ESAB ARC250i User manual

ARC250i

INVERTER MMA

Welding Power Source

Instruction manual

ARC250i

INVERTER MMA WELDING POWER SOURCE

Instruction manual

For

Installation, Operation & General maintenance

CONTENTS

Item

Page No.

SAFETY

1-2

RATING AND INSTALLATION

CAUTIONS FOR INSTALLATION

CONNECTIONS

5-6

WELDING OPERATIONS

WIRING DIAGRAM

TROUBLESHOOTING

PARTS LIST AND EXPLODED VIEW

10-11

ESAB INDIA LOCATIONS AND CONTACT DETAILS

SAFETY

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 recommendations should be observed in addition to

the standard regulations that apply to the workplace.

Trained personnel well acquainted with the operation of the welding equipment must

carry out all the work. 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:

• its operation

• location of emergency stops

• its function

• relevant safety precautions

• welding

2. The operator must ensure that:

• no unauthorized person is stationed within the working area of the equipment

when it is started up.

• no one is unprotected when the arc is struck

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,

flameproof clothing, and 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.

• Only a qualified electrician may carry out work on high voltage equipment.

• 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.

Read and understand the instruction manual before installing or operating.

ESAB can provide you with all necessary welding protection and accessories.

WARNING

Arc welding and cutting can be injurious to yourself and others. Take

precautions when welding.

Ask for your employer’s safety practices which should be based on manufacturers’

hazard data.

ELECTRIC SHOCK –Can kill

• Install and earth the welding 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.

• Warn bystanders of the risk.

MALFUNCTION –Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding

Do not dispose of electrical equipment together with normal waste!

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 the local representative. By applying this Directive you

will improve the environment and human health

RATING

RATING OF ARC250i INVERTER WELDING POWER SOURCE

CHARACTERISTICS

CONSTANT CURRENT TYPE

Input:

SUPPLY VOLTAGE, PHASE & FREQUENCY

230V± 15%, 1Phase, 50 Hz, AC

MAXIMUM INPUT CURRENT

48 A

MAXIMUM RATING

11.02 KVA

Output:

OUTPUT CURRENT RANGE

DC 30-250A

OPEN CIRCUIT VOLTAGE

80 V DC

TYPE OF WELDING CURRENT CONTROL

STEPLESS

CLASS OF INSULATION

‘H’

COOLING

FORCED AIR COOLED

APPROX DIMENSION (LxWxH) IN MM

435 x 170 x 330

WEIGHT (APPROX)

10.7 KG.

INSTALLATION

The complete installation should consist the following items:

Description

Type

Quantity

Welding Power Source

ARC250i

Welding Cable with Holder

Earth cable with Clamp

CAUTIONS FOR INSTALLATION

Provide a Switch Box for every Welding Power Source, and use designated

fuse

Tolerance of Power Voltage Variation is 10% of rated input voltage.

a) Installation place

Install in the place where less moisture and dust exist. Avoid direct sunlight and

rain, and maintain ambient temperature within –10o to +45o C as much as

possible.

Keep the welding power source at least 20 cm. away from the wall (if any).

In case of installation of more two units side by side, a distance of more than 20

cm is recommended between the two power sources.

Use a shield to protect the welding arc in case of excessive air draft.

b) Ventilation

Adequate ventilation is recommended at the place of installation. For

example the following guideline should be followed:

a) In case of the area being more than 300 square meters (per unit), no

ventilation is required, provided the room is not completely airtight.

b) In case of the area being less than 300 square meters and the welding

is continuously performed, adequate ventilation is recommended with

the help of vent fan or exhaust duct.

c) While performing the grounding work, it is recommended that a skilled

electrician does the work.

Connections

1. Welder’s Placement

Connection between Welder and Power Source

Notice: Input Power supply earth connection is not power supply neutral.

Air switch

Input power

Connection between Welder and Electrode Holder (Output Connection diagram)

Insert the OKC connector of the welding cable on the electrode holder into current

output “+” electrode adaptor on the lower half of the front panel and then rotate down

clockwise.

Insert the OKC connector of earth cable with earth clamp into current outp

The earth clamp is connected with work piece.

Notice: Do not use steel plate or the materials alike which are poor conductor,

to connect between welder and work piece.

2. EXTENSION CORD - We do not recommend an extension cord because of the

voltage drop they produce. This drop in voltage can affect the performance of the

welder. If you need to use an extension cord, we recommend you check with a

qualified electrician and your local electrical codes for your specific area. Do not use

an extension cord over 25 ft. in length.

3. INSTALLATION OF OPTIONAL TIG TORCH

3.1 Remove the ground cable and the electrode holder from the weld output

connections. Install the ground cable to the Positive (+) weld output connection.

3.2 Secure the ground clamp to the work piece

3.3 Connect a regulator to a cylinder of ARGON gas. Then connect the gas

connection from the TIG torch to the regulator.

3.4 Connect the TIG torch weld cable to the Negative (-) weld output connection.

3.5 Set desired amperage on the amperage control knob on the front panel of the

welder.

3.6 Turn on the input power switch on the welder.

Be aware that the TIG torch will be electrically energise when the Input Power Switch

on the welder is turned on.

3.7 Turn on the regulator on the cylinder of shielding gas and adjust the regulator to

approximately 20 CFH. Then open the shielding gas valve on the torch to start the

flow of shielding gas.

3.8 Touch the tungsten that is installed in the TIG torch, to the work piece and quickly

pull away approximately 1/4" to create an arc.

WELDING OPERATION

High voltage danger from power source! Consult a qualified electrician for

proper installation of receptacle at the power source. This welder must be

grounded while in use to protect the operator from electrical shock. If you are

not sure if your outlet is properly grounded, have it checked by a qualified

electrician. Do not cut off the grounding wire or alter the plug in any way and do

not use any adapter between the welder's power cord and the power source

receptacle. Make sure the POWER switch is OFF then connect your welder's

power cord to a properly grounded 230 VAC, 50 HZ, single phase, 50 amp power

source.

1 Current display

2MMA/Lifttig

switch

3 Current Output “-” Electrode

OKC Connector Socket

4 welder’s

handle

5 Alarm Indicator

6 ARC force

7Welding Current Adjustment

Knob

8 Current Output

“+”

Electrode OKC

Connector Socket

9 Power Input Wire

10. Air switch

Once the installation of the equipment is completed, connect the work Cable to

the negative output terminal and the cable end of the electrode holder to the

Positive output terminal. These cable connections should be tightened properly

to avoid electrical heating due to loose connections. Put the main Switch box in

‘ON’. Turn on “Power ON/OFF switch” on the rear panel. The Display on the

panel of the Power Source will glow and the fan will start rotating. Now the

equipment is ready. Connect an Electrode with the Electrode Holder. The

welding current can be controlled by the current control potentiometer mounted

on the front panel of the Power.

Welding Current Adjustment

Put the MMA/ TIG switch to ‘MMA’ mode. Now set the DC output current as

required with the help of the current control potentiometer and ignite an

experimental Arc. For the fine-tuning of the required current, set the parameters

using the Ammeter mounted on the front panel of the power source.

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