrial
type.
A protective earth connection must be made in accordance with regulations. The power
source must be correctly connected to earth to protect the operator. It is indispensable to
provide good earthing by means of the yellow-green lead in the power cable, to prevent
discharges due to accidental contacts with earthed objects. The chassis, which is conductive,
is electrically connected with the earth lead. If the equipment is not correct connected with
the earth lead it may cause electric shocks which are dangerous for the operator.
The power source works at mains voltages differing by 20% from the rated mains (400 V
rated, minimum voltage 320 V, maximum voltage 480 V).
Heliarc 283i AC/DC Heliarc 353i AC/DC
Mains voltage 400 V, 3~ , 50/60 Hz 400 V, 3~ , 50/60 Hz
Fuse 20 A 25 A
Connection instruction cooling unit
Make sure that the Heliarc is correctly connected to earth to protect the operator. It is
indispensable to provide good earthing by means of the yellow-green lead in the power
cable, to prevent discharges due to accidental contacts with earthed objects.
The chassis, which is conductive, is electrically connected with the earth lead. If the
equipment is not correct connected with the earth lead it may cause electric shocks which
are dangerous for the operator.
The cooling unit must be connected to the power source with the special ILME multipole plug
supplied. Make sure that the power source is turned off and disconnected from the mains
power supply before making any electrical connections between the cooling unit and the
power source.
If the cooling unit is going to be connected to three phase mains voltage, replace the special
ILME 4-way plug with a three phase plug. Connect the supply wires to only two of the
contacts (black-brown) of the plug and the earth led (yellow/green) to the earth contact.

4 INSTALLATION
0463 369 001 - 13 - © ESAB AB 2013
Connect the cooling unit to the power source
1. Remove the screws (1), the safety bolt (2) and the door panel (3).
2. Remove the plastic cap at the rear of the trolley chassi.
3. Pull the cooling unit input cable through the hole at the rear of the trolley chassi.
4. Fasten the input cable with the screws (4).
The Heliarc 353i AC/DC is already equipped with a connector to connect the cooling unit. To
start the cooling unit it is necessary to switch on both the power source and the cooling unit.
Hydraulic connection
Connect the water delivery pipe of the torch to water output coupling on the cooling unit.
Connect the water return pipe of the torch to the water input coupling on the cooling unit.

5 OPERATION
0463 369 001 - 14 - © ESAB AB 2013
5 OPERATION
5.1 Overview
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!
5.2 Connections and control devices power source
Front connections
Type Connection PIN Description
TIG
YES A Gas
TIG TORCH B Negative
YES D-F Pin
EARTH CLAMP E Positive
Type Connection PIN Description
MMA
NO A Gas
EARTH CLAMP B Negative
POSSIBLE REMOTE F Pin
ELECTRODE E Positive
NOTE!
Connection D, 2 pin cannon, can be used for either analogue foot control or
torch.
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

5 OPERATION
0463 369 001 - 15 - © ESAB AB 2013
Cooling unit connection
4 Pin
connector
PIN Description
Power supply
1 Power supply common
2 Power supply 115/230 V AC
3 Power supply 400 V AC
GRD 4 Chassis common
14 pin connector
14 Pin
connector
PIN Description
Torch trigger A Torch switch
B Torch switch
Remote control
E Remote control circuit common
F +5 V DC input remote control
G +5 V DC output remote control
D +5 V DC output remote control
GRD H Chassis common
2 pin connector
2 Pin
connector
PIN Description
Torch trigger
A Torch switch
B Torch switch

