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

0460 446 301 -4- © ESAB AB 2019

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

0460 446 301 -5- © ESAB AB 2019

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

0460 446 301 -6- © ESAB AB 2019

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

0460 446 301 -7- © ESAB AB 2019

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

0460 446 301 -8- © ESAB AB 2019

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

0460 446 301 -9- © ESAB AB 2019

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

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.

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