ESAB Caddy Arc 151i User manual

Valid for serial no. 927-xxx-xxxx0460 446 101 GB 20110628

Caddy®

Arc 151i, Arc 201i

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Control panel 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Mains power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Recommended fuse sizes and minimum cable area 8. . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 PFC - Power factor correction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Connections and control devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Connection of welding and return cable 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Overheating protection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 MMA welding 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 TIG welding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Remote control unit 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Inspection and cleaning 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 FAULT-TRACING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Fault codes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING SPARE PARTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 DISMANTLING AND SCRAPPING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 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 work

place.

All work must be carried out by trained personnel well-acquainted with the operation of the welding equipment. Incorrect oper

ation 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, 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.

CAUTION

This product is solely intended for arc welding.

WARNING

Do not use the power source for thawing frozen pipes.

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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 precausions 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.

Warn bystanders of the risk.

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

PROTECT YOURSELF AND OTHERS!

CAUTION

Read and understand the instruction manual before

installing or operating.

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.

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

2 INTRODUCTION

Arc 151i, Arc 201iis a welding current power source intended for use with coated

electrodes (MMA welding) and TIG welding.

ESAB's accessories for the product can be found on page 19.

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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.

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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

Imax MMA

13.8 A

21.3 A

24.1 A

24.9 A

Mains supply Zmax 0.35 ohm Zmax 0.30 ohm

No-load power 30 W 30 W

Voltage/current range, MMA

A31 8 A /20 V - 150 A /26 V -

A33 4 A /20 V - 150 A /26 V 4 A /20 V - 170 A /26.8 V

Voltage/current range TIG 3 - 150 A 3 - 220 A

Permissible load at MMA

25% duty cycle

60% duty cycle

100% duty cycle

150 A / 26.0 V

100 A / 24.0 V

90 A / 23.6 V

170 A / 26.8 V

130 A / 25.2 V

110 A / 24.4 V

Permissible load at TIG

20% duty cycle

25% duty cycle

60% duty cycle

100% duty cycle

150 A / 16.0 V

120 A / 14.8 V

110 A / 14.4 V

220 A / 18.8 V

150 A / 16.0 V

140 A / 15.6 V

Power factor at maximum current 0.99 0.99

Efficiency at maximum current 80% 81%

Open-circuit voltage

A31 without VRD function 1)

A33 VRD function deactivated 2)

VRD function activated 2)

58 - 72 V

55 - 60 V

< 35 V

55 - 60 V

< 35 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 x b x h 418 x 188 x 208 mm 418 x 188 x 208 mm

Weight

with A31

with A33

7.9 kg

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.

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.

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.

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4 INSTALLATION

The installation must be executed by a professional.

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

distrubution network operator if necessary, that the equipment may be connected.

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 11.5 A 13.4 A

Welding cable, area 16 mm216 mm2

Fuse

anti-surge

type C MCB

16 A

13 A

16 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.

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5 OPERATION

General safety regulations for the handling of the equipment can be found on

page 4. Read 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 machine on a 16 A fuse.

The PFC also protects the machines 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

1Connection (+)

MMA: for return cable or welding cable

TIG: for return cable

4Connection (+)

MMA: for return cable or welding cable

TIG: for Tig torch l

2Connection for remote control unit 5Toggle switch for mains power supply 0 / 1

3Control panel, see under 2.2 6Mains cable

cmha2p11

cmha2p10

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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 Ø1.6 to Ø3.25.

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 com

pletely.

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, how

ever, you have to use lateral movements.

This manual suits for next models

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