5 OPERATION
0463 369 001 - 16 - © ESAB AB 2013
Front panel
Item Denomination
1 Power source live LED
2 Welding enabled LED
3 Over temperature LED
4 Volt display
5 Ampere display
6 AC mode button
7 AC mode LED
8 AC frequency setting, 20-200 Hz
9 AC balance setting, 10-90%
10 Pulse mode button (0.4-300 Hz DC, 0.4-2 Hz AC)
11 Pulse mode LED
12 Pre-gas (0.1-2.5 sec) Post-gas (0.1-30 sec) button
13 Base current button (10-90%)
14 Slope up/down button (slope up 0.1-10 sec, slope down 0.1-10 sec)
15 Encoder knob for current setting and other settings
16 HF LED
17 HF button
18 Select mode button
19 Remote control button
20 Remote button LED
21 Mode TIG dual schedule LED
22 Mode TIG spot LED
23 Mode TIG 4 stroke LED

5 OPERATION
0463 369 001 - 17 - © ESAB AB 2013
Item Denomination
24 Mode TIG 2 stroke LED
25 Mode Stick LED
5.3 Quick set up
5.3.1 Operation mode selection
Press the select mode button (1) repeatedly until the desired mode is selected, indicated by
a green LED.
5.3.2 Stick (SMAW) mode
1. Press the select mode button (1) repeatedly until the Stick w/Hot start & Arc force LED is
lit.
2. Press the select mode button (1) for a few seconds until "HS" is shown in the V display.
3. Set the value for hot start with the encoder knob (2).
4. Press the select mode button (1) for a few seconds unit "HS" is shown in the V display.
5. Press the select mode button (1) again, "AF" is shown on the V display.
6. Set the value for the arc force with the encoder knob (2).

5 OPERATION
0463 369 001 - 18 - © ESAB AB 2013
5.3.3 TIG (GTAW) two stroke mode with remote switch
1. Press the select mode button (1) repeatedly until the TIG two stroke LED is lit.
2. Keep the slope up/down button (3) pressed and adjust the slope up/down time (0.1 to 10
seconds) with the encoder knob (2).
5.3.4 TIG (GTAW) two stroke mode with foot control
1. Press the select mode button (1) repeatedly until the TIG two stroke LED is lit.
2. Keep the slope up/down button (3) pressed and adjust the slope up/down time with the
encoder knob (2) to the minimum time.
5.3.5 TIG (GTAW) four stroke mode

5 OPERATION
0463 369 001 - 19 - © ESAB AB 2013
1. Press the select mode button (1) repeatedly until the TIG four stroke LED is lit.
2. Keep the slope up/down button (3) pressed and adjust the slope up/down time (0.1 to 10
seconds) with the encoder knob (2).
3. Keep the base current button (4) pressed and adjust the current level (10-90% of main
amps) with the encoder knob (2).
5.3.6 TIG (GTAW) spot mode
1. Press the select mode button (1) repeatedly until the TIG Spot mode LED is lit.
2. Adjust the spot time, shown in A display, with the encoder knob (2).
3. Set the spot welding current level in Normal TIG mode.
4. Press the select mode button (1) repeatedly until the TIG Spot mode LED is lit.
5.3.7 AC mode
1. Press the AC mode button (1) to turn on the AC mode.
2. Adjust the spot time, shown in A display, with the AC frequency button (2).
3. Adjust the balance (10 to 90%) with the AC balance button (3).
4. Press the AC mode button (1) for 3 seconds to turn off the AC mode.

5 OPERATION
0463 369 001 - 20 - © ESAB AB 2013
5.3.8 Pulse mode - Peak/Background
1. Press the pulse mode button (1) to turn on the pulse mode.
2. Adjust the peak current level with the encoder knob (2).
3. Adjust the background current level with the base current button (3).
5.3.9 Pulse mode - Frequency/Duty cycle
1. With the pulse mode ON, press the pulse mode button (1) to switch between "FRE"
(frequency) and "DUT" (duty).
2. In "FRE" mode adjust the pulse frequency (AC: 0.4 to 2 Hz, DC: 0.4 to 300 Hz) with the
encoder knob (2).
3. In "DUT" mode adjust the duty (30 to 65% peak width) with encoder knob (2). More duty
= more heat.
4. Press the pulse mode button (1) for 3 seconds to turn off the pulse mode.